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TECHNICAL FIELD
The present disclosure relates to a propulsion system for a vehicle and more particularly to a continuously variable transmission using a dual rotor switched reluctance machine.
BACKGROUND
Internal combustion engines can be used to power a generator and create electric energy which is stored and in turn drives an electric motor to propel a vehicle. This technique has been used effectively in vehicles such as locomotives and hybrid automobiles. Typically this process involves a generator that produces AC power. The AC power can be converted to DC power using, in some cases using a rectifier, but more popularly uses an AC-DC converter. The DC power can then be stored and a DC-AC inverter can be used to supply 3-phase power to an AC motor used to drive the vehicle.
This arrangement, while relatively efficient, has several drawbacks. One involves the cost of the high power components used in the AC-DC converter and the DC-AC inverter. Another is the loss of inertia provided by the flywheel of a standard engine-clutch-transmission drivetrain that allows smoother performance in the event of momentary engine power changes.
WO0034066 (“the '066 patent”) discloses a dual rotor machine with a stator surrounding an output rotor and an input rotor surrounded by the output rotor. The stator and input rotor each have windings, the output rotor has embedded permanent magnets that interact with fields generated at the stator and input rotor. The input rotor requires slip rings to carry current to the input rotor windings. The permanent magnets of the '066 patent impose a substantial cost penalty on the system. The slip rings of the '066 patent also have a cost impact due to the elaborate construction requirements and also create a reliability weakness at the contacts between the slip rings and the shaft.
SUMMARY OF THE DISCLOSURE
In a first aspect, an energy conversion machine has a stator having a cylindrical shape with an inner circumference and an outer circumference. The stator is fixedly mounted and has poles extending radially between the inner circumference and the outer circumference. Each pole has an electrical winding. The energy conversion machine also includes an input rotor rotatably mounted adjacent to one circumference of the stator, such as an outer circumference of the stator. The input rotor is free of windings and may be free of permanent magnets other than magnets used for position sensing. The energy conversion machine can also include an output rotor rotatably mounted adjacent to the other circumference of the stator, for example, an inner circumference. The output rotor is also be free of windings and permanent magnets. The energy conversion machine also includes a controller that selectively energizes the stator electrical windings to transfer torque developed between the input rotor and the stator to the output rotor.
In another aspect, a method of converting energy from a power source to a mechanical load can include providing a switched reluctance machine with a first rotor and a second rotor, each rotor overlapping a stator, the stator having a cylindrical shape and fixedly mounted with respect to the first rotor and the second rotor, receiving power from the power source at the first rotor, and energizing a first stator pole during a stoke angle of the second rotor. Concurrent with the energizing of the first stator pole, the method can include energizing a second stator pole once for each pole of the first rotor that passes the second stator pole, the second stator pole adjacent to the first stator pole and transmitting torque to the mechanical load via the second rotor.
In yet another aspect, a system for propelling a vehicle can include an engine and an energy conversion machine having an input rotor coupled to the engine and an output rotor. The energy conversion machine can also include a stator having a cylindrical shape with an inner circumference and an outer circumference, the stator fixedly mounted and having stator poles extending between the inner circumference and the outer circumference, with each pole having an electrical winding. The input rotor can be rotatably mounted adjacent to one circumference of the stator, the input rotor free of windings and permanent magnets other than position sensing magnets. The output rotor can be rotatably mounted adjacent to the other circumference of the stator, the output rotor being free of windings and permanent magnets other than position sensing magnets. The energy conversion machine can also include a controller that selectively energizes the stator electrical windings to transfer torque developed between the input rotor and the stator to the output rotor. The system can include a driveshaft coupled to the output rotor and a propulsion device that converts torque from the output rotor received via the driveshaft to propel the vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of a simplified and exemplary vehicle in accordance with the current disclosure;
FIG. 2 is a cutaway view of a dual rotor machine;
FIG. 3 is a cross-section view of the dual rotor machine;
FIG. 4 is a cross-section view of the dual rotor machine depicting activation of a stator pole;
FIG. 5 is a cross-section view of the dual rotor machine depicting activation of adjacent stator poles;
FIG. 6 is a schematic diagram of an embodiment of control electronics;
FIG. 7 is a flow chart of a method of operating the dual rotor machine;
FIG. 8 is a prior art control diagram for a switched reluctance motor;
FIG. 9 is a control diagram for the dual rotor machine;
FIGS. 10 a -10 b are input and output torque diagrams for the dual rotor machine in Quadrant 1 with an output angle of 5 degrees;
FIGS. 11 a -11 b are instantaneous torque input and output charts for Quadrant 1 operation of the dual rotor machine;
FIGS. 12 a -12 b are input and output torque diagrams for the dual rotor machine in Quadrant 4 with an output angle of 5 degrees;
FIGS. 13 a -13 b are instantaneous torque input and output charts for Quadrant 4 operation of the dual rotor machine; and
FIG. 14 is a definition of operating regimes a vehicle powered by a dual rotor machine.
DETAILED DESCRIPTION
FIG. 1 illustrates a vehicle 140 powered by an engine 142 , a gear box 144 and a driveshaft 146 , similar to the vehicle shown in FIG. 1 . In some embodiments, the gear box 144 may not be used. A dual rotor machine 148 can include an input rotor 150 coupled to the drive shaft 146 , a stator 152 , an output rotor 154 , and control electronics 156 used to time energizing pole windings in the stator 152 . The output rotor 154 can be coupled to a driveshaft 158 , and in prior-art fashion transmit torque via axle 160 and propulsion device 162 .
FIG. 2 is a cutaway view of an embodiment of a dual rotor machine 148 , also known as a dual rotor switched reluctance machine. The dual rotor machine 148 can include, as discussed above, an input rotor 150 , an output rotor 154 , and a stator 152 . The input rotor 150 can be coupled to the driveshaft 146 so as to receive power from or return power to the engine 142 . The output rotor 154 can be coupled to the driveshaft 158 . Bearings, such as bearing 170 , may be used to support rotating devices. For example, the driveshaft 146 may be supported by mounts 178 and associated bearings.
The stator 152 can be mounted by supports 180 and provide support to both the input rotor 150 and the output rotor 154 via respective bearings. As will be appreciated, numerous variations exist for providing the mechanical mounting between the stator and the two rotors.
As will be discussed in more detail below, the stator 152 includes numerous poles 172 having windings 174 that can be coupled to the control electronics 156 via leads 176 . The dual rotor machine 148 can also include an input rotor position sensor 182 and an output rotor position sensor 184 . The actual location and construction of the sensors 182 and 184 may vary in known fashion but can include optical or Hall Effect sensors and may be used by the control electronics 156 to determine the position of input rotor poles and output rotor poles with respect to stator poles.
FIG. 3 is a cross-section view of the dual rotor machine 148 shown at view ‘X’ of FIG. 3 . This view shows the input rotor 150 , the stator 152 , and the output rotor 154 . This view also shows a first stator pole 172 and corresponding windings 174 as well as a second stator pole 200 and its corresponding windings 202 . Also illustrated is one of a plurality of input rotor poles 204 . In this exemplary embodiment, the input rotor has 12 poles, the stator 152 has six poles, and the output rotor 154 has four poles. In common fashion, opposite stator poles are energized concurrently, so in the following discussions only the upper half of the dual rotor machine 148 are discussed.
Other configurations of poles are also viable. Further, the input and output rotors may be reversed so that the input rotor is along an inner circumference of the stator 152 and the output rotor is mounted along an outer circumference of the stator 152 . These alternate configurations are enabled as long as the relationship between input rotor and output rotor timing with respect to the stator 152 discussed below is preserved.
FIG. 4 and FIG. 5 depict in simplified fashion operation of the dual rotor machine 148 at two points of time in an operating sequence. This operation is in so-called Quadrant 1, that is forward direction and accelerating. Other quadrants include Quadrant 2, forward operation/decelerating, Quadrant 3, reverse operation/accelerating, and Quadrant 4, reverse operation/decelerating.
FIG. 4 illustrates the dual rotor machine 148 with a first stator 172 having its windings 174 energized. In this example, both rotors are rotating counterclockwise. As the windings 174 of the first stator 172 are energized, the outer, or input rotor pole 204 is pulled toward the stator pole 172 . The adjacent poles are inactive. In an embodiment this represents an input torque of about 2.0 KiloNewton-meters (KNm). Similarly, the output rotor 154 is pulled toward the stator 172 with a torque of about 1.6 KNm.
FIG. 5 illustrates the dual rotor machine 148 slightly later in the cycle, denoted by the rotation of the input rotor 150 from reference A to reference B. the inner, or output rotor 154 has not significantly changed position.
Stator pole 174 is energized so that the output pole of rotor 154 is still pulled toward the first stator pole 172 . Stator pole 200 is also energized. The output pole that is fully aligned with stator pole 200 has no net torque. However, because the stator poles 172 and 200 are energize, the breaking magnetic field connection between the input poles and the stator poles 172 and 200 increases the stored energy in their respective magnetic fields. This increased field at stator pole 172 has a direct impact on the torque of the output rotor and a neutral effect on the output rotor pole aligned with stator pole 200 . In both cases, electrical power can be returned to the capacitor 216 . In an exemplary embodiment, the output torque imparted to the output rotor 154 can be about 2.2 KNm while the energy returned to the dual rotor machine 148 by the input rotor 150 can be about −4.8 KNm.
This effect is discussed in more detail below, but at a high level, energy from the magnetized input rotor pole builds the magnetic field at the stator pole as it breaks away from the respective stator poles and results in a net increase in energy at the dual rotor machine 148 . That energy is then transferred to the output rotor.
FIG. 6 illustrates one embodiment of control electronics 156 suitable for use with the dual rotor machine 148 of FIG. 3 . Recalling that opposite pairs of stator poles can be operated together, the control electronics includes drivers for three sets of stator pole windings depicted by inductors 174 , 202 , and 218 . Each of the drive circuits are the same and include a low side drive transistor 208 a high side drive transistor 214 and a pair of diodes 210 and 212 . A capacitor 216 can be used to store electricity used to drive the stator pole windings and/or filter the DC ripple generated by the dual rotor machine 148 . A battery (not depicted) may be connected to the capacitor 216 to supplement the capacitor 216 , for example, during startup.
A controller 206 receives position information from position sensors on the input rotor and the output rotor, or corresponding driveshafts. The controller 206 also includes output drivers for each of the paired transistors that drive the stator pole windings. The transistors 208 and 214 can be insulated gate bipolar transistors (IGBT) known for their high current capacity and fast switching speed. In operation, when both transistors 214 and 208 are turned on current flows through winding 174 (and it's paired pole) and builds up a magnetic field. When the transistors 208 and 214 are turned off at an appropriate point during the rotation of the respective rotors 150 and 154 , the collapsing magnetic field generates electric current that is transmitted via diodes 212 and 210 back to the capacitor 216 .
Compared to a prior art implementation that uses separate AC-DC converters and DC-AC inverters, the current embodiment uses a single converter to receive excess electrical energy from the stator winding 174 as well as to deliver drive current to the stator 174 , improving both the cost and reliability of the system because of the decreased number of components.
INDUSTRIAL APPLICABILITY
A dual rotor machine 148 can be employed in any application where power from an engine needs to be converted to drive a vehicle or other mechanical device. The dual rotor machine 148 is particularly well-suited to continuously variable transmission (CVT) applications where a diesel or gasoline engine 142 may be operated at a nearly constant speed to improve its efficiency and the CVT is responsible for drive speed and direction.
Because the input rotor 150 and output rotor 154 share a common stator 152 , magnetic energy can be directly transmitted from the input rotor 150 to the output rotor 154 without externally storing electricity as an intermediate step. This eliminates the prior art the requirement that all magnetic energy be converted to AC electrical energy in a generator set, stored or filtered, and converted to DC electrical energy before being applied as magnetic energy in the motor portion of the set.
Further, the use of a shared stator 152 eliminates at least one stator from the hardware associated with separate generator-motor sets, including the windings which are generally made from relatively expensive copper wires. Overall, the sharing of a stator, elimination of the DC-AC inverter, and elimination of the other associated mounting hardware and duplicate control electronics can result in a CVT that may be half the size and weight of a similar horsepower generator-motor set.
Because neither the input rotor nor the output rotor requires windings or permanent magnets for operation, slip rings and expensive magnets can be eliminated, improving both cost and reliability over motor-generator sets or other prior art dual rotor devices.
FIG. 7 is a flow chart of a method 220 of operating a dual rotor machine 148 . At block 222 , a switched reluctance machine can be provided with a first rotor 150 and a second rotor 154 , each rotor overlapping a common stator 152 . The stator 152 may have a cylindrical shape and be fixedly mounted with respect to the first rotor 150 and the second rotor 154 . The first rotor 150 may have an integer multiple of poles of both the stator 152 and the second rotor 154 . For example, the second rotor 154 can have four poles and the first rotor 150 can have 12 poles in a ratio of 3:1. The stator 152 can have 6 poles with a ratio of 2:1 input poles to stator poles. In an embodiment, The first rotor 150 can have 12 poles, the second rotor 154 can have four poles and the stator 152 can have six poles. Both the first rotor 150 and the second rotor 154 may be free of windings or permanent magnets other than position sensing magnets.
The stator 152 can have poles, e.g., poles 172 , 200 , extending from an inner circumference to an outer circumference of the cylindrical shape, each stator pole 172 , 202 electrically energized with a corresponding, axially opposite stator pole. A vehicle associated with the dual rotor machine 148 may have a gearbox 144 between the power source 142 and the first rotor 150 that maintains a rotational speed of first rotor 150 above a rotational speed of second rotor 154 during operation. While not necessary, there may be advantages to maintaining this speed relationship when convenient so that input rotor poles always have multiple stator pole crossings compared to output rotor poles crossing of a stator pole.
At a block 224 , power can be received from the power source at the first rotor 150 . For example, the power source may be a diesel or gasoline engine 142 and the first rotor 150 (or input rotor) can be turned by the engine either directly or via a gearbox 144 .
At block 226 , a first stator pole 172 can be energized during a stoke angle of the second rotor 154 . A stoke angle is that range of angles of an output rotor pole 155 over which a particular stator pole can effectively cause motion in a desired direction. Output stoke angle can be calculated as 360 degrees/(output rotor poles*stator phases). In the illustrated embodiment, the six stator poles are paired so that there are 3 stator phases. Therefore, the output stoke angle of the embodiment can be calculated as 360 degrees/(4*3)=30 degrees.
Referring briefly to FIG. 8 , a prior art control diagram 240 for a 6/4 (6 stator poles and 4 rotor poles) switched reluctance motor is shown. The control diagram 240 shows a control signal 242 and corresponding control current 244 (Ia, Ib, Ic) for each stator pole pair. As illustrated, successive stator poles are energized for 30 degrees of mechanical rotation (Ro) of the output rotor 154 .
Returning to FIG. 7 , at a block 228 , concurrent with the energizing of the first stator pole, a second stator pole is energized once for each pole of the first rotor that passes the second stator pole. The second stator pole can be adjacent to the first stator pole. For forward and accelerating operation (Quadrant 1) the second stator pole energized can be adjacent to the first stator pole in a downstream direction of rotation of the first rotor.
Turning briefly to FIG. 9 , a control diagram 246 for the dual rotor machine 148 is shown. In order to create the desired motion in the forward (in this case, counterclockwise) direction, the stator poles with respect to the output rotor 150 are excited as shown in FIG. 8 . In addition, the adjacent stator pole pair is excited once for each input pole that passes the adjacent stator pole. In the illustration, when the B stator is excited with current Ib, the C stator pole is excited once for each input rotor pole that passes the C stator pole. As discussed above, energizing the stator pole during the overlap of an input rotor pole causes energy from the input rotor 150 to build the magnetic field at the adjacent stator pole when the input pole breaks free of the energized stator pole. This transfers energy from the input rotor to the stator 152 and subsequently to the output rotor. In the illustrated embodiment, during the Ib output rotor phase, the Ic stator pole is pulsed during input rotor pole crossings. Similarly, during the Ia output rotor phase, the Ib stator pole is pulsed; and during the Ic output rotor phase, the Ia stator pole is pulsed.
Returning to FIG. 7 , at a block 230 torque from the output rotor (i.e, the second rotor) is transmitted to the mechanical load, such as a wheel or track that drives the vehicle.
FIG. 14 illustrates one definition of operating regimes for a vehicle powered by a dual rotor machine 148 and will be referred to in the following discussion. Quadrant 1 340 is defined as forward and accelerating. Quadrant 2 342 is defined as reverse and braking. Quadrant 3 is defined as reverse and accelerating. Quadrant 4 is defined as forward and braking. As described for quadrants 1 and 2, each quadrant deals with either positive or negative torque between the engine 142 and the dual rotor machine 148 as well as positive or negative torque between the dual rotor machine 148 and the propulsion devices 162 .
FIGS. 10 a and 10 b are input and output torque diagrams for the dual rotor machine in Quadrant 1 with a fixed output rotor angle of 5 degrees. In FIG. 10 a , a torque diagram 250 shows input side torque over 25 degrees (5 degrees to 30 degrees) of input rotor angle. The torque diagram 250 shows a first torque curve 252 with only one stator pole (“B”) energized and a second torque curve 254 with the B stator pole and an adjacent stator pole (“C”) active. Referring to Table 1, below, a stator energizing scheme is summarized for Quadrant 1 operation.
TABLE 1
Forward and accelerating (Quadrant 1)
The output rotor angle of 5 degrees is highlighted in the first column of Table 1 corresponding to the fixed output rotor angle illustrated in FIGS. 10 a and 10 b . Following the column down at 5 and 10 degrees, only the B stator is energized and the actual torque at the input will follow curve 252 . At 15 degrees, the C stator is also energized and the actual torque will follow line 254 from 15 degrees to 30 degrees. Solid reference lines 256 track the torque path.
Referring briefly to FIG. 11 a , input torque diagram 270 illustrates instantaneous input torque 272 over a range of output rotor angles, beyond the fixed angle of FIG. 10 a . The average input torque 274 is negative, showing that power from the engine 142 is converted to torque at the dual rotor machine 148 .
Turning to FIG. 10 b , an output torque diagram 260 for the same fixed output rotor angle of 5 degrees shows output torque as a function of input rotor angle. A first torque curve 262 shows torque with only the B stator pole energized. The second torque curve 264 shows torque with both the B and C stator poles energized. Again referring to Table 1, the actual torque follows solid lines 266 as the B stator pole is energized from 5 to 10 degrees and the B and C stator poles are energized from 15 degrees to 30 degrees.
Referring to FIG. 11 b , chart 276 illustrates instantaneous output rotor torque 278 and average output rotor torque 280 . As can be seen, all the average output rotor torque values 280 are positive, indicating positive (in this case, forward) torque is being generated. FIGS. 10 a , 10 b , 11 a , and 11 b demonstrate operation where power from the engine 142 is captured at the dual rotor machine 148 and positive torque is generated at the output.
While operation in each quadrant will not be discussed in detail, the following figures illustrate operation in Quadrant 2, reverse and braking.
FIG. 12 a shows another instance of the input torque diagram 250 of FIG. 10 a , with B stator pole only curve 252 and B and C stator pole curve 254 . However, referring to Table 2, below, use of a different excitation pattern causes different torque profiles to be generated. From 5 degrees to 15 degrees, both the B and C stator poles are energized, from 20 to 25 degrees only the B stator pole is energized, and at 30 degrees, again both the B and C stator poles are energized.
TABLE 2
Reverse and Braking (Quadrant 4)
Referring to FIG. 13 a , a torque diagram 310 shows instantaneous torque 312 as a function of output rotor angle for Quadrant 4 operation. The average torque 314 is positive, meaning that torque is being returned to the engine in a form of engine braking.
Similarly, FIG. 12 b shows another instance of the output rotor torque diagram 260 with B stator pole torque curve 262 and B and C stator pole torque curve 264 for an output rotor angle of 5 degrees. Using the energizing pattern highlighted in Table 2, the actual output torque follows solid lines 300 as the energizing scheme is implemented over the increasing input rotor angles.
FIG. 13 b shows a torque diagram 316 with instantaneous output torque 318 as a function of output rotor angle. The average power is signified by each solid bar 320 . FIGS. 12 a , 12 b , 13 a , and 13 b demonstrate operation where power from the propulsion device 162 (e.g., tires) is captured at the dual rotor machine while the vehicle is in reverse and braking. In turn, the dual rotor machine 148 transmits positive torque to the engine, causing the engine to attempt to increase in speed.
Operation in Quadrants 3 and 4 are similarly embodied by selecting stator pole activation sequences to positive or negative input torque and positive or negative output torque. The variations in torque shown in FIGS. 11 a , 11 b and 13 a , 13 b is called torque jitter and is a known side effect in switched reluctance motors and generators. The mass of the input rotor 150 and output rotor 154 provides a certain flywheel effect and can smooth torque jitter. In some embodiments, the moment of inertia of the input rotor 150 is greater than that of the output rotor, providing engine-side inertia while allowing the output rotor to be more responsive to changes in speed and/or direction.
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A dual rotor switched reluctance machine with a fixed stator and separate input and output rotors on either side of the fixed stator is used to transmit power between a power source such as an gas engine and a mechanical drive unit such as wheels or tracks. A switched reluctance motor configuration, such as a 6/4 motor can be combined with a with a higher pole count switched reluctance generator to allow simultaneous operation of the dual rotor machine as both a generator and a motor. Because the fixed stator has the only set of windings the control electronics are greatly simplified over separate motor-generator configurations.
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RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 11/867,882, filed Oct. 5, 2007, now U.S. Pat. No. 7,944,082, issued May 17, 2011, which is incorporated herein by reference.
BACKGROUND
Power supply systems for network devices generally provide power to multiple zones within the network devices and also contain backup power supplies commonly referred to as redundant power systems. In some circumstances, a direct current (DC) power system may provide N+N redundant power where N DC power supplies (e.g., N=2) provide power to the N zones within the device and N DC power supplies (e.g., N=2) provide backup power to the N zones. In other circumstances, an alternating current (AC) power supply system may provide M+1 redundant power, where M AC power supplies (e.g., M=3) provide power to the zones and one AC power supply provides redundant power. These existing N+N DC power systems and M+1 AC power systems typically require two different connection modules within the device or require separate and distinct connection ports within a same connection module within the device, which adds to both the cost and complexity of the device.
SUMMARY
In accordance with one aspect, a device is provided. The device may include a connection module that includes a number of ports, where each port is configured to receive both an alternating current (AC) power supply and a direct current (DC) power supply; where the connection module provides power from the received power supplies to a plurality of field replaceable units (FRUs).
According to another aspect, a method may include providing a first number of ports, where each port is configured to receive both an alternating current (AC) power supply and a direct current DC power supply; receiving into the first number of ports at least one of a first number of DC power supplies or a first number of AC power supplies; providing a second number of power zones; and delivering power to the second number of power zones, where N+N redundant power is applied to the second number of power zones when the first number of DC power supplies are received into the first number of ports and where M+1 redundant power is applied to the second number of power zones when the first number of AC power supplies are received into the first number of ports.
According to another aspect, a device may include two power zones, where each power zone includes a plurality of field replaceable units (FRUs); and a connection module, where the connection module includes four ports, where each port is configured to receive both an alternating current (AC) power supply and a direct current (DC) power supply, where the connection module connects the received four power supplies to the two power zones within the device.
According to another aspect, a device may include means for receiving a power supply, where the means for receiving a power supply is configured to receive both an alternating current (AC) power supply and a direct current (DC) power supply; and means for providing power to power zones, where N+N redundant power is applied to the power zones via the means for providing power when a plurality of DC power supplies are connected to a plurality of means for receiving a power supply and M+1 redundant power is applied to the power zones via the means for providing power when a plurality of AC power supplies are connected to a plurality of means for receiving a power supply.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments described herein and, together with the description, explain the embodiments. In the drawings,
FIG. 1 is a diagram of an exemplary device connected to a network;
FIG. 2 is a diagram of the use of a connection module to supply N+N or M+1 redundant power to power zones within the exemplary device of FIG. 1 ;
FIGS. 3A and 3B illustrate the connection module of FIG. 2 supplying redundant power within the exemplary device of FIG. 1 according to a first N+N exemplary implementation;
FIGS. 4A and 4B illustrate the connection module of FIG. 2 supplying redundant power within the exemplary device of FIG. 1 according to a first M+1 exemplary implementation;
FIGS. 5A and 5B illustrate the connection module of FIG. 2 supplying redundant power within the exemplary device of FIG. 1 according to a second N+N exemplary implementation;
FIGS. 6A and 6B illustrate the connection module of FIG. 2 supplying redundant power within the exemplary device of FIG. 1 according to a second M+1 exemplary implementation; and
FIG. 7 is a flow diagram of an exemplary process for supplying N+N or M+1 redundant power to the exemplary device of FIG. 1 using the exemplary connection modules shown in FIGS. 3A-6B .
DETAILED DESCRIPTION
The following detailed description of the embodiments refers to the accompanying drawings. The same reference numbers in different drawings may identify the same or similar elements. Also, the following detailed description does not limit the embodiments. Instead, the scope of the embodiments is defined by the appended claims and equivalents of the claimed features.
FIG. 1 shows an exemplary device 110 in which concepts described herein may be implemented. As shown, device 110 may connect to network 120 . Device 110 may include a network device for performing network-related functions, such as for example, a router, a server or a switch. Network 120 may include the Internet, an ad hoc network, a local area network (LAN), a wide area network (WAN), a metropolitan area network (MAN), a cellular network, a public switched telephone network (PSTN), any other network, or a combination of networks. Device 110 may communicate with other devices (not shown) and may communicate through a wired or wireless communication links via network 120 .
FIG. 2 is a block diagram illustrating the use of a connection module to supply N+N or M+1 redundant power connections to power zones within device 110 according to exemplary implementations described herein. Device 110 may include a number of field replaceable units (FRUs) 210 , a connection module 220 , a number of power entry modules (PEMs) 230 - 0 to 230 - 3 (collectively referred to as PEMs 230 ) that supply N+N redundant power 235 , and a number of power supplies (PSs) 240 - 0 to 240 - 3 (collectively referred to a PSs 240 ) that supply M+1 redundant power 245 . As shown, a number of FRUs 210 may be included in each of the power zones (i.e., zone 0 and zone 1 shown by way of example) within device 110 .
FRUs 210 may include any replaceable unit or assembly of electronic devices. When device 110 takes the form of a network device, such as a router, a web server, a switch, or the like, each FRU 210 may include a line card. FRUs 210 may be included in each of the different power zones within device 110 (e.g., zone 0 or zone 1 ). In one example, zone 0 may contain seven (7) FRUs 210 and zone 1 may contain seven (7) FRUs 210 . Continuing with this example, the total power required by device 110 may be 2400 Watts, where each of the 14 FRUs 210 may require 235 Watts and additionally, each zone may also include a cooling fan motor assembly (not shown) where each cooling fan motor assembly may require 150 Watts of power. FRUs 210 may include two input connections to receive power and two output connections to return power, where the two input connections may be diode-ORed together and the two output connections returning power may be diode-ORed together, for example.
Connection module 220 may include connection ports to receive power from PEMs 230 or PSs 240 and supply power to FRUs 210 . As described in FIGS. 3A-6B below, connection ports within connection module 220 may receive either one of a number of PEMs 230 or a number of power supplies (PSs) 240 and may supply N+N redundant power when PEMs 230 are connected and may supply M+1 redundant power when PSs 240 are connected to connection module 220 .
PEMs 230 may include a non load sharing DC power supply and connections necessary to connect to connection module 220 . PSs 240 may include a load sharing AC power supply, circuitry to convert AC power to DC power and connections necessary to connect DC power to connection module 220 .
FIGS. 3A and 3B illustrate the connection module of FIG. 2 supplying redundant power within the exemplary device of FIG. 1 according to a first N+N exemplary implementation. FIG. 3A depicts connection module 220 , which includes midplane 310 , power over Ethernet connection 320 and interconnect module 330 , supplying N+N redundant power from multiple PEMs 230 - 0 through 230 - 3 to FRUs 210 .
Midplane 310 of connection module 220 may include electrical connections that may connect FRUs 210 to interconnect module 330 . Midplane 310 may also include a power over Ethernet connection 320 in order to provide power to FRUs 210 via an Ethernet connection.
Interconnect module 330 may include connection ports used to receive power from PEMs 230 and circuit pathways to deliver power to midplane 310 . For example, interconnect module 330 may include four connection ports 340 - 1 to 340 - 4 (collectively referred to as connection ports 340 ) that may receive power from four power entry modules PEMs 230 that may be plugged into ports 340 . As shown, each connection port 340 may include nine connection pins that may connect to respective power entry modules 230 . It should be understood that the number of pins contained in interconnect module 330 may be more or less depending on the requirements of a power delivery system of device 110 and/or the requirements of the power entry modules 230 plugged into ports 340 . Dashed line connections shown in interconnect module 330 indicate circuit pathways that are present, but, are not used in DC power connections, as described further below.
Power entry modules (PEMs) 230 may include a DC power supply and connections to enable power to be supplied from the DC power supply to interconnect module 330 . In this example, PEMs 230 may include nine pins that may be used to connect to interconnect module 330 . As mentioned above, it should be understood that the number of pins contained in PEMs 230 may be more or less depending on the requirements of a power delivery system of device 110 and/or the requirements of the interconnect module 330 .
FIG. 3B shows an enlarged view of a port 340 and a PEM 230 as connected in FIG. 3A . As shown, port 340 includes nine pins (labeled 1 - 9 ). Similarly, PEM 230 includes nine pins that connect to the nine pins in port 340 . In the example shown in FIG. 3B , the first two pins of each PEM 230 may be connected to the positive terminal of the DC power supply, and the fourth and fifth pins of each PEM 230 may be connected to a negative side of the DC power supply. When PEMs 230 are plugged into ports 340 the first two pins of port 340 may receive power from the positive terminal of the DC power supply and the fourth and fifth pins of port 340 may return power to the negative side of the DC power supply. As the third and sixth pins of PEMs 230 are not connected to either the positive or negative terminals of a DC power supply, these pins do not supply or return power to/from interconnect module 330 . Therefore, in the example shown in FIG. 3A , the dashed line connections between ports 340 using the third and sixth pins represent circuit paths that exist but do not perform power delivery.
Using the exemplary connection ports and circuit pathways included in interconnect module 330 , as shown in FIG. 3A , PEM 230 - 0 supplies power to zone 0 FRUs 210 and PEM 230 - 1 supplies power to zone 1 FRUs 210 . PEM 230 - 2 supplies backup power to zone 0 FRUs 210 and PEM 230 - 3 supplies backup power to zone 1 FRUs 210 . In this manner, interconnect module 330 provides power from PEMs 230 in a 2+2 redundant manner, where two PEMs ( 230 - 0 and 230 - 1 ) provide power to the two zones, and each of the two PEMs ( 230 - 0 and 230 - 1 ) have a redundant or backup power supply (i.e., PEM 230 - 2 and 230 - 3 respectively).
Specifically, pins one and two of PEM 230 - 0 (and connection port 340 - 0 ) deliver power from the positive terminal of DC power supply to zone 0 FRUs 210 . Power returning from zone 0 FRUs 210 to the negative terminal of DC power supply may return via the fourth pin of connection port 340 - 0 (and PEM 230 - 0 ). Similarly, PEM 230 - 2 supplies backup power to zone 0 FRUs 210 in the same manner as PEM 230 - 0 . Pins one and two of PEM 230 - 1 (and connection port 340 - 1 ) deliver power from the positive terminal of DC power supply to zone 1 FRUs 210 . Power returning from zone 1 FRUs 210 to the negative terminal of DC power supply may return via the fourth pin of connection port 340 - 1 (and PEM 230 - 1 ). Similarly, PEM 230 - 3 supplies backup power to zone 1 FRUs 210 in the same manner as PEM 230 - 1 .
FIGS. 4A and 4B illustrate the connection module of FIG. 2 supplying redundant power from AC power supplies within the exemplary device of FIG. 1 according to a first M+1 exemplary implementation. FIG. 4A depicts connection module 220 , which includes midplane 310 , power over Ethernet connection 320 and interconnect module 330 , supplying M+1 redundant DC power from PSs 240 - 0 through 240 - 3 to FRUs 210 .
Interconnect module 330 may include connection ports used to receive power from PSs 240 and circuit pathways to deliver power to midplane 310 . For example, interconnect module 330 may include the same connection ports 340 - 1 to 340 - 4 (described above with respect to FIG. 3A ) and which may receive output DC power from four AC power supplies PSs 240 - 0 to 240 - 3 that may be plugged into ports 340 . As shown, connection ports 340 may include nine connection pins that may connect to PSs 240 . It should be understood that the number of pins contained in interconnect module 330 may be more or less depending on the requirements of a power delivery system of device 110 and/or the requirements of the PSs 240 plugged into connection ports 340 .
Power supplies (PSs) 240 may include a load sharing AC power supply, AC to DC conversion circuitry and connections to enable output DC power to be supplied from PSs 240 to interconnect module 330 . In this example, PSs 240 may include nine pins that may be used to connect to connection ports 340 in interconnect module 330 . As mentioned above, it should be understood that the number of pins contained in PSs 240 may be more or less depending on the requirements of a power delivery system of device 110 and/or the requirements of the interconnect module 330 .
FIG. 4B shows an enlarged view of a port 340 and a PS 240 as connected in FIG. 4A . As shown, port 340 includes nine pins (labeled 1 - 9 ). Similarly, PS 240 includes nine pins that connect to the nine pins in port 340 . In the example shown in FIG. 4B , the first three pins of each PS 240 may be connected to the positive (DC output) terminal of the AC power supply and the fourth, fifth and sixth pins of each PS 240 may be connected to a negative (DC output) terminal of the AC power supply. When each PS 240 is plugged into port 340 the first three pins of port 340 may receive power from the positive (DC output) terminal of the AC power supply and the fourth through sixth pins of port 340 may return power to the negative (DC output) terminal of the AC power supplies. As the seventh through ninth pins of each PS 240 are not connected to either the positive or negative terminals of an AC power supply, these pins do not supply or return power to/from interconnect module 330 . As the third and sixth pins of each PS 240 are connected to the positive and negative terminals of the AC power supply, the connections between ports 340 as shown in FIG. 4A are utilized, unlike FIGS. 3A-3B . As shown in FIG. 3A , the third and sixth pins are not connected to the DC power supply terminals, thus the dashed line connections shown in FIG. 3A are not used (i.e., do not perform power delivery/return).
Using the exemplary connections included in interconnect module 330 as shown in FIG. 4A , PS 240 - 0 , PS 240 - 1 , PS 240 - 2 and PS 240 - 3 each supply power to zone 0 FRUs 210 and supply power to zone 1 FRUs 210 . Only three power supplies are required to deliver full power to the FRUs 210 and any one of the four PSs 240 may fail without impacting the system. In this manner, interconnect module 330 provides DC power from PSs 240 in a 3+1 redundant manner, where any three PSs provide power to both of the two zones, and one PS provides redundant or backup power to the two zones.
Specifically, regarding PS 240 - 0 , pins one and two of connection port 340 - 0 deliver power from the positive terminal of AC power supply (in PS 240 - 0 ) to zone 0 FRUs 210 . Power returning from the zone 0 FRUs 210 to the negative terminal of AC power supply (in PS 240 - 0 ) may return via the fourth and fifth pin of connection port 340 - 0 . Additionally, pin one of connection port 340 - 0 is connected to pin three of connection port 340 - 1 . In this manner, power may also be provided from PS 240 - 0 to zone 1 FRUs 210 via pin three of connection port 340 - 1 .
Regarding returning power from zone 1 FRUs 210 , pin 4 of connection port 340 - 0 (that carries returning power from zone 0 FRUs 210 ) may be connected to pin six of connection port 340 - 3 . In this manner, power is returned from zone 1 FRUs 210 to the negative terminals of AC power supplies included in both PS 240 - 0 and PS 240 - 3 . Connecting the positive terminals of power supplies included in PS 240 - 0 and PS 240 - 1 and the negative terminals of power supplies included in PS 240 - 0 and PS 240 - 3 , ensures that power supplies included in PS 240 - 0 and PS 240 - 1 are not directly connected in parallel. For example, if both the positive and negative terminals of the power supplies included in PS 240 - 0 and PS 240 - 1 were connected together, a short circuit (of either power supply) would cause power from both power supplies to be dissipated throughout the FRUs 210 . By connecting returning power (supplied from PS 240 - 0 ) from zone 0 FRUs 210 to PS 240 - 3 (via pin six of connection port 340 - 3 ), a short circuit of the power supply in PS 240 - 0 results in power from only that one power supply being dissipated throughout the system (as opposed to power from both the power supplies in PS 240 - 0 and PS 240 - 1 ).
Regarding PS 240 - 1 , pins one and two of connection port 340 - 1 deliver power from the positive terminal of AC power supply (in PS 240 - 1 ) to zone 1 FRUs 210 . Power returning from the zone 1 FRUs 210 to the negative terminal of AC power supply (in PS 240 - 1 ) may return via the fourth and fifth pin of connection port 340 - 1 . Additionally, pin one of connection port 340 - 1 is connected to pin three of connection port 340 - 0 . In this manner, power may also be provided from PS 240 - 1 to zone 0 FRUs 210 .
Regarding returning power (supplied by PS 240 - 1 ) from zone 0 FRUs 210 , pin 4 of connection port 340 - 1 (that carries returning power from zone 1 FRUs 210 ) may be connected to pin six of connection port 340 - 2 . In this manner, power is returned from zone 0 FRUs 210 to the negative terminals of AC power supplies included in both PS 240 - 1 and PS 240 - 0 . Connecting the positive terminals of power supplies included in PS 240 - 1 and PS 240 - 2 and the negative terminals of power supplies included in PS 240 - 1 and PS 240 - 2 ensures that power supplies included in PS 240 - 1 and PS 240 - 2 are not directly connected in parallel. For example, if both the positive and negative terminals of the power supplies included in PS 240 - 1 and PS 240 - 2 were connected together, a short circuit (of either power supply) would cause power from both power supplies to be dissipated throughout the FRUs 210 . By connecting returning power (supplied from PS 240 - 1 ) from zone 1 FRUs 210 to PS 240 - 2 (via pin six of connection port 340 - 2 ), a short circuit of the power supply in PS 240 - 1 results in power from only that one power supply being dissipated throughout the system (as opposed to power from both the power supplies in PS 240 - 1 and PS 240 - 2 ).
Regarding PS 240 - 2 , connection port 340 - 2 supplies power to zone 0 FRUs 210 and returns power (to PS 240 - 2 ) via pin four. Positive terminals of power supplies in PS 240 - 2 and PS 240 - 3 are connected together (via pins 1 and 3 of connection ports 340 - 2 and 340 - 3 ) while returning power via pin four of connection port 340 - 2 may be connected to the negative terminal of the power supply included in PS 240 - 1 . As described above, connecting the positive terminals of power supplied connected in PS 240 - 2 and 240 - 3 without connecting the returning power paths of PS 240 - 2 and PS 240 - 3 , ensures that a short circuit of the power supply contained in PS 240 - 2 results in power from only that one power supply being dissipated throughout the system.
Regarding PS 240 - 3 , connection port 340 - 3 supplies power to zone 1 FRUs 210 via pin one and returns power (to PS 240 - 3 ) via pin four. Positive terminals of power supplies in PS 240 - 2 and PS 240 - 3 are connected together (via pins 1 and 3 of connection ports 340 - 2 and 340 - 3 ) while returning power via pin four of connection port 340 - 3 may also be connected to the negative terminal of the power supply included in PS 240 - 0 . As described above, connecting the positive terminals of power supplied connected in PS 240 - 2 and 240 - 3 without connecting the returning power paths of PS 240 - 2 and PS 240 - 3 , ensures that a short circuit of the power supply contained in PS 240 - 3 results in power from only that one power supply being dissipated throughout the system.
As described above, the connections provided by interconnect module 330 allow power to be provided from each PS 240 to both zones ( 0 and 1 ). Also, the returning power connections provided by interconnect module 330 ensure that a short circuit of any power supply may be an isolated short circuit where power from only the shorted power supply is dissipated throughout the system. Further, as the connections provided by connection ports 340 (and midplane 310 ) are identical in both FIGS. 3A and 4A , interconnect module 330 may receive either four AC power supplies (PSs 240 ) or may receive four DC power supplies (PEMs 230 ) and provide power to FRUs without requiring a change of connections. In this manner, interconnect module 330 may provide either N+N redundant power (2+2 as shown in FIG. 3A ) and M+1 redundant power (3+1 as shown in FIG. 4A ).
FIGS. 5A and 5B illustrate the connection module of FIG. 2 supplying redundant power within the exemplary device of FIG. 1 according to a second N+N exemplary implementation. FIG. 5A depicts connection module 220 , which includes midplane 510 , power over Ethernet connection 520 and interconnect module 530 , supplying N+N redundant power from PEMs 230 - 0 through 230 - 3 to FRUs 210 .
Midplane 510 may include electrical connections that may connect FRUs 210 to interconnect module 530 . Midplane 510 may also include a power over Ethernet connection 520 in order to provide power to FRUs 210 via an Ethernet connection.
Interconnect module 530 may include connection ports used to receive DC power from PEMs 230 and circuit pathways to deliver power to midplane 510 . For example, interconnect module 530 may include four connection ports 540 - 1 to 540 - 4 that may receive power from four power entry modules PEMs 230 that may be plugged into ports 540 . As shown, connection ports 540 may include nine connection pins that may connect to power entry modules 230 . It should be understood that the number of pins contained in interconnect module 530 may be more or less depending on the requirements of a power delivery system of device 110 and/or the requirements of the power entry modules 230 plugged into connection ports 540 .
Power entry modules (PEMs) 230 may include a DC power supply and connections to enable power to be supplied from the DC power supply to interconnect module 530 . In this example, PEMs 230 may include nine pins that may be used to connect to interconnect module 530 . As mentioned above, it should be understood that the number of pins contained in PEMs 230 may be more or less depending on the requirements of a power delivery system of device 110 and/or the requirements of the interconnect module 530 .
FIG. 5B shows an enlarged view of a port 540 and a PEM 230 as connected in FIG. 5A . As shown, port 540 includes nine pins (labeled 1 - 9 ). Similarly, PEM 230 includes nine pins that connect to the nine pins in port 540 . In the example shown in FIG. 5B , the first two pins of connection port 540 may be connected to the positive terminal of the DC power supply and the fourth and fifth pins of connection port 540 may be connected to a negative side of the DC power supply. As the third and sixth pins of each PEM 230 are not connected to either the positive or negative terminals of a DC power supply, these pins do not supply or return power to/from interconnect module 530 . Therefore, in the example shown in FIG. 5A , the dashed line connections between ports 540 using the third and sixth pins (are present, however) do not perform power delivery.
Using the exemplary connections included in interconnect module 530 as shown in FIG. 5A , PEM 230 - 0 supplies power to zone 0 FRUs 210 and PEM 230 - 1 supplies power to zone 1 FRUs 210 . PEM 230 - 2 supplies backup power to zone 0 FRUs 210 and PEM 230 - 3 supplies backup power to zone 1 FRUs 210 . In this manner, interconnect module 530 provides power from PEMs 230 in a 2+2 redundant manner, where two PEMs ( 230 - 0 and 230 - 1 ) provide power to the two zones, and each of the two PEMs ( 230 - 0 and 230 - 1 ) have a redundant or backup power supply (i.e., PEM 230 - 2 and 230 - 3 respectively).
Specifically, pins one and two of PEM 230 - 0 (and connection port 540 - 0 ) deliver power from the positive terminal of DC power supply to zone 0 FRUs 210 . Power returning from zone 0 FRUs 210 to the negative terminal of DC power supply may return via the fourth pin of connection port 530 (and PEM 230 - 0 ). Similarly, PEM 230 - 2 supplies backup power to zone 0 FRUs 210 in the same manner as PEM 230 - 0 . Pins one and two of PEM 230 - 1 (and connection port 530 ) deliver power from the positive terminal of DC power supply to zone 1 FRUs 210 . Power returning from zone 1 FRUs 210 to the negative terminal of DC power supply may return via the fourth pin of connection port 540 (and PEM 230 - 1 ). Similarly, PEM 230 - 3 supplies backup power to zone 1 FRUs 210 in the same manner as PEM 230 - 1 .
FIGS. 6A and 6B illustrate the connection module of FIG. 2 supplying redundant power within the exemplary device of FIG. 1 according to a second M+1 exemplary implementation. FIG. 6A depicts connection module 220 , which includes midplane 510 , power over Ethernet connection 520 and interconnect module 530 , supplying M+1 redundant power received from AC power supplies included in PSs 240 - 0 through 240 - 3 to FRUs 210 .
Interconnect module 530 may include connection ports used to receive power from a device and circuit pathways to deliver power to midplane 510 . For example, interconnect module 530 may include four connection ports 540 - 1 to 540 - 4 that may receive DC output power from four AC power supplies PSs 240 - 0 to 240 - 3 that may be plugged into ports 540 . As shown, connection ports 540 may include nine connection pins that may connect to PSs 240 . It should be understood that the number of pins contained in interconnect module 530 may be more or less depending on the requirements of a power delivery system of device 110 and/or the requirements of the PSs 240 plugged into connection ports 540 .
Power supplies (PSs) 240 may include a load sharing AC power supply, AC to DC conversion circuitry and connections to enable output DC power to be supplied from the AC power supplies to interconnect module 530 . In this example, PSs 240 may include nine pins that may be used to connect to connection ports 540 in interconnect module 530 . As mentioned above, it should be understood that the number of pins contained in PSs 240 may be more or less depending on the requirements of a power delivery system of device 110 and/or the requirements of the interconnect module 530 .
FIG. 6B shows an enlarged view of a port 540 and a PS 240 as connected in FIG. 6A . As shown, port 540 includes nine pins (labeled 1 - 9 ). Similarly, PS 240 includes nine pins that connect to the nine pins in port 540 . In the example shown in FIG. 6B , the first three pins of each PS 240 may be connected to the positive (DC output) terminal of the AC power supply and the fourth, fifth and sixth pins of each PS 240 may be connected to a negative (DC output) terminal of the AC power supply. When each PS 240 is plugged into port 540 the first three pins of port 540 may receive power from the positive (DC output) terminal of the AC power supply and the fourth through sixth pins of port 540 may return power to the negative (DC output) terminal of the AC power supplies included in PS 240 . As the seventh through ninth pins of each PS 240 are not connected to either the positive or negative terminals of an AC power supply, these pins do not supply or return power to/from interconnect module 530 . As the third and sixth pins of each PS 240 are connected to the positive and negative terminals of the AC power supply, the connections between ports 540 as shown in FIG. 6A are utilized, unlike FIGS. 5A-5B . As shown in FIG. 5A , the third and sixth pins are not connected to the DC power supply terminals, thus the dashed line connections shown in FIG. 5A are not used (i.e., do not perform power delivery/return).
Using the exemplary connection ports and circuit pathways included in interconnect module 530 , as shown in FIG. 6A , PS 240 - 0 , PS 240 - 1 , PS 240 - 2 and PS 240 - 3 each supply power to zone 0 FRUs 210 and supply power to zone 1 FRUs 210 . Any one of the PSs 240 may supply backup power to zone 0 FRUs 210 and zone 1 FRUs 210 . In this manner, interconnect module 530 provides power from PSs 240 in a 3+1 redundant manner, where any three PSs provide sufficient power to both of the two zones, and one PS may provide redundant or backup power to the two zones.
Specifically regarding PS 240 - 0 , pins one and two of connection port 540 - 0 deliver power from the positive terminal of AC power supply (in PS 240 - 0 ) to zone 0 FRUs 210 . Power returning from the zone 0 FRUs 210 to the negative terminal of AC power supply (in PS 240 - 0 ) may return via the fourth and fifth pin of connection port 540 - 0 . Additionally, pin one of connection port 540 - 0 is connected to pin three of connection port 540 - 1 . In this manner, power may also be provided from PS 240 - 0 to zone 1 FRUs 210 via pin three of connection port 540 - 1 .
Regarding returning power from zone 1 FRUs 210 , pin four of connection port 540 - 0 (that carries returning power from zone 0 FRUs 210 ) may be connected to pin six of connection port 540 - 1 . In this manner, power is returned from zone 1 FRUs 210 to the negative terminals of AC power supplies included in both PS 240 - 0 and PS 240 - 1 . Connecting both the positive terminals of power supplies included in PS 240 - 0 and PS 240 - 1 and the negative terminals of power supplies included in PS 240 - 0 and PS 240 - 1 connects these power supplies in parallel. A short circuit of either of the power supplies included in PS 240 - 0 and PS 240 - 1 may cause power from both power supplies to be dissipated throughout the FRUs 210 , however as the power supplies are connected in parallel, this prevents twice the voltage of one power supply (due to a series connection) from being applied across the FRUs 210 if a short circuit occurs.
Regarding PS 240 - 1 , pins one and two of connection port 540 - 1 deliver power from the positive terminal of AC power supply (in PS 240 - 1 ) to zone 1 FRUs 210 . Power returning from the zone 1 FRUs 210 to the negative terminal of AC power supply (in PS 240 - 1 ) may return via the fourth and fifth pin of connection port 540 - 1 . Additionally, pin one of connection port 540 - 1 is connected to pin three of connection port 540 - 0 . In this manner, power may also be provided from PS 240 - 1 to zone 0 FRUs 210 .
Regarding returning power (supplied by PS 240 - 1 ) from zone 0 FRUs 210 , pin 4 of connection port 540 - 1 (that carries returning power from zone 1 FRUs 210 ) may be connected to pin six of connection port 540 - 0 . In this manner, power is returned from zone 0 FRUs 210 to the negative terminals of AC power supplies included in both PS 240 - 1 and PS 240 - 0 . Connecting the positive terminals of power supplies included in PS 240 - 1 and PS 240 - 0 and the negative terminals of power supplies included in PS 240 - 1 and PS 240 - 0 connects these power supplies in parallel, which prevents twice the voltage of one power supply (due to a series connection) from being applied across the FRUs 210 if a short circuit occurs.
Regarding PS 240 - 2 , pins one and two of connection port 540 - 2 deliver power from the positive terminal of AC power supply (in PS 240 - 2 ) to zone 0 FRUs 210 . Power returning from the zone 0 FRUs 210 to the negative terminal of AC power supply (in PS 240 - 2 ) may return via the fourth and fifth pin of connection port 540 - 2 . Additionally, pin one of connection port 540 - 2 is connected to pin three of connection port 540 - 3 . In this manner, power may also be provided from PS 240 - 2 to zone 1 FRUs 210 .
Regarding returning power (supplied by PS 240 - 2 ) from zone 1 FRUs 210 , pin 4 of connection port 540 - 2 (that carries returning power from zone 0 FRUs 210 ) may be connected to pin six of connection port 540 - 3 . In this manner, power is returned from zone 1 FRUs 210 to the negative terminals of AC power supplies included in both PS 240 - 2 and PS 240 - 3 . Connecting the positive terminals of power supplies included in PS 240 - 2 and PS 240 - 3 and the negative terminals of power supplies included in PS 240 - 2 and PS 240 - 3 connects these power supplies in parallel, which prevents twice the voltage of one power supply (due to a series connection) from being applied across the FRUs 210 if a short circuit occurs.
Regarding PS 240 - 3 , pins one and two of connection port 540 - 3 deliver power from the positive terminal of AC power supply (in PS 240 - 3 ) to zone 1 FRUs 210 . Power returning from the zone 1 FRUs 210 to the negative terminal of AC power supply (in PS 240 - 3 ) may return via the fourth and fifth pin of connection port 540 - 3 . Additionally, pin one of connection port 540 - 3 is connected to pin three of connection port 540 - 2 . In this manner, power may also be provided from PS 240 - 3 to zone 0 FRUs 210 .
Regarding returning power (supplied by PS 240 - 3 ) from zone 0 FRUs 210 , pin 4 of connection port 540 - 3 (that carries returning power from zone 1 FRUs 210 ) may be connected to pin six of connection port 540 - 2 . In this manner, power is returned from zone 0 FRUs 210 to the negative terminals of AC power supplies included in both PS 240 - 2 and PS 240 - 3 . As described above, connecting the positive terminals of power supplies included in PS 240 - 2 and PS 240 - 3 and the negative terminals of power supplies included in PS 240 - 2 and PS 240 - 3 connects these power supplies in parallel, which prevents twice the voltage of one power supply (due to a series connection) from being applied across the FRUs 210 if a short circuit occurs.
FIG. 7 is an exemplary process 700 of delivering power using connection module 220 , as shown in FIGS. 3A-6B . Referring to FIGS. 3A-6B , process 700 may begin by providing a first number of ports via an interconnect module (block 710 ). As shown in both FIGS. 3A and 4A for example, four connection ports 340 - 0 to 340 - 3 , may be included in interconnect module 330 . Also, as shown in both FIG. 5A and FIG. 6A for example, four connection ports 540 - 0 to 540 - 3 may be included in interconnect module 530 . Process 700 may continue by receiving either a first number of DC power supplies or a first number of AC power supplies into the interconnect module (block 720 ). As shown in FIG. 3A for example, four connection ports 340 - 0 to 340 - 3 in interconnect module 330 may receive four DC PEMs 230 - 0 to 230 - 3 . As shown in FIG. 4A for example, the same four connection ports 340 - 0 to 340 - 3 in interconnect module 330 may also receive four AC power supplies PSs 240 - 0 to 240 - 3 . As shown in FIG. 5A for example, four connection ports 540 - 0 to 540 - 3 in interconnect module 530 may receive four PEMs 230 - 0 to 230 - 3 . As shown in FIG. 6A for example, the same four connection ports 540 - 0 to 540 - 3 in interconnect module 330 may also receive four AC power supplies PSs 240 - 0 to 240 - 3 . Once connected via ports ( 340 or 540 ), either N+N (e.g., 2+2) redundant power or M+1 (e.g., 3+1) redundant power may be provided via the interconnect module (block 730 ).
In other examples, interconnect module 330 may include two or six connection ports 340 . In these examples, the number of power zones within device 110 may be one or three respectively. For example, if interconnect module 330 includes only two connection ports 340 , there may be only one power zone for the FRUs 210 . With only two connection ports 340 , 1+1 redundant DC input/DC output power and 1+1 redundant AC input/DC output power may be provided to the single power zone. Referring to FIGS. 3A and 4A , connection ports 340 - 0 and 340 - 2 in interconnect module 330 may be used to provide 1+1 redundant DC input/DC output power and 1+1 redundant AC input/DC output power to the single power zone (zone 0 ).
If interconnect module 330 includes six connection ports 340 , there may be three power zones for the FRUs 210 . With six connection ports 340 , 3+3 redundant power and 5+1 redundant power may be provided to the three power zones. Referring to FIGS. 3A and 4A , two additional connection ports 340 may be required to provide 3+3 redundant power and 5+1 redundant power to the three power zones. In this example, when supplying DC power, the two additional connection ports 340 may be connected such that one port provides power and one port provides backup power (as shown in FIG. 3A ) and when supplying AC power, the two additional ports 340 may be connected (via interconnect module 330 ) in the same manner as ports 340 - 2 and 340 - 3 (as shown in FIG. 4A ) to supply power to the third power zone. In this example, the positive terminals of additional power supplies may be connected without connecting the returning power paths directly, as described above.
In other examples, interconnect module 530 may include two or six connection ports 540 . In these examples, the number of power zones within device 110 may be one or three respectively. For example, if interconnect module 530 includes only two connection ports 540 , there may be only one power zone for the FRUs 210 . With only two connection ports 540 , 1+1 redundant DC input/DC output power and 1+1 redundant AC input/DC output power may be provided to the single power zone. Referring to FIGS. 5A and 6A for example, connection ports 540 - 0 and 540 - 2 may be used to provide 1+1 redundant DC input/DC output power and 1+1 redundant AC input/DC output power to a single power zone (zone 0 ).
If interconnect module 530 includes six connection ports 540 , there may be three power zones for the FRUs 210 . With six connection ports 540 , 3+3 redundant power and 5+1 redundant power may be provided to the three power zones. Referring to FIG. 5A and FIG. 6A , two additional connection ports 540 may be required to provide 3+3 redundant power and 5+1 redundant power to the three power zones. In this example, when supplying DC power, the two additional connection ports 540 are connected such that one port provides power and one port provides backup power (as shown in FIG. 5A ) and when supplying AC power, the two additional ports 540 may be connected (via interconnect module 530 ) in the same manner as ports 540 - 2 and 540 - 3 (as shown in FIG. 6A ) to supply power to the third power zone. In this example, both the positive and negative terminals of additional power supplies may be connected, as described above.
As described above, as the connections provided by interconnect module 530 and connection ports 540 (and midplane 510 ) are identical in FIG. 5A and FIG. 6A , interconnect module 530 may receive a number of AC power supplies or may receive a number of DC power supplies and provide power to FRUs 210 without requiring a change of connections. In this manner, interconnect module 530 may provide either one of N+N redundant power or M+1 redundant power.
CONCLUSION
Implementations described herein may allow ports within an interconnect module to receive either an AC power supply or a DC power supply. Connections within the interconnection module allow for either N+N redundant power or M+1 redundant power to be applied to power zones within the device.
The foregoing description of preferred embodiments of the present embodiments provides illustration and description, but is not intended to be exhaustive or to limit the embodiments to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practice of the embodiments. For example, while series of acts have been described with regard to FIG. 7 , the order of the acts may differ or be performed in parallel in other implementations consistent with the present embodiments. Furthermore, various implementations have been described with respect to two power zones and using 2+2 redundant power distribution or 3+1 redundant power distribution. However, the connection module described herein may be applied, with minor modifications, to any N+N or M+1 redundant power distribution system.
Even though particular combinations of features are recited in the claims and/or disclosed in the specification, these combinations are not intended to limit the invention. In fact, many of these features may be combined in ways not specifically recited in the claims and/or disclosed in the specification.
No element, act, or instruction used in the description of the principles of the embodiments should be construed as critical unless explicitly described as such. Also as used herein, the article “a” is intended to include one or more items. Where only one item is intended, the term “one” or similar language is used. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise.
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A device may include an interconnect module that includes a number of ports, where each port is configured to receive both an alternating current (AC) power supply and a direct current (DC) power supply; where the interconnect module provides power from the received power supplies to a plurality of field replaceable units (FRUs).
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to Korean Application No. 10-2008-0089624, filed on Sep. 11, 2008; the content of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to a connector, more specifically, a connector for linear members of wall structure which allows a variety of guide rails, fences, and pipes to be conveniently assembled in a desired pattern.
BACKGROUND OF THE INVENTION
Wall structures used for guard rails of stairs, guide rails for discriminating between a roadway and a footway, and fences for representing boundaries of land generally have posts that are vertically positioned at a distance and blocking members between the posts. Especially, lattices made by linear members, for example, bars and pipes, etc. are usually used.
Recently, many of self-governing bodies use wall structures which are designed to present a fine sight or to represent symbols of the bodies. Accordingly, there are continuous efforts to provide a variety of designs onto the wall structures. In addition, one must consider a functionality and an utility as well as a sense of beauty.
Guide rails of prior art generally includes vertical pipes anchored to the ground by anchor bolts, transverse pipes, and elongated pipes spanning between the vertical pipes and the transverse pipes. The pipes are connected, for example, by welding methods to construct the guide rails. In that case, the pipes are cut in a predetermined length and a predetermined cutting angle and then welded each other. This is a time-consuming work and limits the design of the guide rails. The inventor of the present invention had developed a improved pipe thread for guide rail to address the problems, which is pending as a Korean Patent Application no. 10-2004-0079751.
A front view of the guide rail 100 according to above Korean Patent Application is shown in FIG. 1 . In the drawings, pipes P are connected radially to the Connectors 1 . One end of the pipe is connected to the connector 1 and the other end is connected to a frame, for example, a post. The present invention is to improve the connector 1 shown FIG. 1 .
The object of the invention is thus to provide a improved connector for linear members of wall structure, which makes it possible to connect the linear members and then construct wall structures, such as guard rails, fences and guide rails, etc. in a simple manner. Another object of the invention is to provide a simple and slim connector for linear members.
SUMMARY OF THE INVENTION
To achieve the above objects, the connector in accordance with the present invention includes:
a central body of annular shape; at least one socket member, one end of the socket member being connected to the central body and the other end being connected to a linear member, such as a pipe, a wire or a bar; and a rail means that connects the central body and the socket member such that the socket member can be moved along the circumferential surface of the central body.
According to one aspect of the invention, the central body comprises a cylinder member; the rail means comprises at least one annular, L-shape guide groove, and at least one latch to engage the guide groove and to prevent the socket member from disengaging therefrom. Cover members having a circular disc and a rim, respectively, are fitted onto the opposite sides of the cylinder member such that at least one guide groove is concealed
According to the present invention, wall structures are easily constructed by assembling a plurality of linear members including pipes and bars in various patterns. Also, the connector according to the present invention has a simple structure, and thus the present invention can achieve lower costs.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and therefore, are not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a front view of a guide rail constructed by connectors of the present invention;
FIG. 2 is a perspective view of a connector according to a first embodiment of the present invention;
FIG. 3 is a exploded view of the connector shown in FIG. 2 ;
FIGS. 4A and 4B are cross-sectional views of the connector taken from the line A-A in FIG. 2 ;
FIG. 5 is a front view of the connector shown in FIG. 2 ;
FIGS. 6A and 6B are cross-sectional views of a connector according to a second embodiment of the present invention;
FIGS. 7A , 7 B, 8 A and 8 B are cross-section views of the connectors according to a third and a forth embodiments of the present invention;
FIG. 9 is a front view of the connector according to another embodiment of the present invention;
FIGS. 10A and 10 are cross-sectional views of a connector according to a fifth embodiment of the present invention;
FIG. 11 is a cross-sectional view of a connector according to a sixth embodiment of the present invention;
FIG. 12 is a exploded view of the connector shown in FIG. 11 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a front view of a guide rail constructed by the connectors of the present invention. FIG. 2 is a perspective view of a connector according to a first embodiment of the present invention. FIG. 3 is an exploded view of the connector shown in FIG. 2 . FIGS. 4A and 4B are cross-sectional views of the connector taken from the line A-A in FIG. 2 . FIG. 5 is a front view of the connector shown in FIG. 2 . FIGS. 6A and 6B are cross-sectional views of a connector according to a second embodiment of the present invention. FIGS. 7A , 7 B, 8 A and 8 B are cross-section views of the connectors according to a third and a forth embodiments of the present inventions. FIG. 9 is a front view of the connector according to another embodiment of the present invention. The connectors of the present invention are used in same applications as the connector 1 shown in FIG. 1 .
A plurality of linear members are radially connected to the central body of annular shape. At least one socket member is located between the central body and the linear member. One end of the socket member is connected to the central body and extends out radially, and the other end of the socket member is connected to the linear members such as pipes, wires and bars. The rail means is located at the connection between the central body and the socket member so that the socket member moves along the circumferential surface of the central body with one end of the socket member being connected to the central body. The rail means may be installed in various ways. As noted, the central body and the rail means can be modified within the scope of the present invention.
Referring to FIGS. 2 to 5 , one embodiment of the present invention is described.
In one embodiment, a cylinder member 2 is used as the central body. Two L-shaped guide grooves 4 and latches 10 engaging the guide grooves are used as the rail means.
The cylinder member 2 having a constant width includes two guide grooves 4 along the circumferential surface. The cylinder member 2 can be made as an unitary piece or made by two or more pieces. Referring to the FIG. 2 , the cylinder member 2 has a ring shape with a thickness of 1 to 4 cm, and two L-shaped guide grooves 4 are symmetrically provided on the cylinder member 2 .
Provided at one end of the socket member 6 is a flange 8 . Latches 10 also are provided on the flange 8 such that the flange 8 can be moved along the guide grooves 4 . Once the latches 10 engage with the guide grooves 4 , the socket member 6 can not move away radially, but can rotate along the circumferential edges of the cylinder member 2 . The flange 8 of the socket member 6 has a curved shape that corresponds to the curvature of the cylinder member 2 .
According to one embodiment of the invention, a slot 12 for inserting the latch 10 is provided on the surface of the cylinder member 2 . The slot is preferably closed after the required numbers of the latches 10 are inserted. Alternatively, the slot 12 remains open, in this case, the socket member is preferably positioned at a distances from the slot.
Linear members are connected to the other end of the socket member 6 . For this, a thread 13 is provided on the other end of the socket member 6 . As described above, the linear member may comprise bar, wire, and pipe etc. In the drawings, linear members are shown as pipes P, and the linear members are referred to as pipes P below.
Similar to the conventional plumbing methods, the socket member 6 and the pipe P may be joined by threads. For this connection, there is provided, for example, a male thread on the other end of the socket member 6 and a female thread on the inside of the pipe P. In addition to the threads, other connecting means, such as rivets and welds can be employed.
One or more socket members 6 can be mounted onto the cylinder member 2 and all of the socket members 6 need not to have a same shape. As shown in FIG. 9 , one of the socket members 6 can be connected to a post C of the wall structure. In this case, a bracket 11 can be provided at the other end of socket member 6 .
Cover members 14 , 15 are fitted onto the opposite sides of the cylinder member 2 . As shown in the drawings, the cover members 14 , 15 can be fitted on by hooks. Specifically, rims 14 a, 15 a of the cover members 14 , 15 are joined such that the the rims cover over the flanges 8 of the socket members 6 and conceal the guide grooves 4 . Recesses 16 are provided on the flange 8 of the socket members and protrusions 20 are provided on the underside of the cover members 14 , 15 . The protrusions 20 engage with the recesses 16 .
Cover members 14 , 15 are joined together by a center bolt 22 and a center nut 24 to prevent the cover members 14 , 15 and the cylinder member 2 from disengaging. The center bolt 22 and the center nut 24 can be molded integrally with each of the cover members 14 , 15 . Alternatively, the cover members 14 , 15 can be joined by hooks other than the bolt-nut joining means.
According to another embodiment of the invention, as shown in FIGS. 6A and 6B , the cover members 14 , 15 may be engaged with the socket members 6 by threads. For this, for example, a male screw is provided on the top surface of the socket member 6 and a female screw is provided on the inside of the rims 14 a, 15 a of the cover members 14 , 15 . According to this embodiment, components, for example, the center bolt 22 (see FIG. 4 ) of above embodiment are not needed any more.
Connectors for linear members according to another embodiments are described below. FIGS. 7A , 7 B, 8 A and 8 B are cross-sectional views of the connectors according to the embodiments of the invention. In these embodiments, the central body is the cylinder member 2 and cover members 14 , 15 with rims on the edges thereof are fitted onto the opposite sides of the cylinder member 2 .
The rail means are formed by the circumferential surface of the cylinder member 2 and the rims 14 a, 15 a of the cover members. The circumferential surface is provided with two guide grooves 4 and two latches 10 formed at one end of the socket member 6 are engaged with the guide grooves 4 .
According to this embodiment, generally L-shaped guides are formed by assembling the cover members 14 , 15 and the socket members 6 . The socket members 6 can not moved away radially by the L-shaped guides formed between the cover members 14 , 15 and the socket members 6 . As a result, unlikely the above embodiments, the cover members 14 , 15 may be essential constitutions of the rail means in this embodiment.
Referring to FIGS. 8A and 8B , the cover members 14 , 15 are engaged with each other by a center bolt 22 and a center nut 24 . Alternatively in the embodiment shown in FIG. 7 , the cover members 14 , 15 and the socket members 6 may be joined each other by threads. In this case, means for joining the cover members 14 , 15 each other is not needed.
Referring to FIGS. 8A and 8B , the cover members 14 , 15 and the socket members 6 are snap-fitted by protrusions 20 and recesses 16 and the cover members 14 , 15 are engaged with each other by a center bolt 22 and a center nut 24 .
FIGS. 10A and 10B are cross-sectional views of a connector according to yet another embodiment of the present invention. In this embodiment, the cover members 14 , 15 and the cylinder member 2 are joined together by threads. Guides formed by assembling the cover members 14 , 15 and the socket members 6 are used as rail means. The guides prevent the socket members 6 from moving away from the cylinder member 2 radially. In this embodiment, like the above embodiments, the central body is embodied as the cylinder member 2 and the cover members 14 , 15 and the rail means are embodied as the guides that are formed by joining the cylinder member 2 and the cover members 14 , 15 .
In the embodiments, while the cylinder members 2 are described and shown as a cylindrical shape, the present invention is not limited to this shape. Instead, the cylinder members 2 can have any shapes including an oval shape, or a polygon shape with round edges.
FIG. 11 is a cross-sectional view of a connector according to yet another embodiment of the present invention and FIG. 12 is a exploded view of the connector shown in FIG. 11 . In this embodiment, unlikely the above embodiments, the cylinder members 2 (see FIGS. 2 to 10 ) are omitted. In this embodiment, only cover members 14 , 15 are used as central body. In addition, the rail means are formed by the rims 14 a, 15 a of the cover members 14 , 15 and a guide groove located around the socket member 6 . The cover members 14 , 15 are joined together by the center bolt 22 and the center nut 24 .
Connectors for linear members are assembled to a frame for a plastic greenhouse or a glasshouse by mounting the socket members 6 to the cylinder members 2 , installing the cylinder members 2 to posts, screwing elongate pipes used as rafters to the socket members 6 , and positioning the cylinder members 2 at vertices of a triangle such that the elongate pipes are sides of the triangle.
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Connectors for linear members of wall structure which allows a variety of guide rails, fences, and pipes to be assembled in a desired pattern conveniently are provided. The connector includes a central body of annular shape; at least one socket member 6 , the one end of the socket member being connected to the central body and the other end being connected to the linear member, such as pipe, wire or bar; and a rail means that connects the central body and the socket member such that the socket member can be moved along the circumferential surface of the central body.
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BACKGROUND OF THE INVENTION
The present invention relates to the field of data processing, and in particular, to technology which is especially effective when applied to an instruction processor in a system using a program controlled method, for example, to a microprocessor system having an instruction to control access to a memory having an array data structure called a queue.
In a microcomputer system, there has been known a method in which a memory area called an entry having a fixed size is established in a memory and each memory area is linked by use of an index called a pointer, thereby configuring the memory to have an array data structure (queue) by means of software (operating system).
For the general configuration of the queue, reference is made to FIG. 4, in which a plurality of entries ENT 0 , ENT 1 , ..., ENTn are provided in a memory and each entry has a pointer Pa as the first field thereof, in which there is stored an address indicating the first or starting address of an entry following that entry, thereby forming a sequence of data in an array by linking the entries with the pointers. In some cases, there is provided a queue having a double link structure, namely, one in which each entry is provided with a pointer Pb following the pointer field Pa so as to indicate a backward linkage of the entry. The queue configured in this fashion is used in a case where, for example, each entry is used to store jobs (or tasks) requested from a plurality of users and an entry satisfying a predetermined condition is selected from the entries for execution.
Conventionally, for example, in a computer such as the VAXll of the Digital Equipment Corporation (DEC), there are instructions which serve to insert, to delete, and to replace entries, thereby facilitating the creation of the queue ("DEC VAXll Architecture Handbook", DEC, 1979, pp. 176-195).
In a computer of the type described above, however, a search for a desired entry from a queue has not been provided. Consequently, in a case where a desired entry is to be retrieved, the search operation must be effected by use of a sequence of data transfer instructions (MOVE instructions).
As a result, a long period of time is required to retrieve an entry of a queue, which leads to a disadvantage that the efficiency of the operating system for effecting the table control in the multitask processing, the multiuser processing, and the like is deteriorated.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to increase the speed of the queue retrieval operation in a microprocessor system configured to include an instruction system supporting the creation of a queue and thereby to improve the efficiency of the operating system handling multitask, multiuser processing, and the like.
The above and other objects and novel features of the present invention are achieved in a microprocessor configured to have an instruction system supporting the creation of a queue, and in which a new retrieval instruction is added to retrieve a queue. The queue retrieval instruction is effected after data necessary for the queue retrieval, such as the first address of the first entry, a compare value as a condition for the selection, and an offset value of the retrieval data in the entry, are set into predetermined registers. The first address of a desired entry is obtained by the queue retrieval instruction and by a register set instruction preceding the queue retrieval instruction so as to increase the queue retrieval speed, which makes it possible to achieve the object that the efficiency of the operating system handling multitask, multiuser processing, and the like is improved.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
FIGS. 1A-1C are explanatory diagrams illustrating examples of the format of a queue search instruction according to the present invention;
FIG. 2 is a schematic block diagram illustrating an example of a microprocessor for executing the queue search instruction according to the present invention.
FIG. 3 is a flowchart depicting an example of a processing procedure in a case where the queue search instruction is executed by means of a microprogram.
FIG. 4 is a schematic diagram depicting an example of a queue formed in a memory for purposes of explaining the operation of the present invention; and
FIGS. 5A-5C are flowcharts showing another example of a processing procedure in a case where the queue search instruction is executed by means of a microprogram.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1A shows an embodiment of the instruction format of a queue retrieval instruction (to be referred to as a queue search instruction herein) in a case where the present invention is applied to a microprocessor having an instruction processing system in which the instruction is 16 or 32 bits.
The queue search instruction shown in FIG. lA includes operation designation fields OP 1 and OP 2 , respectively, containing 16 high-order bits and 8 low-order bits each representing operation codes, an end condition designation field EC designating an end condition of the instruction, a size designation field Sz indicating the magnitude of a compare value, a format bit field Bi designating the format of the instruction, an M bit field indicating the presence or absence of a mask of R 6 , an E bit indicating the end value of the queue, and a U bit designating the direction of the search operation.
FIG. 1B shows a second format of the queue search instruction according to the present invention. The second instruction format is different from the first instruction format (FIG. 1A) in a point that an immediate addressing is adopted for the offset value. Namely, in the second instruction format, the 5 low-order bits of the 7 bits constituting the operation designation field OP 2 in the first instruction formation are replaced with the immediate field IM.
For the queue search instruction, the discrimination between the first format and the second format is effected by use of the bit Bi, for example, if the bit Bi is "0", the 5 low-order bits of the instruction word are treated as the operation designation field OP 2 ; whereas, if the bit Bi is "1", the 5 low-order bits of the instruction word are treated as the immediate field IM. However, since the immediate field IM comprises five bits, the 5-bit code of the immediate field must be converted into 32-bit wide data by use of sign expansion, or
In this embodiment, the end condition designation field EC includes four bits, which are defined, for example, as listed in Table 1 as follows.
TABLE 1______________________________________END CONDITIONNo. B B B B CONTENTS______________________________________1 0 0 0 0 UNCONDITIONAL END2 0 0 0 1 = R.sub.33 0 0 1 0 ≠ R.sub.34 0 0 1 1 < R.sub.35 0 1 0 0 > R.sub.36 0 1 0 1 = R.sub.3 OR = R.sub.47 0 1 1 0 ≠ R.sub.3 AND ≠ R.sub.48 0 1 1 1 < R.sub.3 OR > R.sub.49 1 0 0 0 > R.sub.3 AND < R.sub.4______________________________________
In this diagram, the conventional symbols =, ≠, <, and > have their well-known meaning. End conditions No. 1 to No. 5 represent the cases where the end conditions are established according to the comparison between the data read from an entry with the value in the register R 3 , whereas the end conditions No. 6 to No. 9 denote the cases where the end conditions are set depending on the comparison between the value of the register R 3 and that of the register R..
In addition, the size designation field Sz is constituted by two bits and, for example, if the two bits are "00", the compare value includes eight bits; and if the two bits are "01", the compare value includes 16 bits; and if the two bits are "10", the compare value includes 32 bits. Consequently, in a case where the compare value is preliminarily loaded in a register (32 bits) as will be described later, the system operates according to the contents of the size designation field Sz to handle information of the 8, 16, or 32 low-order bits as the effective compare value.
Furthermore, in the embodiment described above, when the M bit is "0", it is indicated that the mask of the register R 6 is absent; whereas, when the M bit is "1", the mask is indicated to be present. The E bit denotes the end condition of the queue, namely, for E=0, the end condition is "0"; whereas for E=1, the end condition is indicated by the content of the register R 2 . The code U of the lower-most bit of the operation designation field OP 2 is treated as a code indicating the search direction of the instruction. For example, for U=0, the search is effected in the forward direction; whereas U=1, the search is effected in the backward direction.
Incidentally, in the instruction formats shown in FIGS. 1A and 1B, the arrangement of the respective fields in the 32-bit area does not possess any substantial meaning. However, in a microprocessor in which the read unit of an instruction is selected to be 16 bits, the 32-bit queue search instruction is split into two words so as to be read in an instruction register through two 16-bit read operations.
FIG. 1C is a schematic diagram illustrating another form of the queue search instruction according to the present invention. This queue search instruction comprises 16 bits. The operation designation fields OP 1 , OP 2 , and OP 3 are used to specify that this instruction is a queue search instruction. Furthermore, in addition to the 2-bit size designation field SZ and the 4-bit end condition designation field EC, the instruction format includes the M bit, the U bit, and the like. An offset value necessary for an execution of this instruction is previously set into the register R 5 , for example. In addition, the P bit designates the size of data to be handled. For example, for P=0, the data size is 32 bits; whereas for P=1, the data size is 64 bits.
FIG. 2 is a schematic block diagram illustrating an example of the hardware configuration of th microprocessor operating by use of an instruction system having the queue search instruction according to the present invention.
The microprocessor of this embodiment includes a control section operating under control of microprograms. That is, in an LSI chip 1 constituting the microprocessor, there is disposed a micro (read only memory) ROM 2, which is accessed by a micro address generator circuit 5 and sequentially outputs micro instructions contained in the microprograms.
The micro address generator circuit 5 is supplied with a signal obtained by decoding in an instruction decoder a code of a macro instruction fetched by an instruction register 3. Based on the supplied signal, the micro address generator circuit 5 forms the corresponding micro address and supplies the address to the micro ROM 2, which is used to read the first micro instruction of a series of micro instruction groups executing the macro instruction. Based on the micro instruction code, the system generates control signals for components, such as an execution unit 6 having various temporary registers, data buffers, an arithmetic logic unit (ALU), an address calculation unit (AU), and the like.
The read operations of the second and subsequent micro instructions in the sequence of micro instruction groups corresponding to the macro instruction are effected by supplying the micro ROM 2 with the code of the next address field of the micro instruction are effected by supplying the micro ROM 2 with the code of the next address field of the micro instruction previously read. That is, there is provided a micro instruction latch 9 for keeping the next address in the previous micro instruction, and the read operations of the second and subsequent micro instructions are achieved based on an output from the micro instruction latch 9 and an address from the micro address generator circuit 5. A sequence of micro instructions thus read is decoded by a micro instruction decoder 10, which outputs a control signal to control the execution unit 6, thereby executing the macro instruction. The address calculation unit (AU) calculates an address of the memory based on information, such as an offset value.
In this embodiment, the buffer store method is adopted; namely, a cache memory 7 is disposed in the microprocessor LSI so as to register to the cache memory 7 the program data to be frequently used among the data stored in an external memory 9. This enables to increase the speed to fetch a program. However, the provision of a cache memory is not essential to the present invention.
Next, in FIG. 3, there is shown a processing flowchart of a microprogram in a microprocessor to decode and to execute the queue search instruction. In the microprocessor of this embodiment, however, it is assumed that the first address of the search start entry, the compare value, and the offset value (unnecessary in the second instruction format) required for the queue search are preliminarily loaded in predetermined general-purpose registers, for example registers R 1 , R 3 , and R 5 , respectively, for an execution of the queue search instruction.
Furthermore, the status register in the microprocessor is provided with a flag (to be referred to as an F flag herein) indicating whether or not the search has been completed. If the F flag is "0", the search is indicated to have been successfully completed; whereas if the F flag is "1", the entry to be retrieved is indicated to be missing.
Referring now to the flowchart of FIG. 3, a description will be given of an execution procedure of the queue search instruction. First, in step S1, the first address of the starting entry in the register R 0 is copied into a temporary register TEMP (which cannot be accessed by the user). Next, in step S2, the memory is accessed by use of an address obtained by adding the offset value in the register R° , or the immediate field of the instruction, to the address in the register R° so as to read data, which data is then compared with the search data (compare value) in the register R 3 , thereby judging whether or not the specified condition (Table 1) is satisfied. In this example, the end condition BBBB is indicated to be 0001. That is, assuming the entry ENT 0 to be the search start entry in FIG. 4, an access is made at a position of an address obtained by adding the offset value OF to the first address A of the entry ENT 0 to read a data Key stored therein and a judgement is effected to determine whether or not the data Key corresponds to the search data in the register R 3 .
If the step of S2 results in a Yes (equal to) result, control is passed to step S7 to clear the F flag to 0, thereby terminating the instruction. That is, the fact that the data Key read in the step S2 corresponds to the search data (compare value) indicates that the address in the register R° is the first address of the entry to be obtained and hence the retrieval can be terminated with the address retained in the register R° . I the example of FIG. 4, the instruction execution is terminated with the address A 0 stored in the register R 0 .
When the step S2 results in a No (not equal to) result, the program proceeds to step S3, where it is determined whether the code of the bit U is equal to "0" or not. If the bit U is "1", step S4 is effected to access memory at an address obtained by adding "4" to the address in the register R 0 so as to obtain data and to store the obtained data in the register R 0 . In a case where the data width is 32 bits and the address can be specified in word units, the position obtained by adding "4" to the entry start address in the register R 0 indicates the pointer Pb in which the first address of the next entry is stored in a search in the backward direction in FIG. 4. Consequently, this makes it possible to effect a backward search of the queue.
On the other hand, when the bit U is "0", control is passed to step S5 and the address contained in the register R° is used to access the memory so as to store data in the register R 0 . That is, in FIG. 4, the first address of the next entry indicated by the forward-directional pointer Pa of the entry for which the search has just finished is stored in the register R 0 .
Thereafter, the program proceeds to step S6 to compare the value in the register R 0 at this point with the value in the temporary register TEMP into which the value of R 0 has been loaded in the step S1, thereby determining whether or not these values correspond to each other. If the values do not match each other, control returns to the step S2 to repeat the procedure described above; otherwise, control is passed to step S8 to set the F flag to "1", thereby terminating the processing. That is, the fact that the values of these registers correspond to each other in the step of S6 means that the position of the entry to be retrieved in FIG. 4 has returned to the entry from which the search was started, namely, an objective entry has not been found by the search operation through the queue. The processing thus terminates the operation by indicating that the search is unsuccessful.
When the queue search instruction is executed and the F flag is cleared to "0" at the termination of the operation as described above, the address stored in the register R 0 at the point is the first address of the objective entry; thereafter, by reading data in the associated entry based on the address in the register R 0 , the multitask processing, multiuser processing, and the like can be smoothly effected.
As described above, in this embodiment, the queue search can be executed by use of an instruction on the assumption that the registers R 0 , R 3 , and R 5 contain the first address of the search start entry, the compare value, and the offset value, respectively. Consequently, compared to a method in which the search is effected by use of, for example, a MOVE instruction, when the queue search instruction is not provided, the efficiency of the operating system of this method is considerably improved. Furthermore, the period of time required to retrieve the entry is minimized.
Incidentally, in addition to the queue search instruction, the microprocessor used in the embodiment described above is also provided with instructions to insert, to delete, and to replace entries.
FIGS. 5A-5C are flowcharts of another embodiment according to the queue search instruction of the present invention. When the instruction is to be executed, information necessary for the queue search is previously written in predetermined registers in the microprocessor. That is, the registers R 2 , R 3 , R 4 , R 5 , and R 6 are loaded with the first address of the search end entry, the first oompare value, the second compare value, the offset value, and data for the mask, respectively. The data for the mask is data used to assign data to predetermined bits among a plurality of bits constituting a data item. Furthermore, in this embodiment, two registers R 0 and R 1 are disposed to store the first addresses of entries. Namely, the first address of the entry being searched for is set into the register R 0 ; whereas the first address of the entry immediately preceding the entry being searched for is set into the register R 1 . With the provision of the register R 1 in addition to the register R 0 , the flexibility for recognizing the first address of the entry under the search is increased in the microprocessor. Moreover, the status register in the microprocessor is provided with a flag F and a flag V. The flag F is used to indicate the result of the search using the first compare value in the register R:, whereas the flag V is disposed to indicate the result of the search using the second compare value in the register R.. Consequently, when the second compare value is not used in judging the result of the search, information provided by the flag V does not have any particular meaning. Incidentally, when flag F or V is 0, it is indicated that the search condition is satisfied; whereas, when flag F or V is 1, the search condition is indicated not to have been satisfied. An example of the search condition has already been listed in Table 1.
Referring now to the flowchart of FIG. 5A, the execution procedure of the queue search instruction will be described. First, in step SI, it is judged whether or not an interrupt request exists. If this is the case, the interrupt request takes precedence and therefore the queue search instruction is terminated; otherwise, control is passed to step ST2. In the step ST2, the content of the register R 0 is set to the register R 1 , which updates the content of the register R 1 . In the step ST3, it is judged whether or not the U bit is 0. For U=0, it is indicated that the forward-directional search is to be effected and hence the program proceeds to step ST9, where the memory is accessed to obtain data by use of an address in the register R 1 and the data is loaded in the register R 0 . For U=1, it is indicated that the backward-directional search is to be effected and hence the program proceeds to step ST4, where the memory is accessed to obtain data by use of an address obtained by adding 4 to the address in the register R 1 and the obtained data is loaded in register R 0 .
The ST4 or ST9 sets the first address of the entry to be retrieved to the register R 0 . Next, in step ST5, it is judged whether or not the content of the register R 0 matches that of the register R 2 . If the contents match each other, it is indicated that the entry to be retrieved reaches the position of the search end entry; consequently, the flag F is set to "1" (step ST10) and the search instruction is terminated. If the contents do not match each other, control is passed to the step ST6, where it is judged whether or not the mask is necessary for the data to be used for the retrieval. A condition of M=1 indicates that the mask is necessary and the program proceeds to step ST12 shown in FIG. 5B. The processing flowchart of FIG. 5B will be described later. A condition of M=0 indicates that the mask is unnecessary and control is passed to step ST7, where it is determined whether or not the content of the register R. is necessary in judging the search end condition. If the content is necessary, the program proceeds to step ST17 of FIG. 5C. The processing flowchart of FIG. 5C will be described later. If the register R 4 is unnecessary, control is transferred to step ST8, where the memory is accessed to obtain data by use of an address calculated by adding the offset value in the register R° to the address in the register R 0 and the data is compared with the compare value in the register R 3 , thereby judging whether or not the specified condition (Table 1) is satisfied. In this example, the end condition BBBB is indicated to be 0001. That is, in FIG. 4, assuming the entry ENT° to be the search start entry, the memory is accessed by use of an address obtained by adding the offset value OF to the first address A of the entry ENT° so as to read data Key at the resultant address, and then it is judged whether or not the data Key matches the search data in the register R 3 . If the step ST8 results in a Yes (equal to) result, control is passed to step ST11 and the flag F is cleared to "0", thereby terminating the instruction. Namely, the fact that the data Key read in the step ST8 matches the search data (compare value) means that the address in the register R 0 at that point is the first address of the objective entry; consequently, the search can be terminated with the address retained in the register R 0 . In the example of FIG. 4, the processing is terminated with the address A 0 retained in the register R 0 . If the step ST8 results in a No (not equal to) result, control returns to the step STI.
Next, the processing flow of FIG. 5C will be described. The processing flow of FIG. 5C is required when the step ST7 of FIG. 5A results in a Yes result in the judgement. In the example of FIG. 5C, the end condition BBBB is indicated to be 1000. In the step ST17, the memory is accessed to attain data by use of an address calculated by adding the offset value in the register R: to the address in the register R 0 , and then the data is compared with the first compare value in the register R 3 for the judgement. When the data is greater than the first compare value, one of the end conditions is satisfied; consequently, the flag F is set to "0" (step ST20) and then control is passed to step ST18. If the data is equal to or less than the first compare value, the end condition is not satisfied; consequently, the program proceeds to step ST18 with the flag F retained at the initial value, "1".
In the step of ST18, the data is compared with the second compare value in the register R. for judgement. When the data is less than the second compare value, one of the end conditions is satisfied; consequently, the flag V is set to "0" (step ST21) and then control is passed to step ST19. If the data is equal to or greater than the second compare value the end condition is not satisfied; as a consequence, the program proceeds to step ST19 with the flag F retained at the initial value "1". In the step ST19, it is judged whether or not both of the flags F and V are "0". If F=0 and V=0, all end conditions are satisfied and hence the instruction processing is terminated. If only F=0 or V=0, the end conditions are not satisfied, and hence control returns to the step ST1.
Next, the processing flow of FIG. 5B will be described. The processing flow of FIG. 5B is required when the step ST6 of FIG. 5A results in a Yes result. In the step ST12, like the step ST7 of FIG. 5A, it is judged whether or not the content of the register R 4 is necessary in judging the search end condition. In a case where the content of the register R 4 us necessary, the flow is basically the same as that of FIG. 5C; consequently, description thereof will be omitted. If the content of the register R 4 is not required, control is passed to step of ST13, where the memory accessed to attain data by use of an address calculated by adding the offset value in the register R 5 to the address in the register R 0 and the data is masked with the content of the register R 6 . More specifically, the data and the content of the register R 6 are ANDed and the result is set into the register R 7 . The step ST14, the compare value in the register R 3 and the content of the register R 6 are ANDed and the result is set into the register R 8 . In the step ST15, the content of the register R 7 is compared with the content of the register R 8 to judge whether or not the specified conditions (Table 1) are satisfied. In this example, the end condition BBBB is indicated to be 0001. If the step ST15 results in a Yes result in the judgement, control is passed to the step ST16, where the flag F is cleared to "0", thereby terminating the instruction. If the step ST15 results in a No result, control returns to the step ST1.
As described above, according to the present invention, in a microprocessor configured to include an instruction system supporting the creation of a queue, a new instruction to search a queue is added and the queue search instruction is executed after the first address of the search start entry, the compare value as the selection condition, and the offset value of the search data in an entry each necessary for the queue search, are preliminarily loaded in predetermined registers; consequently, the first address of the desired entry can be attained by a queue search instruction and a register setting instruction preceding the queue search instruction, which increases the speed of the queue search and which makes it possible to obtain a substantial improvement in the efficiency of the operating system handling the multitask processing, the multiuser processing, and the like.
While the present invention has been described with reference to the exemplary embodiments, it is not restricted to those embodiments, and it is to be appreciated that the embodiments can be changed or modified in various fashions without departing from the scope and spirit of the invention. For example, in the embodiments, although the queue search is executed with an instruction on assumption that the registers R 0 , R 3 , and R 5 are preliminarily loaded with the first address of the search start entry, the compare value, and the offset value, respectively, the data items such as the first address need not be set into the registers by use of instructions, namely, the data items may be supplied as operands of the queue search instruction.
A description has been given of a case where the present invention is applied to an instruction format of a microprocessor, which is a utilization field as the background of the invention; however, the present invention is not restricted by such case, but also can be used in an instruction format in the data processing system of a general purpose computer, a minicomputer, or the like utilizing a program control system.
The effect obtained by the representative features of the present invention disclosed in this specification will be briefly described. That is, the queue retrieval speed is increased, and so the efficiency of the operating system handling the multitask processing, the multiuser processing, and the like can be improved.
While the present invention has been described with reference to the particular illustrative embodiments, it is not restricted by those embodiments but only by the appended claims. It is appreciated that those skilled in the art can change and modify the embodiments without departing from the scope and spirit of the invention.
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A method for searching the memory of a data processing apparatus including a decoder for decoding the contents of an instruction and an execution unit for executing the instruction based on an output from the decoder is performed in response to a search instruction which identifies a desired data storage area from a plurality of data storage areas in the memory which includes an array data structure.
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FIELD OF INVENTION
This invention relates to improvements in or relating to prefabricated self-supporting modular room elements of vibrated reinforced concrete suitable to construct buildings or dwellings of single or multiple units on a horizontal and/or vertical level wherein the said improvements concern substantially a better shape and structuralization of the single elements and an improved method of joining the elements, providing a more rational utilization and furthermore allowing to employ the elements in antiseismic constructions.
BACKGROUND OF THE INVENTION
Prefabricated elements of various types are known in the prior art which present disadvantages of different natures, as for instance the U.K. Pat. Ser. No. 1,456,645 in the name of NIEVES with the title "CONSTRUCTING BUILDINGS USING PREFABRICATED PARTS" uses elements of different shapes. However to build one single room in this case it is necessary to employ two elements, which have to be joined at half the height of the room sidewalls and in some cases even three joining points are required. Furthermore single slabs are used to form ceilings, which method proves to be very inconvenient and expensive. The U.K. Pat. Ser. No. 913,841 in the name of HENDERSON with the title "A METHOD OF CONSTRUCTING A BUILDING FROM PRECAST CONCRETE COMPONENTS" presents basically the same inconveniences as the preceding one; the U.K. Pat. Ser. No. 1,246,369 in the name of WOOD with the title "MULTI-STOREY BUILDING ASSEMBLY FORMED WITH PRE-FABRICATED MODULES "utilizes elements with joints between two panels, wherein these panels are laterally supported by two other opposing elements; the U.K. Pat. Ser. No. 1,007,144 in the name of PATENT CONCERN N.V. with the title "IMPROVEMENTS IN OR RELATING TO BUILDINGS CONSTRUCTED OF PREFABRICATED ELEMENTS" presents all its elements in a parallelepiped box shape which presents problems and inconveniences in particular as far as the transport to the construction site is concerned; the same problems are provided by the U.K. Pat. Ser. No. 1,429,357 in the name of GORSKI with the title "IMPROVEMENTS IN OR RELATING TO BUILDINGS" which presents also only elements of parallelepiped box shape; and finally the U.K. Pat. Ser. No. 1,382,709 in the name of WEESE with the title "IMPROVEMENTS IN OR RELATING TO BUILDING SYSTEMS" uses a series of parallelogram shaped modules, which originally have a folded state and are erected only at the construction site and this fact naturally causes higher costs in labour particularly for the assembling and joining of these modulars.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to overcome the disadvantages of the prior art as mentioned above. For such a solution the innovative essentialities of the present invention comprise three basic prefabricated modular room elements of variable dimensions according to the known particular specific conditions, these elements being of vibrated reinforced concrete and being constructed in a building yard or on site:
One element is shaped like a bridge having a so-called inverted "U" shape and constitutes the standard element for a room, comprising two upright sidewalls and a slab for the ceiling,
one element has the shape of an inverted "L" substantially constituting a sidewall and a ceiling of an adjacent room and will be connected to the upper end of a room sidewall,
one cell element of parallelepiped box shape is open at the ceiling being intended to form a service unit with the relative aperture for an entrance door, wherein two opposing sidewalls are prolonged beyond the endwall of the said service unit to form a "sheath" for the passage of the service installations, which essentially has an "U" shape sitting on the horizontal level extending towards the outside.
A variation of the inverted "U" shaped element is presented by furnishing it with a frontal groove to receive the upright rectangular panels which form the front closing panels for the said "U" shaped elements which allow apertures for intermediate openings as for instance for windows or lower ones for instance for garages etc.
A further novelty is the furnishing of a multitude of iron rods, protruding in semicircles from the edges of the said elements to effect the jointing and moreover at the base edges are grooves of inverted "U" shape provided to improve the joining facilities and also recesses to favour the jointing. This coupling of said elements is also improved by inserting one ore more binding reinforcing bars lengthwise between the jointing edges, inside the said rings before grouting the binding cement mortar between the elements themselves or between the elements and the eventually preexistent and predisposed structures. The jointing and connecting of the said structures effected with this system are so strong as to resist every horizontal or vertical strain, even dynamic ones, such as telluric events, particularly to earthquakes, creating antiseismic structures giving a maximum of security.
As above mentioned the modification of the inverted "U" shaped element creating "ceiling" elements consists of the fact that contrary to the elements of parallelepiped form this new type of element presents in his frontview a shape of inverted "U" of a rectangular form without a base and in its sideview a a trapezoidal form instead of a rectangular one and the upper panel of the inverted "U" shaped or bridge element instead of being horizontal will be inclined in relation to the slope of the roof.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more evident from the description and the accompanying drawings representing embodiments of the invention, which respectively represent:
FIG. 1 the system of a few assembled inverted "U" shaped elements disposed side by side and one above the other in a perspective view,
FIG. 2 a perspective view of the inverted "L" shaped element supported by the service unit element,
FIG. 3 a perspective view of an exemplifying realization of rowhouses with a connected row of garages,
FIG. 4 a perspective front view of the structuration of the rowhouses of FIG. 3 from the opposite side,
FIG. 5 a perspective view of the inverted "U" shaped elements constituting a ceiling unit in an example of coupling same side by side,
FIG. 6 another perspective view of a series of covering elements of inverted "U" shape coupled together as an example,
FIG. 7 a close view of a set of inverted "U" shaped elements and service elements in an upright assembled position, a few of the inverted "U" shaped elements forming the ceiling of any one story.
FIG. 8 a schematicised perspective view of a combination of assembled inverted "U" shaped elements, inverted "L" shaped elements and service unit elements, and the letters "a,b,c,d" indicate the positions relating to the new joining system of the elements,
FIG. 9 a partial view of the vertical section of the jointing system of the elements in the horizontal level, "a" in FIG. 8,
FIG. 10 a top view of the structuralization of the jointing system of FIG. 9,
FIG. 11 a partial view of the horizontal section of the joining area between the vertical walls on top of the various elements, "b" in FIG. 8,
FIG. 12 a partial view of the vertical section of the joining system at the lower edge of the various elements for the support on the ground on the foundation level "c" in FIG. 8,
FIG. 13 a partial sectional view on the vertical level of the longitudinal horizontal joining area of the various elements assembled side by side at the "floor level", "d" in FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The above mentioned figures illustrate the inverted "U" shaped elements of parallelepiped form (FIG. 1) (A) which present at the end of the upper and lower sidewall edges a multitude of rod irons protruding in semicircles (1,2) on top as well as on the bottom for the entire length, except for two free areas at the extreme ends (3) which constitute the bearing feet for the extrem lower edges.
Between the two bearing feet (3) the recess of the lower edge for the formation of a space (6) is to be noted, which is intended to receive the said semicircled tying iron rods and adjoining the said feet and on the inside between them are grooves (5) provided with an inverted "U" shape to receive the tying stirrups as explained later on.
The element of inverted "U" shaped (A) presents furthermore at its terminal edges of the walls and slabs a multitude of tying iron rods for the jointing, spaced in groups (7) which fact will be explained in more detail hereafter, (in this specific case these spaced groups (7) are only shown in the jointing of the headslabs, whereas they are not shown in FIG. 1 at the top edge of the vertical walls, but it is obvious that with this joining system the said groups of iron rods (7) may also be provided at the vertical edges of the sidewalls as it will be explained in detail later on).
Analogously it is to be understood that the elements of inverted "L" shape (B) and the service elements (C) have the same structure as the "U" shaped elements (A) at the base edges and the lateral edges to effect their joining, even though in FIG. 2 the said forms and structures are not shown to simplify the exemplary scheme of the said figure.
Furthermore the "bridge" or inverted "U" shaped elements as shown in FIG. 3 may vary at the joining of the upper edge and at the joining means at the lower edge to allow the fitting in of such panels as shown respectively as (D and E) in FIGS. 3,4.
The "bridge" or inverted "U" shaped elements may have trapezoidal shapes as shown as (A') in FIG. 5; they may also have various heights to allow them to be assembled side by side in order to form a continuous roof (A' in FIG. 5); it is also possible to utilize only one of them to construct a dwelling unit, as for instance illustrated in the FIGS. 3 and 4, or a set of them as shown in FIG. 5.
Furthermore the inverted "U" shaped elements may also be considerably shorter than the one that forms a full story in order to realize covering elements only (A") as shown in FIG. 6.
For the joining of the elements in cases which do not require antiseismic structures it is obvious that the lower bases of the said elements are mounted directly on the ground as shown in FIG. 7. However in this cases stirrups are always provided which protrude upwards (8) and have a section of an inverted "U" in contraposition with a centerhole to be used for the locating, fastening and centering of the various elements in superimposition.
The FIG. 7 shows particularly the third or posterior part of the service element with the passage section (C) illustrating that the endwall already carries the holes and cavities (9) to receive in this specific case the watertank for the W.C. and other holes for the utilities inlet and/or outlet for the services (4,10) and as desired other holes for all generally known services.
Furthermore FIG. 7 shows the various inverted "U" shaped elements at the so-called "slab" level presenting between them the various sealings effected with cement mortar (11) the modus of which will be described later on.
In all cases of antiseismic joining or all structures where the building or a monobloc is desired the joining system for the elements is such as shown in FIGS. 8,9, 10,11,12,13.
The figures also show that the edges lying on the vertical level of each element have a semidovetail shape open on one side (12) whereas on the opposite side the end edge touches an adjacent edge (13) and all corners are bevelled (14).
On the part of the hollow undercut of the semidovetail (12) the semicircular reinforcement iron rods (7) cast outwards and cross between themselves to form a full circle and in the center of these circles at least one tying iron bar (15) may be inserted; it is furthermore established that the opening of the dovetail shape assumes varying widths (12',12") precisely more narrow in the area of the sealing with cement mortar only and larger at the area of the tying with the reinforcing bars (7,15) (12" in FIG. 10).
When two vertical walls of two adjacent elements have to be assembled on top as well as side by side a determinate space has to be left between the sidewalls which is to be filled with suitable insulating material (16) in FIG. 11. According to the preceding description tying stirrups are also utilized in the area of the joinings by tying the various elements at a four module corner with loop elements (17); in FIG. 11, with stirrup loops provided around the two adjacent longitudinal bars (15) causing another tying connection of two single adjoining elements.
A variation of the lower base end of the inverted "U" shaped elements set on the ground, particularly for structures in elevation is shown in FIG. 12, wherein the said semicircular rods are projecting out sideways (17) from the base element to connect with the semicircular rods (18) emanating out of the foundation (19) with a few longitudinal tying bars (20) inserted inside of the so created circles before the grouting of the base (21) of the set is effected.
The connection of the edges on the floor and in crossing superimposition ("d" in FIG. 8) is clearly evident in FIG. 13, showing the utilization of the said semicircular rods (1,2), however in this specific case they have a rectangular shape and cross the semicircular or arcuate rods (7',7"), which in this specific case are also of a rectangular shape. They are used in the respective different heights within the dovetail shape (12) or in the entire thickness, before finally a few bars (15) tying the said semicircles are inserted.
Naturally the dovetail groove or semidovetail groove on the external edges or on one section of the external edges of the various elements may be more or less deep, more or less outlined and more or less symmetrical (example FIG. 13), contrary to the symmetric jointings shown in the normal cases of the FIGS. 9,10,11.
This dissymmetry is required to allow the installation of single dividing wall elements (example FIG. 13) instead of two adjacent walls which would form a gap (example FIG. 11)and also to facilitate the casting.
It is evident that the invention is not limited to the embodiments heretofore described and represented, and that other means and embodiments may be derived therefrom without leaving the scope of the invention.
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Improvements in or relating to prefabricated self-supporting modular room elements for the construction of buildings, including substantially three basic modular elements, one of an inverted "U" shape, one of an inverted "L" shape and a service unit element furnished at their edges with the required means for the joining such as protruding semicircular iron rods, which by crossing themselves form an entire circle, inside which are inserted lengthwise reinforcing iron bars to strengthen the jointing before the grouting of the cement mortar and the horizontal edges are provided with grooves and recesses to receive the panels to be erected is disclosed.
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CROSS REFERENCE TO RELATED APPLICATION
This application is the US National Stage of International Application No. PCT/DE2003/002721, filed Aug. 12, 2003 and claims the benefit thereof. The International Application claims the benefits of German Patent application No. 10237341.8 DE filed Aug. 14, 2002, both of the applications are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
The invention relates to a device for the generation and/or destruction of vortices in a flow medium, said device comprising one or more profiles arranged in a flow duct and provided for flow around by the flow medium. It relates, further, to a method especially suitable for operating the device.
BACKGROUND OF THE INVENTION
The controlled generation or destruction of vortices plays an important part in many flow-related applications. Since vortices contain rotational energy and can therefore both absorb and discharge energy, they are used for the controlled transmission of energy from a flow-around profile to the flow medium or into a boundary layer or for the exchange of energy, in particular including heat, or of substances between different regions of a flow.
For the efficient transport of a flow medium, for example, systems are used consisting of stationary vortex generators which transmit energy to the flow medium as a result of the generation of vortices. In this case, it is desirable to keep the pressure loss which the flow medium experiences along the system consisting of vortex generators as low as possible. In particular, the mean mass flow with respect to the pressure loss is to be as high as possible.
Owing to the use of vortex generators in the flow duct, velocity fluctuations can also be imparted to a flow medium. Such velocity fluctuations, which are generated, for example, by means of shockwaves occurring at vortex generators, considerably increase both heat exchange and mass transfer in the flow medium transversely to the flow direction. By virtue of the targeted mounting of vortex generators in the flow duct, an intensified cooling action of the flow on components subjected to especially high thermal load can thus be achieved. In this case, the vortex generators should be positioned and dimensioned in such a way that the heat transmission coefficient in relation to the pressure loss which the flow medium experiences along the system consisting of vortex generators is as high as possible. Thus, for example due to the use of a system consisting of vortex generators in a gas turbine, cooling air can be saved both in the region of the combustion chamber and in the region of the turbine blades, and consequently, with at the same time the efficiency of the gas turbine being increased, its NOx emissions can be lowered.
The intensified mass transfer transversely to the flow direction in a flow medium with velocity fluctuations may be utilized for the intensified mixing of the flow medium. For example, owing to the especially thorough mixing of fuel gas and air in a gas turbine plant, a complete combustion of the fuel gas can be achieved and therefore its NOx emissions can be lowered.
The diversity of technical applications of vortex generators or vortex destroyers means that there is great interest in the theoretical calculation of the occurrence and development of vortices. They are necessary, in particular, in order to configure the shape and positioning of vortex generators and vortex destroyers optimally in terms of their action on a flow medium. The calculation of turbulent flows is conventionally carried out either explicitly by solving the Navier-Stokes equation of the problem, although this is a procedure which is too complex and involves too high an outlay, above all in the case of three-dimensional applications, or else via corresponding models of the classic hydrofoil theory.
Within the framework of the classic hydrofoil theory, admittedly, turbulent flows at components which are rigid, that is to say with a passive flow around and not accelerated, can be described. However, with components which are active, that is to say moved in an accelerated manner, the classic hydrofoil theory falls down. To be precise, it presupposes the smooth flow-off of the flow medium at the trailing edge of the flow-around profile, what is known as the Kutta condition, and also a finite onflow velocity and a quasistatic linear treatment. A breakaway of the flow from the flow-around profile and a rolling-up of vortices which occur, such as takes place in the case of non-stationary flow processes on profiles moved in an accelerated manner, cannot be treated within the framework of the theory. Where technical applications are concerned, therefore, vortex generators with a passive flow around are normally used, which can be described by means of classic aerodynamics. However, vortex generators with a passive flow around have comparatively high dynamic resistances. If they are placed in a flow duct, this therefore results in an undesirably high pressure drop in the flow medium.
SUMMARY OF THE INVENTION
The object on which the invention is based is, therefore, to specify a device for the generation of vortices in a flow medium of the abovementioned type, by means of which, along with as low a pressure drop as possible, vortices can be generated in a flow medium in an especially simple way and at an especially low outlay in energy terms. Furthermore, a method especially suitable for operating the device is to be specified.
As regards the device, this object is achieved, according to the invention, in that the device comprises one or more profiles arranged in a flow duct and provided for flow around by the flow medium, the profiles being provided with a mechanical, electromagnetic or electrohydraulic drive for a periodic movement in relation to the flow medium with an angular frequency ω.
What may be provided as “profiles” in this context are any desired suitably dimensioned and contoured fittings in the flow duct, which, particularly in terms of their shape, are adapted to the flow conditions expected as a consequence of design in the flow duct.
The invention in this case proceeds from the consideration that, for a high efficiency of the vortex generator, the mean throughput of flow medium in relation to its pressure loss along the flow duct should be as high as possible. In order to keep the pressure loss low, the transmission of energy from the vortex generator to the flow medium should consistently be improved. A better transmission of energy can be achieved in that the energy content of the generated vortex is increased. As has become clear, higher energy contents can be achieved by means of active, that is to say accelerated vortex generators, both in laminar and in turbulent flows, in that the vortex is accelerated before its breakaway from the profile of the vortex generator. For especially high efficiency, therefore, vortex generators should be moved in an accelerated manner in relation to the flow duct. A uniform vortex generation which satisfies these requirements can in this case be achieved in an especially simple way by means of a periodic movement of the vortex generator.
In order to understand the processes at periodically moved vortex generators, use can be made of the knowledge that a vortex generated by such a vortex generator and breaking away can be described effectively by means of a spatially limited vortex having a rigid core, what is known as a “finite edge vortex”. Such a vortex, immediately after its formation on the trailing edge of the flow-around profile, is filled up by flow medium flowing in toward its center, up to the rest of its progression in time, as a radius a which is assumed to be constant. As a result, the vortex is set in rotation, and its rotational velocity increases further during the subsequent “adhesion phase”. In this case, the vortex experiences a net throughflow by flow medium, and the component of the flow from the direction of the profile trailing edge increases up to a maximum value. The vortex, after reaching its stable size, adheres to the profile until this maximum value is reached, and then breaks away.
While the vortex is still adhering to the profile, its rotation induces a tangential flow along the profile surface, what may be referred to as the “sheathing flow”. The aerodynamic interaction of the sheathing flow with the onflow of the flow medium onto the profile generates an orthogonal pair of forces, propulsion and resistance. Depending on which of the two forces predominates, the character of the interaction between flow medium and profile changes. Thus, for example in the case of a movement of the profile with a comparatively high frequency, the propulsion character of the interaction predominates and energy is transmitted from the vortex generator to the flow medium, whereas, in the case of the movement with low frequency, the resistance character predominates and energy is transferred from the flow medium to the vortex generator.
These findings within the framework of what is known as the “finite edge vortex model” are utilized when new characteristic quantities are employed. What is suitable as a characteristic quantity describing the propulsion characteristic or resistance characteristic of the flow is the ratio of the flow velocity averaged over a movement period of the profile with respect to the mean cross section of the profile to the maximum flow velocity at the profile trailing edge. If this quantity f:=v m /v max is between 0.2 and 0.5, the flow has a propulsion character. By contrast, if f is higher than 0.5, it has a resistance character.
The Reynolds' number of the maximum edge flow around, the reduced frequency and the Strouhal number can be used as further important characteristic quantities.
The Reynolds' number of the maximum edge flow around is in this case defined as the product of the maximum flow velocity at the profile trailing edge and the elongation of the flow-around profile, divided by the kinematic viscosity of the flow medium, the reduced frequency is defined as the product of the angular frequency of the periodic movement and elongation of the flow-around profile, divided by the flow velocity averaged over a movement period of the profile with respect to the mean cross section of the profile, and the Strouhal number is defined as the frequency of the periodic movement and the elongation of the flow-around profile, divided by the flow velocity averaged over the movement period of the profile with respect to the mean cross section of the profile. Said characteristic quantities are used instead of the external constant profile onflow velocity employed in classic aerodynamics and permit substantially more differentiated and more realistic characterization of the resulting flow.
Advantageously, the shape, number and size of the profiles are selected such that, when the vortex generator is operating, the quotient of the flow velocity averaged over the movement period of the profile with respect to the mean cross section of the profile and the maximum flow velocity at the profile trailing edge has a predetermined value. In particular, this value may be selected such that, depending on the type of technical application, a flow with a resistance character or with a propulsion character is obtained as a result.
Depending on the technical task to be fulfilled by the vortex generator, different types of periodic movements of the profiles are conceivable and beneficial. Advantageous basic forms of periodic movements are periodic displacements of the profiles perpendicularly to the flow direction of the flow medium, rotations of the profiles about an axis of rotation perpendicularly to the flow direction in the manner of a pivoting through an angle φ, and the rotation of pairs of profiles with the same angular frequency ω and the same phase about their respective axis of rotation, the axes of rotation being oriented antiparallel to one another, and also periodic displacements of the profiles parallel to the flow direction of the flow medium.
To improve the efficiency of the vortex generator and for adapting it optimally to its technical task, the profiles, if appropriate, execute combinations of said basic forms of the periodic movements. Advantageously, the periodic movement of the profile may consist, in particular, of a combination of a displacement of the profile in relation to the flow duct and of a rotation of the profile about an axis of rotation.
In many applications, it is beneficial to destroy a generated vortex again after it has covered a particular distance in the flow duct. This is the case, for example, when the residual wake energy of the vortex is to be utilized as fully as possible. In such a case, the vortex generator is advantageously followed on the flow medium side by a device for the destruction of vortices.
Since, in the case of low drive power, active vortex generators are capable of transmitting energy and substances in an especially efficient way, they may be used in a multiplicity of technical sectors. In the conveyance of a flow medium through a flow duct or a pipeline, the aim is, for example, to achieve as high a mass flow as possible, with at the same time a low pressure loss in the flow medium. However, the desired increase in the flow velocity of the flow medium, along with a low pressure loss, can be achieved precisely with the aid of an active vortex generator. A device for the active generation of vortices is therefore advantageously arranged in the flow duct of a conveying zone, said device comprising a number of vortex generators which execute a periodic movement with the same angular frequency ω and the same phase.
Alternatively to this, the phase of the vortex generators may also be opposed, that is to say displaced at 180 degrees with respect to one another.
A further important use of active vortex generators is to increase the efficiency of cascade flows. Cascade flows are employed in order to maximize the mean efficiency of an axial cascade, with at the same time as low a pressure loss as possible. For this purpose, for example, guide vanes precede the moving blades of a gas turbine on the flow medium side. For a further increase in the cascade efficiency, the axial cascade is advantageously preceded on the flow medium side by a device for the active generation of vortices which device comprises a number of profiles which execute a periodic movement with the same angular frequency ω and the same phase. In particular, periodic flow pulses can thereby be generated, which are optimally coordinated in their period and length with the likewise periodic actual cascade flow. Furthermore, the “clocking effect”, as it is known, which increases the efficiency of the cascade and is not yet fully understood theoretically may be utilized, this coming under consideration when individual cascades moved in relation to one another interact with one another.
Velocity fluctuations imparted to a flow medium can be utilized for the especially efficient cooling of components subjected to high thermal load. Such velocity fluctuations can be generated in an especially efficient way by means of active vortex generators and considerably increase both the heat exchange and the mass transfer in the flow medium transversely to the flow direction. Thus, by virtue of the targeted mounting of active vortex generators in the flow duct, an efficient cooling of components subjected to particularly high thermal load can be achieved. For this purpose, a cooling device advantageously comprises a flow duct, a cooling stream conducted through the flow duct and a device which is arranged within the flow duct and which has one or more periodically moved profiles for the active generation of vortices.
Velocity fluctuations imparted to a flow medium also intensify the mass transfer transversely to the flow direction. This effect can be utilized in a controlled manner for the intensified mixing of a flow medium. Especially high mixing quality, with at the same time a low pressure loss, can be achieved in that active vortex generators are used in order to generate the velocity fluctuations. It is usually desirable for the velocity fluctuations imparted to the flow medium by generated vortices to be destroyed again after mixing is concluded. A mixing zone therefore advantageously comprises a device for the active generation of vortices which is followed on the flow medium side by a device for the destruction of vortices.
By means of an active vortex generator, substance and energy streams can be generated and/or intensified in an especially efficient way, with at the same time a low pressure drop within the flow medium, for example during the mixing of fuel gas and air in a compressor or during the cooling of the component subjected to especially high thermal load. The active vortex generator is therefore advantageously used in a gas turbine.
As regards the method, said object is achieved in that one or more profiles arranged in a flow duct and provided for flow around by a flow medium are moved periodically with the angular frequency ω by means of an external drive.
New findings within the framework of what is known as the “finite edge vortex model” show how it is possible in a controlled manner to influence the imparting of a resistance character or propulsion character of a flow around moved profiles, that is to say the direction of energy transmission between profile and flow medium. An important characteristic quantity within this model is the quotient of the flow velocity averaged over a movement period of the profile with respect to the mean cross section of the profile and the maximum flow velocity at the profile trailing edge. Advantageously, the direction of energy transmission between moved profile and flow medium is set by this quotient. Alternatively, the direction of energy transmission between profile and flow medium can also be set via the product of the maximum flow velocity at the profile trailing edge and of the elongation of the flow-around profile, divided by the kinematic viscosity of the flow medium.
In many technical applications, disadvantages may arise when, as the flow progresses further, generated vortices bring about a comparatively high degree of turbulence of the flow. Advantageously, therefore, the generated vortices are completely or partially destroyed again downstream of the position in the flow duct at which they were generated.
As calculations within the framework of the “finite edge vortex model” have yielded, substance and energy streams can be generated and/or intensified by the use of active vortex generators especially efficiently and with a comparatively low pressure drop within the flow medium. The method for the generation of vortices by means of active vortex generators is therefore especially suitable for various technical applications, for example for the transportation or mixing of flow media, for increasing the efficiency of cascade flows and for the cooling of components subjected to especially high thermal load.
The advantages achieved by means of the invention are, in particular, that vortices can be generated at a comparatively low outlay in energy terms as a result of the use, now provided, of periodically moved vortex generators. The periodic movement of the profiles can in this case be implemented in a comparative simple way in technical terms by the use of an external mechanical, electrical or electrohydraulic drive. When active, in contrast to passive, vortex generators are used, substance and energy streams can be generated and/or effectively intensified in a flow medium, with at the same time especially low pressure losses within the flow medium. The low pressure loss can in this case be attributed to the fact that active vortex generators are characterized by very low resistances.
On account of the beneficial technical properties mentioned, active vortex generators have a multiplicity of application possibilities. Due to the use of active vortex generators, for example, the cascade flow in the compressor of a gas turbine can be configured more efficiently and the clocking effect can be utilized to an increased extent. The cooling of components subjected to thermal load can also be improved by means of active vortex generators, and therefore cooling air can be saved. Furthermore, owing to the use of active vortex generators, a more thorough mixing of, for example, fuel gas and air prior to combustion, for the reduction of NOx emissions, is possible. An increase in the efficiency of the gas turbine and a reduction in its emissions can thus be achieved at a comparatively low outlay in technical terms.
BRIEF DESCRIPTION OF THE DRAWINGS
An exemplary embodiment of the invention is explained in more detail with reference to a drawing in which:
FIG. 1 shows a profile around which a flow medium flows and at the trailing edge of which a vortex is generated,
FIG. 2 shows various versions of a device comprising one or more profiles for the generation of vortices in a flow medium,
FIG. 3 shows a zone for the transport of a flow medium, said zone comprising a device for the generation of vortices,
FIG. 4 shows a further zone for the transport of a flow medium,
FIG. 5 shows a cylindrical section, unrolled into the plane, through a guide-vane and moving-blade row of a gas turbine, said row being preceded by a device for the generation of vortices,
FIG. 6 shows a device for the cooling of components subjected to high thermal load, and
FIG. 7 shows a device for the mixing of a flow medium.
DETAILED DESCRIPTION OF THE INVENTION
Identical parts are given the same reference symbols in all the figures.
FIG. 1 shows a device for the generation of vortices by means of a profile 1 around which a flow medium S flows and which may be located, for example, in a flow duct, not illustrated in FIG. 1 . The flow direction of the flow medium S is indicated by the arrows 2 in a streamlined manner. The profile 1 can be moved by means of an external drive, not illustrated in FIG. 1 , the movement generally being composed of a displacement of the profile 1 over a distance x and of a rotation of the profile 1 through an angle φ. The movement takes place periodically at an angular frequency ω. During the movement of the profile 1 in relation to the flow medium S, two vortices are formed at the trailing edge 4 of the profile 1 during each period of the movement, grow immediately after their formation, adhere to the trailing edge 4 for a short time and then break away.
The vortices which are formed can be described comparatively realistically with the aid of the “finite edge vortex model”. Within the framework of this model, vortices formed at the trailing edge 4 of the profile 1 are not described as ideal vortices, but instead as vortices with a sharply defined radius and with a rigidly rotating core. FIG. 1 illustrates such a “finite edge vortex”, as it is known, 6 . The finite edge vortex 6 , immediately after being formed at the trailing edge 4 of the flow-around profile 1 , is filled up to its radius a by flow medium S flowing toward its center and is set in rotation. Its rotational velocity increases further during the subsequent “adhesion phase”, where the finite edge vortex 6 experiences a net throughflow by flow medium S, and the component of the flow from the direction of the trailing edge 4 increases up to a maximum value. The finite edge vortex 6 breaks away from the trailing edge 4 at the moment at which this maximum value is reached. During the adhesion phase, the rotation of the finite edge vortex 6 induces a tangential flow along the profile surface, what may be referred to as the “sheathed flow”. The sheathed flow comes into interaction with the onflowing flow medium S, an orthogonal pair of forces, the propulsion V, indicated by the arrow 8 , and the resistance W, indicated by the arrow 10 , being obtained.
The character of the interaction between flow medium S and profile 1 depends critically on which of the two forces predominates. As both theoretical investigations within the framework of the “finite edge vortex model” and experimental findings show, in the event of a movement of the profile 1 with relatively high angular frequency ω, the propulsion character of the interaction predominates and energy is transmitted from the profile 1 to the flow medium S. By contrast, in the event of a movement with a low angular frequency ω, its resistance character predominates and energy transmission takes place in reverse from the flow medium S to the profile 1 .
In contrast to the classic hydrofoil theory, the relatively simple “finite edge vortex model” makes it possible to describe the flow around a profile 1 moved in an accelerated manner. It thus makes possible the controlled use of active vortex generators, that is to say those which comprise a number of profiles 1 moved in an accelerated manner. In contrast to a rigid profile, a profile 1 moved in an accelerated manner has considerably lower dynamic resistance. In other words: a moved profile 1 gives rise to a considerably lower pressure loss within the flow medium S than a rigid profile. It can thus be used, for example, for the efficient transportation or mixing of flow media S, a comparatively high throughput of flow medium, with at the same time a low pressure loss, being achieved on account of the low dynamic resistance of the profile 1 .
Various types of periodic movement of the profile 1 may be envisaged. FIG. 2 shows various possibilities for the periodic movement of the profile 1 in relation to the flow medium S. The flow medium S flows through a flow duct 12 in the direction indicated by the arrow 2 . As illustrated in FIG. 2 a, a finite edge vortex 6 can be generated in the flow medium S, in that a profile 1 is displaced periodically over a distance x perpendicularly to the flow direction, that is to say executes a pure translational movement.
FIG. 2 b shows another possibility for the periodic movement of the profile 1 , in which the profile 1 executes a pure rotational movement about an axis of rotation 14 perpendicularly to the flow direction through an angle φ. In technical applications, it is advantageous under some circumstances to use combinations of translational and rotational movements. As shown in FIG. 2 c, a plurality of profiles 1 may also be employed in order to generate vortices. By means of a configuration, as in FIG. 2 c, in which a pair of profiles 1 oscillates in countersynchronism or in synchronism at the exit of a further flow duct 16 arranged in the flow duct 12 , for example,two flow media flowing in the flow duct 12 and in the further flow duct 16 can be efficiently intermixed and/or transported. In such an arrangement, in each oscillation period of the profile 1 , two pairs of finite edge vortices 6 break away from the profile trailing edges 4 and form what is known as a wake 18 in the flow duct 12 . FIG. 2 d shows a device for the generation of finite edge vortices 6 without periodically moved components. Here again, a further flow duct 16 , through which a flow medium S flows, is arranged within a flow duct 12 . However, the flow medium S flows through the further flow duct 16 with a periodic variation of its mass flow m. At the exit 22 of the further flow duct, in each period a pair of finite edge vortices 6 is formed, which breaks away after the adhesion phase and forms a wake 18 in the flow duct 12 .
As calculations within the framework of the finite edge vortex model have yielded, the profiles 1 should follow certain rules in their shape and dimensioning. In particular, the profiles 1 should have a sharp trailing edge which is as long as possible, so that the maximum flow velocity at the trailing edge 4 is as high as possible and the finite edge vortex 6 which occurs has a comparatively small radius. A harmonic oscillation form of the profile 1 is not desirable in every case, in order to achieve a long adhesion phase of the finite edge vortex 6 and high propulsion. Depending on the field of use of the vortex generator, the oscillation frequency and amplitude, the position of the axis of rotation 14 during a rotation and the general shape of the profile 1 must be optimized in such a way that optimal energy transmission between profile 1 and flow medium S takes place by means of as low an external drive as possible and with a low pressure drop.
Owing to the favorable properties of the finite edge vortices 6 , their generation can be utilized, for example, for the transportation of a flow medium. FIG. 3 shows a zone for the transport of a flow medium, said zone comprising a device for the generation of finite edge vortices 6 . As can be seen in FIG. 3 a, a plurality of profiles 1 , for example three, which execute a periodic movement in synchronism are arranged in a flow duct 12 . The periodic movement may consist of a rotation through the angle φ about an axis of rotation 14 or else of a combination of the rotation with a periodic displacement of the profile 1 . In each case two finite edge vortices 6 occur in each period at the respective trailing edges 4 of the profiles 1 oscillating in synchronism. The energy transmitted to the flow medium S by the profiles 1 as a result of vortex formation is utilized for the transport of the flow medium S through the flow duct 12 . If the profiles 1 execute a pure rotational movement, they can be driven by means of the external drive illustrated in FIG. 3 b. For this purpose, the profiles 1 are mounted in the region of their trailing edge 4 on a connecting rod 23 which is connected to a crank drive 26 via an articulated lever 24 . When the vortex generator is operating, the crank drive 26 moves the connecting rod 23 up and down and thus drives the rotation of the profiles 1 about their respective axis of rotation 14 .
If, by contrast, the profiles 1 execute a combination of a translational and rotational movement, they can be driven by means of the external drive illustrated in FIG. 3 c. For this purpose, the drive device illustrated comprises a connecting rod 23 , on which the profile or profiles 1 are mounted in their rear region, and also a further connecting rod 30 which connects the profiles 1 to one another in their front region. When the device is operating, both the connecting rod 23 and the further connecting rod 30 execute a periodic movement in the upward and downward direction which is brought about by an electromagnetic drive 27 and via a further electromagnetic drive 28 , respectively. In order to achieve a rotation of the profiles 1 about the axis of rotation 14 , the electromagnetic drive 27 and the further electromagnetic drive 28 do not operate in phase. Instead, the electromagnetic drive 27 may have a phase lead of 90 degrees with respect to the further electromagnetic drive 28 . The profiles 12 thus execute a combination of a translational movement over the distance x and a rotational movement through the angle φ within the flow duct 12 .
Owing to the use of the device illustrated in FIG. 3 through a flow duct 12 , the flow medium S can be transported especially efficiently through a flow duct 12 . To be precise, as calculations within the framework of the “finite edge vortex model” have yielded, the periodic movement of the profiles 1 ensures that energy is transmitted from the profiles 1 to the flow medium S especially efficiently. In particular, the throughput of flow medium S through the flow duct 12 in relation to the pressure loss can thereby be maximized.
For the efficient transport of a flow medium S through a flow duct 12 , profiles 1 oscillating in countersynchronism, such as are illustrated in FIG. 4 , are also suitable. FIG. 4 a shows an alternative zone for the efficient transportation of a flow medium S. Within a flow duct 12 , a further flow duct 16 is arranged, for example concentrically, at the exit of which is arranged a pair of profiles 1 which in each case execute periodic rotational movements. For this purpose, they oscillate in countersynchronism, that is to say with a phase displacement of 180 degrees, and at their trailing edge 4 generate per period in each case two finite edge vortices 6 which, after their adhesion phase, break away from the trailing edges 4 and generate a wake 18 in the flow duct 12 . In technical applications, it may be beneficial, for example for utilizing the residual wake energy, to destroy the broken-away vortices completely or partially again. For this purpose, the profiles 1 may be followed on the flow medium side by a vortex destroyer, not illustrated in FIG. 4 .
FIG. 4 b shows a drive suitable for operating the vortex generator illustrated in FIG. 4 a. For this purpose, the drive comprises an electromagnetic drive 27 , which activates a hydraulically operating working cylinder 32 , and two articulated levers 24 which are mounted on the profiles 1 and, via their movement caused by the working cylinder 32 , bring about a rotation of the profiles 1 about their respective axis of rotation 14 .
In addition to the efficient transport of a flow medium, active vortex generators may also be employed in various other technical fields. FIG. 5 illustrates the principle of use of active vortex generators for increasing the efficiency of a cascade flow. For this purpose, an axial cascade, illustrated in FIG. 5 a by a cylindrical section unrolled into the plane, is preceded by a number of active vortex generators. FIG. 5 a shows a guide-vane row 33 of a gas turbine, which comprises a number of guide vanes 34 and which is followed on the flow medium side by a moving-blade row 35 comprising a number of moving blades 36 . The guide-vane row 34 and the moving-blade row 36 are arranged in the flow duct, not illustrated in any more detail, through which the flow medium S flows in the direction indicated by the arrow 2 . The guide-vane row 34 is preceded on the flow medium side by a vortex generator row 38 which comprises a number of profiles 1 . The profiles 1 are designed in such a way that they are rotated about their respective axis of rotation 14 by an external drive. During a full oscillation period of the profiles 1 , each profile 1 generates at its trailing edge 4 two finite edge vortices 6 which break away after the adhesion phase and move through the flow duct on the path indicated by the arrow 40 . The finite edge vortices 6 move on their path around the guide vanes 34 due to the energy transmitted to them by the profiles 1 and impinge onto the moving blades 36 which follow the guide vanes on the flow medium side and to which said vortices discharge their energy. The flow pulses thereby generated increase the efficiency of the cascade flow, inter alia due to the utilization of the not yet fully understood “clocking effect” as it is known, an effect which is based on the aerodynamic interaction of various cascades with one another and which comes into force when the cascades assume an exactly defined position with respect to one another. The clocking effect already utilized in the positioning of the guide vanes 34 in relation to the moving blades 36 is further intensified by the profiles 1 as a result of the generation of flow pulses generated so as to match the movement of the moving blades 36 in duration and frequency. Said effect measurably increases the efficiency of the cascade flow and can thus contribute to the increase in efficiency of, for example, a gas turbine and consequently to the lowering of its emissions.
FIG. 5 b shows a possible drive for the profiles 1 illustrated in FIG. 5 a. The profiles 1 are mounted on a common connecting rod 23 in the region of their trailing edge 4 and are supported rotatably about their respective axis of rotation 14 in their front region on a further connecting rod 30 . When the vortex generator is operating, the electromagnetic drive 27 moves the connecting rod 23 upward or downward via the hydraulically operating working cylinder 32 . This results in an in-phase rotation of the profiles 1 about their respective axis of rotation 14 .
The heat exchange and mass transfer in a flow medium transversely to its flow direction can be increased considerably by means of velocity fluctuations imparted to the flow medium. Such velocity fluctuations can be imparted especially simply, and with a comparatively low pressure loss in the flow medium, by the use of active vortex generators. FIG. 6 shows an arrangement in which finite edge vortices 6 generated by the profiles 1 can be utilized for the cooling of components subjected to especially high thermal load. For this purpose, a number of profiles 1 , for example three profiles 1 , are arranged on a common connecting rod 23 in a flow duct 12 of, for example, a gas turbine. The connecting rod 23 can be periodically moved upward in the direction indicated by the arrow 42 and subsequently downward again by means of an external drive. The drive of the connecting rod 23 may in this case take place mechanically, as in FIG. 6 a, or alternatively electromagnetically, as in FIG. 6 b. When operating, on account of the external drive, the profiles 1 execute a translational movement over the distance x within the flow duct 12 and thereby impart the velocity profile p to the flow medium S. The finite edge vortices 6 occurring at the moved trailing edges 4 of the profiles 1 and breaking away from the profiles 1 impart in turn to the velocity profile p periodic velocity fluctuations which considerably increase the heat exchange transversely to the flow direction and thus contribute to the desired improvement in the cooling of the wall 44 . In particular, the improvement in the cooling action of the flow is attributable to the upstream displacement of the laminar/turbulent reversal point of the flow due to the use of the vortex generator. The heat transmission coefficient is thereby markedly increased and the cooling action improved. Thus, with the temperature of the wall 44 remaining the same, flow medium S can be saved or, at the same outlay of flow medium S, an increase in power and efficiency of the gas turbine can be achieved.
The mass transfer transversely to the flow direction, increased as a result of the use of a vortex generator, may also be utilized for the mixing of flow media with one another. For this purpose, as illustrated in FIG. 7 a, a profile 1 , which is moved periodically by means of an external drive, is arranged in a flow duct 12 through which a flow medium S flows in the direction of the arrow 2 . In this case, as illustrated in FIG. 7 b, the drive takes place mechanically via a slider crank. During each period, the periodically moving profile 1 generates two finite edge vortices 4 which occur at its trailing edge 4 and which break away after the adhesion phase. The turbulences thereby generated in a controlled manner ensure an efficient mixing of the flow medium S which may consist, for example, of a plurality of components, such as air and fuel gas or light fuel oil and water, which are to be intermixed with one another. Where a gas turbine is concerned, by virtue of the especially thorough intermixing of fuel gas and air, a complete combustion of the fuel gas and consequently a lowering of the NOx emissions of the gas turbine can be achieved. The profile 1 for the generation of vortices may be followed on the flow medium side by a profile, not illustrated in FIG. 7 , for the destruction of vortices, if a turbulent flow in the further progression is not desired.
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According to the invention, a device for the generation of eddies creates or destroys eddies in a flowing medium in a particularly simple manner, with particularly low energy requirement with the lowest possible pressure drop, whereby the device comprises one or more profiles, for the flowing medium to flow around, which are provided with an external drive for a periodic movement relative to the flowing medium with an angular frequency ω. The profiles are thus periodically displaced with an angular frequency ω by an external drive.
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FIELD OF INVENTION
This invention relates to the field of photographic still cameras and more particularly to a system for providing audio recording and playback in association with individual still photographic prints.
BACKGROUND OF INVENTION
Systems for providing audio recording and playback in association with individual photographic still prints are known in the art. Examples of such systems are disclosed in U.S. Pat. Nos. 3,439,598; 4,270,853; 4,270,854 and 4,905,029. In the '598 patent, a belt driven recording needle inscribes audio information in spiral grooves on the back layer of a multi-laminate slide film. This requires special film and film processing that would allow for removal of the recording film laminate and its attachment to the slide frame for playback by needle-based playback apparatus. In the '854 patent, sound is recorded on an instant print by placing the print, after it has been ejected, into an auxiliary slot in the camera and then proceeding to record the audio on a magnetic strip on the print border. With this system, audio can only be recorded after the picture has been captured and only on an instant print. Also, the only way disclosed for playback is with the camera. The '853 patent discloses a similar apparatus for an instant print camera for recording audio on a magnetic strip in the margin of the instant print paper within a film pack. The '029 patent discloses a microphone and tape recording mechanism to record sound in the camera which is then recorded onto a separate magnetic strip by means of separate recording/playback apparatus. The strip may then be adhesively applied to the photoprint or to the album page adjacent the print and the sound reproduced by means of a special playback apparatus with a reciprocating playback head which is placed against the strip. This arrangement requires a separate tape recording mechanism in the camera.
Additionally, there are three known commercially available systems for combining sound with still photographs. One is the "Talking Picture Frame" sold by Talking Pictures, Inc. which utilizes a special picture frame having a voice recording IC to record the sound in RAM chips in the frame. When the frame is lifted, a microswitch activates the IC to playback the recorded sound.
Another system is the "Mini Box Comm" sold by FotoFonics, Inc. which utilizes a separate record/playback box to record sound on an adhesively backed strip adhered to the photoprint. The print is inserted into the box for recording and playback and the print is in motion during both modes of operation.
The third system is the Mavica electronic camera sold by Sony Corporation which is an electronic camera as opposed to a photographic film camera. Images are acquired by electronic sensors for recording on 2.5" floppy disc memories for subsequent readout by electronic visual display means. Sound is recorded on the floppy disc for subsequent playback along with the recorded image.
A problem with the photographic film systems described above is that the magnetic strips, if kept integral with the prints, are limited to use with instant print cameras. In the case of the system described in U.S. Pat. No. 4,905,029, the sound is recorded on separate strips that may become lost or not easily associated with the prints when they are returned from the photofinisher. In the case of the picture frame the sound is recorded after the print is returned from the photofinisher thus losing the benefit of sound recorded at the time the picture is taken.
Accordingly, there is a need for a simple and compact sound recording system usable with negative or positive film that allows for sound recording at the time of picture taking and that does not become separated from the photographic image.
Another object of the invention is to record the sound with the picture in such a manner as to permanently retain the recorded sound with the film image such that a photofinisher can automatically impress the recorded sound on the photoprint produced by the photofinisher.
It is another object of the invention to provide a sound recording system for still pictures that is not limited to use with instant print cameras.
It is yet another object of the invention to provide a still picture sound recording system that enables the camera user to edit the recorded sound before it is recorded on the image film and sent to the photofinisher.
It is still another object of the invention to provide a still picture recording system that allows the photofinisher to impress the recorded sound on the photoprint in a manner that enables the sound to be played back by compact playback apparatus while the print remains stationary and without the use of bulky reciprocating magnet read head apparatus.
SUMMARY OF INVENTION
These and other objects of the invention are achieved by the provision of a photographic still picture audio recording system adapted to provide audio recording in association with still photographic pictures which comprises a film camera adapted to receive film having a magnetic recording layer thereon. The camera is provided with an audio transducer and signal conversion means for converting audible sound to a digital signal. The camera of the system is further provided with temporary storage means for storing said digital audio signal in the camera and with magnetic recording means for recording said stored digital signal on said film magnetic recording layer. The systems of the invention further includes photofinishing apparatus for producing photographic prints from latent images exposed onto said film in the camera, said photofinishing apparatus including magnetic read means for reading the digital audio signal recorded on the film magnetic layer, means for converting said read digital audio signal into a predetermined encodement format and means for impressing said encodement format onto said photographic prints for subsequent audio playback. In one form of the invention, the encodement format comprises a printed bar code on the front of the photographic print in the margin thereon or on the back of the print. In another form, the encodement format comprises a series of blisters on the print (front margin or backside) which are binary coded in known manner according to the audio information.
BRIEF DESCRIPTION OF DRAWINGS
In the drawings:
FIG. 1 is a diagram illustrating parallel dedicated tracks in a virtually transparent magnetic layer on film and a cross section of the layers of film particularly adapted for use in a camera of the present invention.
FIG. 2 is a schematic illustration of a camera having audio recording apparatus according to the present invention.
FIG. 3 is a schematic block diagram of audio recording and reproducing circuits useful in the camera of FIG. 2.
FIG. 4 is a simplified diagram of photofinishing apparatus adapted to impress audio encodement formats on photoprints according to the present invention.
FIG. 5 is an illustration of a photoprint embodying bar code encodement of audio information initially recorded by the camera of FIG. 2.
FIG. 6 is an illustration of the back of a photoprint embodying blister encodement of the audio information initially recorded by the camera of FIG. 2.
FIG. 7 is a simplified diagram of hand-held apparatus for reading audio encodement from a photoprint bearing audio encodement of FIGS. 5 or 6.
FIG. 8 is a schematic block diagram of playback circuits useful in the apparatus of FIG. 7.
DETAILED DESCRIPTION
Referring now to FIG. 1, a strip 10 of magnetically coated color negative film, 35 millimeters wide, useful in the present invention includes a base 11, various well-known photo-chemical layers 12 on one side of the base 11 and a virtually transparent magnetic layer 13 on the other side. An anti-static and lubricating layer 14 overlies the magnetic layer 13. The film strip 10 includes perforations 15 along the film edge at regular intervals matching the pitch of a metering pawl in a camera adapted to use the film strip 10.
For purposes of recording data in the magnetic layer 13, each frame of the film strip 10 may be formatted as shown in FIG. 1 and more fully described in commonly assigned U.S. Pat. No. 4,977,419, the disclosure of which is incorporated herein by reference. More specifically, the frame area is divided into a plurality of predetermined longitudinal track locations designated in the drawing as outermost tracks C0-C4 and innermost tracks F00-F29. As described more fully in the '419 patent, certain of the tracks may be reserved for recording of information in the camera using magnetic recording means included in the camera. In addition, other tracks may be reserved for use by the photofinisher. Additionally, the '419 patent indicates that certain of the tracks may be used for recording of audio information. Apparatus for magnetically recording information in the camera is more fully described in the patent and is not repeated here except to the extent elements thereof are relevant to an understanding of the present invention.
Referring to FIG. 2, a camera 16 is shown which is specifically adapted to receive and function with film having a magnetic recording layer such as just described. Camera 16 is provided with a built-in audio transducer, e.g. microphone 17, an internally mounted microchip 18, a magnetic recording head 19 and a miniature speaker 20. Referring to FIG. 3, there is shown an expanded block diagram of the circuits and components included in camera 16, the circuits for the most part being embodied in microchip 18. User inputs 22 comprise buttons or switches which condition the camera system microcontroller 23 to initiate and control the various operating functions of the camera, among them the sound recording and playback functions of the present invention. Microphone 17 and speaker 20 are coupled to analog amplifier and data processing circuit 24 to input and play back the audio. A sound processor integrated circuit (IC) 25 serves to convert analog signals input from microphone 17 into coded digital information suitable for storage in a digital memory 26 and for converting the digital information into analog signals suitable for playback through speaker 20. Sound processor 25 may be a Texas Instruments TMS3477 and memory 26 may be a random access memory (RAM) such as a Hitachi HM628128. One of the functions of memory 26 is to serve as a temporary storage facility for the sound data associated with an individual exposed image frame and, for this purpose, is coupled in the "read" mode to film read/write interface circuits 27 to record the stored audio data onto the magnetic layer 13 (MOF) on film 10. A film advance motor controller 28 operates at appropriate times to cause film advance motor 29 to advance the film in either the frame-to-frame direction or in the film prewind/rewind direction, the latter depending on the nature of the camera involved.
In operation, when it is desired to record sound in association with taking a picture, the camera user selects sound recording via a user input selector switch 22 that causes the camera system microcontroller 23 to set the digital memory to the "write" mode and then enables the analog amplifier and data processing circuit 24 for audio recording. Assuming the user desires to have image-related audio, the user talks into the camera microphone to identify the scene with appropriate information, such as, date, time, f-stop, shutter speed, picture taking location, people in the scene, or aims the microphone to record live sounds from the scene. The data processing circuit 24 and sound processor IC 25 convert the incoming analog signal to coded digital data which is then recorded in the digital memory 26. Audio may be recorded into memory 26 in this manner before, during or after the picture-taking event.
Once having recorded the audio in memory 26, it is then possible to review the recorded information via speaker 20 in the camera. To do this, the user selects the "review" mode by means of a user input switch which causes the microcontroller 23 to set the memory 26 to the "read" mode thereby enabling the sound processor 25 and the analog amplifier and data processing circuit 24 to play back audio through speaker 20. If the recorded sound is not satisfactory, the user can easily change it by simply repeating the recording process described above. It is thus apparent that the use of this temporary buffer memory 26 allows quick audio review and, if necessary, re-recording without movement of the film or any other recording medium in the camera and without the actual taking or print-out of the picture as in the case of instant prints.
Following the taking of a picture, the camera system microcontroller 23 checks the status of the memory 26. If there is audio stored in the memory, it sets the memory to the "read" mode to pass the data from the memory to the film read/write circuits. When microcontroller 23 activates motor controller 28 to cause motor 29 to initiate film advance to the next frame, the data transferred from the memory 26 to the recording interface circuits is recorded on the film magnetic layer during the film advance. Once the data is recorded on the film magnetic layer, microcontroller 23 sets the status of memory 26 to empty thus preparing the memory for the next recording event. Microcontroller 23 may also be adapted to allow the user to select post-image capture audio, in which case the camera system microcontroller does not advance the film following exposure, but waits until after the audio capture on film is completed.
Referring to FIG. 4, photofinishing apparatus embodying the invention is adapted to process the film exposed by the camera of FIG. 1, namely film strip 10 having a magnetic recording layer on which audio information has been digitally recorded in the camera. Developed images on film strip 10 are exposed onto a strip of photosensitive printing paper 35 with a print exposure source 36 under the control of print EV control 37. A processor 38 operates to control film advance motor 39 and print EV control 37. The photofinishing apparatus also includes a magnetic read head 40, and playback circuits 41 connected thereto. One output of the playback circuits is applied to processor 38 and another output is applied to a data converter circuit 42. As each frame on the film strip 10 is advanced past the magnetic read head 40 in preparation for being exposed to the print exposure source 36, processor 38 monitors the output of the read head through the playback circuit to derive from data recorded on the film magnetic layer information useful in controlling the exposure process. This procedure is described more fully in commonly assigned U.S. Pat. No. 5,006,878, the disclosure of which is incorporated herein by reference. Additionally, and in accordance with a particular feature of the invention, digital audio signal information recorded on the film magnetic layer of film 10 is applied from the playback circuits 41 to signal converter circuit 42 wherein there is generated an encodement format signal used to drive printer 43 for impressing the encodement format onto the photoprint. Printer 43, for example, may be an inkjet printer adapted to respond to the encodement format signal to print a corresponding bar code format 45 on the photoprint such as is shown in FIG. 5. The bar code encoded information may be printed in the margin of the photoprint, as shown, or it may be printed alternatively on the back side of the print. The printer may also respond to frame specific data such as date and time to print the information in eye readable form on the print as shown.
Alternatively, printer 43 may comprise blister forming apparatus which operates to create blister marks 47, as shown schematically in FIG. 6, on the plastic coating normally used on the photoprint paper. Such blistering apparatus operates to create localized heating of spots on the coating using, for example, a laser beam to form a binary encodement format on the coating.
Having impressed the audio information on the photoprint in the form of a suitable encodement format as described above, the sound subsequently may be reproduced by means of a portable, hand-held playback device 50 shown in FIG. 7 having a form factor about the same as a credit card and only slightly thicker. Such a device comprises a button battery power source 51, a memory storage IC 52, an optical emitter/decoder pair 53, a sound data decoder IC 54, a planar speaker 55, analog drive circuits 56 and digital control logic 57.
Referring to FIG. 8, functional block diagram of circuitry for the device of FIG. 7 comprises user input buttons 58 coupled to digital control logic unit 57 which controls the operation of digital memory 54 and an analog unit 56 which includes speaker amplifier 56a and analog drive and amplitude comparator unit 56b. The latter unit is coupled to the emitter/detector pair device 53 which operates to sense the encodement format on the photoprint and to produce a digital output signal which is temporarily stored in memory unit 52. To play back the audio from the encodement format on the photoprint, the user enables the hand held reader by pressing an "on" switch of user inputs 58 which causes logic unit 57 to set memory 52 to the "store" mode and also to enable an LED (not shown) to indicate the "power on" status. Next the user scans the optical emitter of emitter/detector pair 53 over the encoded audio information, either the blister pattern or the bar code pattern. Preferably the data is encoded in a self-clocking format such as is described in U.S. Pat. No. 4,876,697 or in U.S. Pat. No. 4,954,825, the disclosures of which are incorporated herein by reference, in order to make the reader scanspeed tolerant. While scanning, the unit decodes the printed pattern back into digital data and stores it in the local memory. Once scanned, the photoprint is held in a comfortable manner to be observed while the audio player input switch is activated. The digital control logic 57 then proceeds to set the memory 52 to read, and to enable the sound processor IC 54 to convert the digital signal data to an audio signal which is passed via the amplifier to the speaker. A particular advantage of such an arrangement is that the user can replay the audio as many times as desired without re-scanning the photoprint, since the data is retained in the digital memory 52 until power is removed or until the user clears the memory via the user inputs 58 and control logic unit 57
The invention has been described in detail with particular reference to a presently preferred embodiment, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
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Audio to be recorded in a photographic film camera in association with individual exposed frames is first digitized and stored in a temporary storage memory in the camera allowing playback through a speaker mounted in the camera to permit playback review and editing, as needed. When the film is advanced in the camera to the next exposure frame, the digital audio signal is recorded on a magnetic layer formed on the film. At the photofinisher, the digital audio signal is read and converted to suitable encodement format, such as bar code or binary coded blister marks which are impressed on the photoprint for subsequent playback.
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BACKGROUND OF THE INVENTION
The present invention relates to a system for detecting a crank angle relative to a specific cylinder of an engine for a motor vehicle, and more particularly to a system for discriminating a cylinder to be ignited.
Japanese Patent Application Laid-Open No. 57-124208 discloses a cylinder discriminating system in which a disk is provided to rotate once while a crankshaft of an engine rotates twice and to generate a crank angle signal in the form of pulses sensed by a sensing means. The crank angle signal is used for designating a cylinder within a discriminating range on the disk.
FIGS. 5a and 5b show a diagram in relation to the crank angle signal and a disk 52 secured to a crankshaft in a conventional system. The system has a cam shaft disk having projections and produces cam signal pulses CS for every cylinders. The crank angle signal CA in the form of pulses is generated at projections formed on the periphery of the disk 52 in an angular discriminating range of the crankshaft and the number of the pulses CS is counted to discriminate a corresponding cylinder. The angular discriminating range is shown by C in FIG. 5b, which is between 10° and 100° before the top dead center (BTDC) for the cylinder.
On the other hand, in a four-cylinder engine as an example, there is high probability that the engine stops near an angle of 70° before the top dead center on the compression stroke of a cylinder, which is included in the discriminating range C. Reference S in FIG. 5a designates an engine stop range in which the engine frequently stops. Accordingly, if the engine starts under the condition that the engine has stopped in the range S, the cam signal pulses may be counted in error. In other words, the counted number of the pulses may become less than the actual number thereof, because the pulses CS may be included in the stop range S. Thus, accurate ignition timing is not obtained, which causes backfire of the engine.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a cylinder discriminating system which may eliminate the above described disadvantages of the prior art.
In accordance with the present invention, a cylinder discriminating range is located at a position where engines seldom stop, thereby accurately discriminating cylinders at the starting of the engine.
According to the present invention, there is provided a first disk provided to be rotated in synchronism with a crankshaft of said engine, first indicator means formed on said first disk and disposed in angular ranges of the crankshaft which are out of angular ranges where said engine stops frequently, a first sensor for sensing said first indicator means and for producing crank angle signal, first indicator means in each range being arranged to indicate a particular cylinder of said engine, a second disk rotated once while said crankshaft of the engine rotates twice, second indicator means formed on said second disk provided for discriminating respective cylinder at predetermined angle, second sensor for sensing said second indicator means and for producing cam angle signal, discriminator means responsive to said cam angle signal generated between said crank angle signals for producing discriminating signals representing respective cylinders.
In an aspect of the invention, first indicator means are projections formed on the periphery of the disk.
The other objects and features of this invention will become understood from the following description with reference to the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic illustration of a system according to the present invention;
FIG. 2 is a block diagram of an electronic control unit;
FIGS. 3a, 3b, 4a, and 4b are diagrams showing ignition timing in relation to crank signals and cam signals; and
FIGS. 5a and 5b are diagrams showing crank angle signals and pulse counting ranges in a conventional system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 showing a cylinder discriminating system for a four-cylinder engine for a motor vehicle according to the present invention, a crankshaft 1 of the engine has a crankshaft disk 2 secured thereto. Cylinders of the engine are divided into two groups. The first group consists of No. 1 and No. 3 cylinders, and the second group consists of No. 2 and No. 4 cylinders, in each group, top dead centers for both cylinders are the same timing. The crankshaft disk 2 has four projections 2a and 2b for the first group, and 2c and 2d for the second group which are formed on the outer periphery thereof. Each of projections 2a and 2c is 10° before the top dead center (BTDC) and each of projections 2b and 2d is 80° after the top dead center (ATDC). Between projections 2a and 2b and between projections 2c and 2d are cylinder discriminating ranges D1 and D2 (FIG. 3b) which are outside of the conventional discriminating ranges C (FIG. 5b).
Accordingly, the ranges D1 and D2 do not include an engine stop liable range S. A crank angle sensor 3 is provided adjacent the crankshaft disk 2 for detecting the projections 2a to 2d to produce a crank angle signal at each projection in the form of pulses as shown in FIG. 3a.
A camshaft disk 5 is secured to a camshaft 4 for detecting cam angles. The camshaft 4 rotates once while the crankshaft 1 rotates twice. The camshaft disk 5 is provided with projections 5a, 5c, 5b and 5d formed on an outer periphery thereof. Projections 5a to 5d represent No. 1 to No. 4 cylinders, respectively. Projections 5a and 5c are formed in the range D 1 and projections 5b and 5d are in the range D 2 . A cam angle sensor 6 is provided adjacent the camshaft disk 5 for detecting the projections 5a to 5d to produce a cam angle signal representing the number of the cylinder in the form of pulses as shown in FIG. 3a.
The crank angle signal and the cam angle signal from the sensors 3 and 6 and an intake pipe pressure signal detected by an intake pipe pressure sensor 7 are applied to an electronic control unit 8 comprising a microcomputer. The control unit 8 comprises an input/output interface 8a, a CPU 8b, a ROM 8c for storing control programs, and a RAM 8d for temporarily storing data. An ignition timing is calculated in accordance with a predetermined program and a timing signal is applied to a driver 9 comprising a power transistor. In accordance with the signal, the driver 9 is turned off to apply high-voltage surge to a spark plug 12 of a corresponding cylinder through an ignition coil 10 and a distributor 11.
Referring to FIG. 2, the control unit 8 comprises a crank angle signal discriminating means 20 applied with the crank angle signal from the crank angle sensor 3 and the cam angle signal from the cam angle sensor 6. The crank angle signal discriminating means 20 discriminates a crank angle signal A dependent on projection 2a or 2c from a crank angle signal B dependent on projection 2b or 2d in accordance with the cam angle signal. Namely, as shown in FIG. 3a, after a crank angle signal is detected, if a cam angle signal is not detected before the next crank angle signal is detected, the next crank angle signal is discriminated as crank angle signal A. If a cam angle signal is detected between the crank angle signals, the next crank angle signal is discriminated as crank angle signal B. These crank angle signals A and B are applied to a pulse repetition rate calculator 21 where a pulse repetition rate T AB is obtained in accordance with the time difference between an A signal detected time and a B signal detected time. That is to say, angular velocity of the crankshaft 1 is calculated. The pulse repetition rate T AB is applied to an engine speed calculator 22 for calculating an engine speed Ne.
The intake pipe pressure signal from the intake pipe pressure sensor 7 is applied to an intake pressure calculator 23 where an intake pressure P corresponding to engine load is calculated. On the basis of the intake pressure P and the engine speed Ne, a basic ignition timing angle ANG SPK is derived from a basic ignition timing table 24. The basic ignition timing angle ANG SPK is applied to an ignition timing calculator 25 to which the pulse repetition rate signal T AB from the pulse repetition rate calculator 21 is applied. An ignition timing T SPK after the B signal detected time is calculated as follows.
T.sub.SPK =(ANG.sub.SPK /(B-A)°)×T.sub.AB
The ignition timing T SPK is set in a timer 26 which starts measuring time in accordance with the crank angle signal B from the crank angle signal discriminating means 20. When the timer reaches a set ignition timing T SPK , a spark signal is applied to the driver 9 for turning off the power transistor. The voltage surge is applied to the spark plug 12 of the cylinder.
At the starting of the engine, ignition operation is performed at the crank angle signal A time. When the crank angle signal B time is detected, the power transistor of the driver 9 is turned on to flow a current to the ignition coil 10.
In order to discriminate cylinders, the cam angle signals dependent on projections 5a to 5d are applied to a counter 30 where each cam angle signal is counted in the discriminating range D 1 or D 2 . The cylinder is discriminated at a cylinder discriminating means 31 in accordance with the counted number of pulses. The counter 30 is applied with the crank angle signal A from the crank angle signal discriminating means 20 so that the counter 30 is reset to count the corresponding pulses. When the cylinder is discriminated at the cylinder discriminating means 31, an output signal is applied to a select means 32 where the corresponding cylinder is selected and a signal is applied to the driver 9 in accordance with a time measured by the timer 26.
Referring to FIGS. 4a and 4b showing a modification of the crankshaft disk, a crankshaft disk 42 is provided with four projections at 112° BTDC and 80° BTDC on the outer periphery thereof. Thus, projections 5a to 5d on the camshaft disk 5 must be positioned so as not to include the engine stop range S. Namely, the projections are provided after 10° BTDC.
In the embodiments described above, although the projections are formed on the disks secured to the crankshaft and the camshaft, the projections can be replaced with notches or slits formed on the crankshaft, camshaft, or other rotors rotated in synchronism with the crankshaft.
The system can be used for controlling fuel injection of the engine.
In accordance with the present invention, cylinder indicator means such as projections are provided in an angular range of the crankshaft which is out of a range where the engine stops most frequently. Thus, cylinders are exactly discriminated by the system at starting the engine to improve starting characteristics of the engine. Since the projections are not disposed in the ignition range, the ignition is not disturbed by the cylinder discriminating pulse signal.
While the presently preferred embodiments of the present invention have been shown and described, it is to be understood that these disclosure are for the purpose of illustration and that various changes and modifications may be made without departing from the scope of the invention as set forth in the appended claims.
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A disk is secured to a camshaft of an engine, and a plurality of projections are provided on a periphery of the disk in angular ranges of a crankshaft which are out of angular ranges where the engine stops frequently. Projections in each range are arranged to indicate a specific cylinder of the engine. A sensor is provided for sensing the projections and for producing cylinder representing signal. A discriminator is provided for producing discriminating signals representing respective cylinders in accordance with the cylinder representing signals.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a fusion protein of PRRS subunit vaccine inducing PRRSV neutralization titers in pigs.
[0003] 2. Description of Related Art
[0004] Porcine reproductive and respiratory syndrome is a porcine infectious disease that primarily strikes respiratory tracts of pigs at various ages and results in sows having reproductive dysfunction. PRRSV is a tough and resistant virus not prone to evoke antibodies having neutralization titers in the infectious pig. Besides, PRRSV is a RNA virus and reproduces easily on the basis of a simplified genetic system, so the probability of genetic mutations is very high. Furthermore, infections and pathogenesis pathway of PRRS virus can be sorted into two stages: (A) infections of epithelium tissues of upper and lower reproductive tracts; and (B) infections of monocytes and macrophages in tissues surrounding reproductive tracts. Thus, the host must have body fluid immunity as well as mucosal immunity with neutralization titers and also a cell-mediated immune response to facilitate removal of the infected viruses and strengthen the host protection mechanisms. However, it is not very easy for PRRSV infectious pig to have neutralization titers in natural conditions, hence typical antibodies basically have little effect on PRRSV, and they even induce mutations in viruses. Furthermore, in antibody-dependent enhancement of phagocytosis, the antibodies could only cause more severe PRRSV infections.
[0005] Taiwan Patent No.1-2289933 (also as U.S. patent publication no. 2004/02147617) discloses a target-cell-specific fusion protein, which utilizes a moiety and a functional domain of Pseudomonas aeruginosa exotoxin to fuse a PRRSV ORF7 nuclear protein fragment, with a KDEL signal peptide added on the carboxyl terminus. The fusion protein can be mass-produced in E. coli. When immunized the fusion protein to pigs, it is possible to decrease or to eliminate viremia after being PRRSV-challenged in the immunized pigs. The full text of the patent is incorporated herein.
[0006] In heterodimerization between ORF5 and ORF6 of PRRSV, epitope Cys-34 of ORF5 and epitope Cys-8 of ORF6 play a critical role in viral infection and the envelope assembly thereof. (Snijder Eric J., Jessica C. et al., Journal of Virology, January 2003, Vol. 77, No. 1:97-104). Besides, the consensus sequence of PRRSV ORF5 (YKNTHLDLIYNA) is an epitope between amino acid 38 th and amino acid 44 th , which is located at N-terminal extracellular domain of PRRSV ORF5 and had been identified as a neutralization epitope (Ostrowski M., J. A. Galeota, et al., Journal of Virology, May 2002, Vol. 76, No. 9:4241-4250).
[0007] Prior arts disclose constructing whole PRRSV ORF5 or ORF6 antigens between PE and KDEL. After immunization of these fusion proteins, the pigs suffered from severe inflammation in their lungs post being PRRSV-challenged, indicating that PRRSV ORF5 or ORF6 have an antigen-specific allergy effect. Manifestly, it is difficult to use them as PRRS vaccine antigens. Thus, to develop a vaccine and effectively protect pigs from PRRS infections, there are a lot of difficulties that have to be overcome. It should need to be designed such as a lower immunotoxicity and having a high neutralization titer.
SUMMARY OF THE INVENTION
[0008] An object of the present invention is to provide a fusion protein, and the method to construct thereof.
[0009] Anther object of the present invention relates to using the fusion protein to prepare a subunit vaccine composed of proteins having neutralization titers.
[0010] Still another object of the present invention is to provide a pharmaceutical composition, comprising the fusion protein of the present invention and pharmaceutically acceptable adjuvants.
[0011] PE-PQGAB-K3 fusion protein of the present invention comprises: a chimeric polypeptide containing N-terminal portions of PRRSV ORF5 and ORF6 structure proteins; a portion of Pseudomonas exotoxin A binding and translocation domains; and a carboxyl terminal domain containing KDEL-KDEL-KDEL(K3) fragment.
[0012] The present invention further comprises a pharmaceutical composition that can serve as a vaccine, comprising: a chimeric polypeptide, which contains N-terminal portions of PRRSV ORF5 and ORF6 structural proteins; a portion of Pseudomonas exotoxin A binding and translocation domain; a carboxyl terminal domain containing KDEL-KDEL-KDEL(K3) fragment; and a pharmaceutically acceptable adjuvant.
[0013] The strain of PRRSV in the present invention is not particularly limited; it can be an American strain, European strain, or Australian strain. There is no particular limitation to the fragments contained in the N-terminal domain of the fusion protein, but they are preferably any PRRSV fragment that is antigenic, such as PRRSV ORF5, ORF6. Taking American strain as an example, the portion of PRRSV ORF6 sequence is preferably as SEQ ID NO.13. The amino acid sequence of the N-terminal portion of PRRSV ORF5 structural protein can be as SEQ ID NO.12. For European strain, the amino acid sequence of the N-terminal portion of PRRSV ORF6 structural protein is preferably as SEQ ID NO.15, and that of the N-terminal portion of PRRSV ORF5 can be as SEQ ID NO.14.
[0014] In the present invention, the nucleic acid sequence of the fusion protein containing a portion of PRRSV ORF5 and a portion of PRRSV ORF6 is modified, and there is no particular limitation to the sequence, but it is preferably a nucleic acid sequence that can be expressed in large amounts in E. coli host-vector system, and the expressed proteins are identical to wild type ones. Taking American strain of PRRSV as an example, preferably the modified nucleic acid sequence is as seen in SEQ ID NO.1. For European strains, preferably the modified nucleic sequence is as SEQ ID NO.10.
[0015] A preferred embodiment of the portion of Pseudomonas exotoxin A binding and translocation domain of the fusion protein in the present invention is a detoxified Pseudomonas exotoxin, which is a fragment from Pseudomonas exotoxin A without domain III. Preferably, the fragment of Pseudomonas exotoxin A binding and translocation domain acts as a ligand moiety which is capable of reacting, recognizing or binding to a receptor on the target cell.
[0016] The pharmaceutical composition of the present invention can comprise a suitable adjuvant known in the art: dispersant, humectant (such as Tween 80), or sterile injections prepared with suspensions (such as sterile injection solutions or oily solutions). Sterile injection preparations can also be used in diluents or solvents of sterile injections or suspensions during innocuous injections, for example, in solutions of 1,3-butanediol. Acceptable carriers or solvents include mannitol, water, ringer solution, and isotonic sodium chloride solution. Besides, sterilized and fixed oils are used in prior arts as solvents or suspension media(for example, synthesized monoglycerides or diglycerides). Fatty acids (such as oleic acids or glyceride derivatives) and natural pharmaceutically acceptable oils (such as olive oil or castor oil, especially polyoxyethylated derivatives thereof) can be used in injectable preparations. The oil solutions or suspensions can also comprise long-chain alcohol diluents, dispersants, caboxylmethyl cellulose, or similar dispersants. Other commonly used surfactants like Tweens and Spans, or emulsifiers and bioavailability enhancers (usually used in manufacturing pharmaceutically acceptable alum solids, liquids or other dosage forms) can also be used for preparing purposes.
[0017] Compositions for oral administration can be any dosage form acceptable for oral administration, comprising, but not limited to, capsules, tablets, emulsions, water suspensions, dispersants, and solutions. In cases of tablets for oral administration purposes, the typical carriers include lactose and corn starch. A lubricant is often added, such as magnesium stearate. For oral administration with capsules, suitable diluents include lactose and corn starch. In cases of oral administration of water dispersants or emulsions, active ingredients could associate with emulsions or suspensions to suspend or disperse in the oil phase. Depending on needs, certain sweeteners, flavoring agents, or coloring agents can be added.
[0018] A nasal aerosol or inhalation composition can be prepared according to techniques well-known in the art of pharmaceutical formulation. For example, such a composition can be prepared as a solution in saline, employing benzyl alcohol or other suitable preservatives, absorption promoters to enhance bioavailability, fluorocarbons, and/or other solubilizing or dispersing agents known in the art. Compositions containing fusion proteins can also be administered in the form of suppositories for rectal administration.
[0019] The carriers of the pharmaceutical composition must be “acceptable”, i.e. compatible to active ingredients in the formulation (preferably, capable of stabilizing the active ingredient) and not deleterious to the subject to be treated. Other examples of the carriers include colloidal silicon dioxide, magnesium stearate, cellose, sodium lauryl sulfate, and D&C yellow No.10.
[0020] The pharmaceutical composition of the fusion protein in the present invention preferably comprises an immune adjuvant. The immune adjuvant used is not limited and can be any conventional one used in vaccines known in the art, comprising Alumigel and oil emulsion, such as Freund's FCA or FIA or mannide mono-oleate emulsifier (ISA720 or ISA206, SEPPIC®, France), preferably ISA206.
[0021] Other objects, advantages, and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a schematic illustration of PE-PQGAB fusion protein of Example 1;
[0023] FIG. 2 is a flowchart of plasmid construction of PE(ΔIII)-PQGAB of Example 1;
[0024] FIG. 3 is the electrophoresis diagram of the nucleic acid fragments synthesized according to Example 1, with four DNA fragments (a:70 bp, b:129 bp, c:186 bp, d:204 bp); and
[0025] FIG. 4 is the plasmid map of PE(ΔIII)-PQGAB.
[0026] FIG. 5 is the result of proteins induced in E. coli Host-vector system and extracted from inclusion bodies by 8M urea extraction. lane 0h, 2h: the total lysis samples at 0 hr and 2 hr after IPTG induction of E. coli with pPE-PQGAB-K3; and lane 8M: 8M urea protein extraction of PE-PQGAB-K3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] The feature of the present invention is based on a finding that, when most structure proteins in ORF5 and ORF6 were removed, leaving dozens of N-terminal amino acids of ORF5 and ORF6, by which constructing a fusion peptide chain PQGAB, and then inserting the peptide chain between PE and KDEL3 sequence was possible, it was confirmed that the fusion protein PE-PQGAB-KDEL3 had serum neutralization titers by mice and porcine immunization tests.
[0028] The following examples are proposed to explain the present invention, but not set forth as to limit the scope thereof.
EXAMPLE 1
PQGAB Fusion Peptide of PRRSV American Strain
[0029] Protein sequences of ORF5 and ORF6 of PRRSV were obtained from the National Center for Biotechnology Information (NCBI, USA) database. It had been known based on aforementioned mechanisms of viral infections that regions of PRRSV having neutralization titers are each N-terminus of ORF5 and ORF6. That is, amino acids No. 2 to 26 of ORF6 structural protein (SEQ ID NO.13), and amino acids No. 30 to 63 of ORF5 structural protein (SEQ ID NO.12). The fused amino acid sequence of the two peptides are illustrated as follows:
[0000]
GSSLDDFCYDSTAPQKVLLAFSITYASNDSSSHLQLIYNLTLC
ELNGTDWLANKFDWA
[0030] The sequence of PRRSV-ORF6-2˜26-ORF5-31˜63 fusion peptide was the combination of (ORF6)-G 2 SSLDDFCYDSTAPQKVLLAFSITY 26 (SEQ ID NO.13) and (ORF5)-A 31 SNDSSSHLQLIYNLTLCELNGTDWL ANKFDWA 63 (SEQ ID NO.12) peptides, wherein the fragment GSSLDDFC is designated “P”, fragment YDSTAPQKVLLAFSITY “Q”, fragment ASNDSSSHLQLIYNLTLC “A”, and ELNGTDWLANKFDWA “B”. Fragment PQ is a portion of ORF6, and Fragment AB is a portion of ORF5. G is the gap or bridge of PQ and AB ploypeptides. G can be the 27 th animo acid of ORF6 or any polypeptide fragment of ORF6 from 27 th to any linked codons. The position G can also be not added any amino acid within the polypeptides of PQ and AB.
[0031] The example employs the PQGAB fusion peptide region to construct a key protein (epitope) capable of inducing neutralization titers and immune protection in order to obtain effects of inducing immune protection in vivo. The schematic illustration of PE-PQGAB-K3 fusion protein and the flowcharts of plasmids construction of PE(ΔIII)-PQGAB and PE(ΔIII)-PQGAB-K3 are shown in FIG. 1 and FIG. 2 , respectively.
EXAMPLE 2
[0032] The preparation of nucleic sequence encoding PQGAB peptide is illustrated below. An amino acid corresponds to various sets of nucleotide triplets, so it is preferable to obtain corresponding nucleotide triplets from literature (such as http://www.kazusa.orjp/codon) that is suitable to be expressed in the E. coli system instead of the corresponding nucleotide triplets not easy to be recognized and expressed by E. coli. Likewise, if the sequence encoding PQGAB peptide is to be expressed in yeast systems, the appropriate nucleotide triplets for expression in yeast systems (such as Saccharomycesor Pichia spp.) are preferred.
[0033] A corresponding sequence with nucleotide triplets suitable to be expressed in E. Coli system was designated according to the amino acid sequence of PQGAB fusion protein. The 5′ and 3′ ends of the corresponding sequence were added by restriction sites for subsequent cloning. To improve efficiency of digestion and facilitate designing PCR primers, both ends of the sequence could be added to with nucleotide triplets with replicating bases, such as CCC, AAA, GGG, or TTT. The nucleic acid sequence encoding PQGAB fusion protein is illustrated in SEQ ID NO.1.
[0034] There are totally 207 nucleotides in SEQ ID NO.1, and when it was cloned into a plasmid by restriction enzymes, some of the nucleotide triplets were cut off, leaving 180-186 nucleotides linked to the plasmid.
[0035] When the target nucleic acid sequence encoding PQGAB fusion protein was identified, the restriction map of the nucleic acid sequence was analyzed by DNA Strider before synthesis, and then each end of the target sequence was linked to restriction site sequences for subsequent cloning, in accordance with the restriction map. The synthesized product of the target sequence must be digested by certain restriction enzymes before cloning, so it is preferable that any restriction site susceptible to the enzymes used be avoided in the structural region of the sequence. If the restriction sites subjected to cloning enzymes exist in the structural region of the target sequence, the target sequence must be re-designated such that different codons of the same amino acids were used, to eliminate restriction sites that were identical for cloning in the structural region of the target sequence.
[0036] Subsequently, the method disclosed in Taiwan Patent No. 1-2289933 (also as U.S. patent publication no. 2004/02147617) is used to modify the corresponding nucleotides codons of wild type amino acids sequence such that the wild type protein was mass expressed in by E. coli system. The essence of modification is to modify wild type nucleic acid sequence such that the normally expressed amino acids were not affected, and expression in E. coli was kept effective. The modified nucleic acid sequence can be synthesized by PCR using a variety of primer pairs. The primers are numbered as shown in Table 1.
[0000]
TABLE 1
the corresponding numbers of primers for PQGAB antigens
of PRRSV American Strain
Forward
Reverse
Target antigen
primer
Seq. ID No.
primer
Seq. ID No.
PQGAB-US
F1
2
R1
6
PQGAB-US
F2
3
R2
7
PQGAB-US
F3
4
R3
8
PQGAB-US
F4
5
[0037] The sequences of forward and reverse primers are shown as follows:
[0038] Forward primer F1 (SEQ ID No.2) corresponds to the amino acid 81 st -124 th of SEQ ID No.1, namely
[0000]
5′-GCT TTC TCC ATC ACC TAC GCT TCC AAC GAC TCC TCC
TCC CAC CT-3′;
[0039] Forward primer F2 (SEQ ID No.3) corresponds to the amino acid 48 th -96 th of SEQ ID No.1, namely
[0000]
5′-C GAC TCC ACC GCT CCC CAG AAA GTT CTG CTG GCT
TTC TCC ATC ACC TA-3′;
[0040] Forward primer F3 (SEQ ID No.4) corresponds to the amino acid 22 nd -65 th of SEQ ID No.1, namely
[0000]
5′-GGT TCC TCC CTG GAC GAC TTC TGC TAC GAC TCC
ACC GCT CCC CA-3′;
[0041] Forward primer F4(SEQ ID No.5) corresponds to the amino acid 1 st -41 st of SEQ ID No.1, namely
[0000]
5′-CCC AAA CCC CAT ATG GAA TTC GGT TCC TCC CTG
GAC GAC T-3′;
[0042] Reverse primer R1(SEQ ID No.6) corresponds to the amino acid 148 th -106 th of SEQ ID No.1, namely
[0000]
5′-A CAG GGT CAG GTT GTA GAT CAG TTG CAG GTG GGA
GGA GGA GTC-3′;
[0043] Reverse primer R2(SEQ ID No.7) corresponds to the amino acid 176 th -133 rd of SEQ ID No.1, namely
[0000]
5′-GC CAG CCA GTC GGT ACC GTT CAG TTC GCA CAG GGT
CAG GTT GTA-3′;
[0044] Reverse primer R3(SEQ ID No.8) corresponds to the amino acid 204 th -164 th of SEQ ID No.1, namely
[0000]
5′-TTT TTT CTC GAG AGC CCA GTC GAA TTT GTT AGC
CAG CCA GTC GG-3′;
[0045] wherein R1, R2 and R3 were reversely complementary sequences of a gene sequence.
[0046] The fragment synthesized with no DNA template was performed firstly. Forward primer F1 and reverse primer R1 were hybridized to each other, wherein 10-18 bases at 3′ ends of each primer were designed complementary to each other, and the resultant complex was read and complemented by polymerase so as to obtain a double-stranded DNA template product.
[0047] After the first round of PCR, 0.01˜4 μl of the PCR product was taken as the template DNA of the second round of PCR, adding therein the second primer pair, i.e. forward primer F2 and reverse primer R2, 0.01˜4 μl each, in conjunction with needed dNTPs, reagents and Pfu polymerse, and the second round PCR was performed. Likewise, primer pair F3 and R3 were added therein and PCR was performed again; the procedures were repeated with primer pair F4 and R3, and thereby a modified PQGAB nucleic acid sequence having 207 bp was obtained.
[0048] The synthesized nucleic acid fragments were subjected to electrophoresis and confirmed that they had the expected sizes. PQGAB-1(207 bp), as shown in FIG. 3 ; PQGAB generated 4 DNA fragments a, b, c, and d (a: 70 bp b: 129 bp c: 186 bp, d: 207 bp).
EXAMPLE 3
PQGAB Fragment of PRRSV European Strains
[0049] The design of the fusion protein in example 1 and 2 aimed at American strain PRRSV, but apart from American strain PRRSV, European strain and Australian strain is also very prevalent globally. Similarity of structural amino acids is not high, only 60-80%, so designs of other ORF5&ORF6 fusion proteins can be done in the same manner as example 1 and 2 to design and synthesize primers.
[0050] Taking PQGAB of PRRSV European strain as the example, the amino acid sequence of the fusion domains is shown in SEQ ID NO.11. It contains ORF6-M1˜I28+ (SEQ ID NO.15), and ORF5-F31˜A64 (SEQ ID NO.14) of the PRRSV European strain.
[0051] After the sequence is confirmed, preparation of PRRSV European strain fusion proteins can be performed in the same manner as examples 1-2. The modified nucleic acid sequence can be synthesized by PCR using a variety of primer pairs. The primers are numbered as shown in Table 2.
[0000]
TABLE 2
the corresponding numbers of primers for PQGAB antigens of
PRRSV European Strain
Forward
Reverse
Target antigen
primer
Seq. ID No.
primer
Seq. ID No.
PQGAB-EP
F1
16
R1
20
PQGAB-EP
F2
17
R2
21
PQGAB-EP
F3
18
R3
22
PQGAB-EP
F4
19
R4
23
[0052] The target nucleic acid sequence encoding PQGAB-EP fusion protein can be synthesized with those primers shown above in vitro, by following the procedure described in example 2. To improve efficiency of digestion and facilitate designing PCR primers, both ends of the sequence could be added to with nucleotide triplets with replicating bases, such as CCC, AAA, GGG, or TTT. The nucleic acid sequence encoding PQGAB-EP fusion protein is illustrated in SEQ ID NO.10.
EXAMPLE 4
Construction of Plasmids Containing the Target Sequence
[0053] Taking the product from example 2 as illustration. The synthesized 207-bp DNA fragment was digested with EcoR1 and Xho1, linked to a E.coli plasmid containing a peptide sequence having functions of binding and translocation, and a carboxyl terminus peptide, and the resultant plasmid was pPE-PQGAB-K3.
[0054] The pET15 plasmid having a T7 promoter and an antibiotic resistance(ampicillin) marker constructed therein can express the fusion protein of PRRSV PQGAB fragment and detoxified Pseudomonas exotoxin ( Pseudomonas exotoxin A without domain III). The vector map is shown in FIG. 4 .
[0055] Finally, the above-mentioned plasmid was transformed into bacterial strains or cells capable of expressing the fusion proteins.
EXAMPLE 5
Expression and Analysis of the Target Protein
[0056] Bacterial strains confirmed having the above mentioned plasmid contained both the plasmid and PQGAB gene in 90% of the population. The strains were prepared as glycerol stocks in 2-ml aliquots and stored at −70° C. In a sterile environment, 2 ml of the stored stocks was inoculated in an autoclaved 500 ml flask containing 200 ml LB (+500 μg/ml Amp), shaken in a rotary incubator at 37° C., 150 rpm for 10˜12 hours, and a culture was obtained. The liquid was cultured until OD600 reached 1.0±0.4.
[0057] In a sterile environment, 50 ml culture liquid was inoculated in each of eight 3000-ml flasks containing 1250 ml LB (+500 μg/ml Amp +50 ml 10% Glucose), shaken at 37° C., 150 rpm for 2˜3 hours until OD 600 reached 0.3±0.1, 50 ppm IPTG was added, the culture was shaken again at 37° C., 150 rpm for 2 hours such that protein production was accomplished.
[0058] Then PE-PQGAB-K3 contained in inclusion bodies was dissolved by 8M urea extraction method, the extracted PE-PQGAB-K3 proteins are shown in FIG. 5 . 300˜400 mg antigen could be obtained from a 10-liter lot of the culture liquid. Obtained antigen was analyzed with Western blot, coomasie blue staining and SDS-PAGE electrophoresis, the density of the bands was measured by densitometer to quantify proteins contained in antigen solutions. 0.2±0.02 mg of the proteins were used as the main ingredient of a low-dosage injection in order to proceed immunization and virus-challenging.
EXAMPLE 6
Immunization and Virus-Challenging in Pigs
[0059] In an SPF farm, pigs were grouped randomly into 3 groups, each having five pigs. Each group was bred in an isolation room equipped with air conditioning and circulation instruments. For pigs of PE-PQGAB-K3 immunization group aged 14 to 28 days, 2 ml vaccine containing 1 ml PE-PQGAB-K3 (containing 200 μg proteins/injection) and emulsified in 1 ml ISA206 (SEPPIC®, France) was injected intramuscularly, and the procedure of immunization was performed twice. The immunization group GP5&M was immunized with PE-ORF5-K3 PE-ORF6-K3(containing 200 μg proteins/injection), respectively. The control group was bred without immunization.
[0060] Two weeks after the last inoculation, 100 mg ketamine solution was administered intramuscularly to tranquilize the pigs, then 1 ml 2% Lidocaine was dropped in the nasal cavities of the pigs to inhibit coughing reflex actions, and then the virus was inoculated in pigs nasally. Five pigs of each group were inoculated with 1 ml MD-1 strain PRRSV cultures having a 1×10 7 TCID 50 /ml dosage.
[0061] 14 days after inoculation, the pigs were sacrificed to proceed with complete autopsy. Lung or liver samples were collected (from both parts of the head lobe central part and auxiliary part of caudate lobe) and fixed by 10% neutral buffered formaldehyde for subsequent tissue pathology examination. The examination was conducted in a blind fashion and evaluated on the basis of interstitial pneumonitis severity (Opriessnig T, P. G. Halbur, et al., Journal of Virology, 76(2002):11837-11844, and Halbur, P. G., P. S. Paul, et al., 1996. J. Vet. Diagn. Investig. 8:11-20) in a scale from 0 to 6, wherein the severity increases with the number.
Experimental Results
[0062] Two weeks post second immunization, leukocytes from porcine blood were tested for PRRSV. The results indicated that viremia did not occur in any pig before PRRSV inoculating. The leukocyte samples were tested with RT-PCR at 3, 7, and 14 days post virus inoculating, respectively, and the results are shown in Table 3.
[0000]
TABLE 3
PRRSV viremia occurrence in pigs post PRRSV
inoculating
PE-ORF5-K3
Day
Control
PE-PQGAB-K3
PE-ORF6-K3
3
3/5
3/5
2/5
7
3/4 (death1*)
2/5
2/4 (death2*)
14
3/4 (death1*)
2/5
2/4 (death2*)
*identified with PRRSV viremia by RT-PCR before death
[0063] All pigs, including those that had been sacrificed and the surviving after the two-week study, were dissected. Macroscopic examinations indicated that the lungs from virus-inoculated pigs of ORF5&ORF6 vaccine group and the control group showed more extensive lesions and severe interstitial pneumonitis, whereas the PE-PQGAB-K3 vaccine group of the present invention did not show as extensive lesions and severe interstitial pneumonitis. As shown in Table 4, the PE-PQGAB-K3 vaccine group of the present invention showed less severity in terms of interstitial pneumonitis than the control group and ORF5&ORF6 vaccine group.
[0000]
TABLE 4
comparisons of macroscopic lung lesions induced by
PRRSV, 14 days post PRRSV inoculating
PE-PQGAB-K3
PE-ORF5-K3,
vaccine
PE-ORF6-K3 vaccine
Control group
group
group
Pig No.
Lesion index
Lesion index
Lesion index
1
6*
5
6
2
6
3
5
3
6
4
6
4
6
4
6
5
5
3
6
Average
5.75 ± 0.50
3.80 ± 0.84
5.80 ± 0.45
*interstitial pneumonitis lesion index
[0000]
TABLE 5
macroscopic lung lesion indexes exhibited by the
PE-PQGAB-K3 vaccine group are significantly lower than control group
and ORF5&ORF6 vaccine group in view of biostatistics.
Number of
Group
individuals
Total
Average
Variance
Control group
5
29
5.8
0.2
PE-PQGAB-K3 group
5
19
3.8
0.7
PE-ORF5&ORF6-K3 group
5
29
5.8
0.2
ANOVA
Variation
Degree of
Critical
source
SS
freedom
MS
F
P-value
value
Inter-group
13.33333
2
6.666667
18.18182
0.000233
3.885294
Intra-group
4.4
12
0.366667
total
17.73333
14
[0064] The above experiments clearly indicate that PE-PQGAB-K3 of the present invention not only can effectively protect pigs from PRRSV infections, but also cause slighter interstitial pneumonitis than other vaccines (such as PE-ORF5-K3, PE-ORF6-K3).
[0065] The antibody titers variation in immunized pigs are shown in table 6. The A group has good IgG ELISA titers, but the IFA and NT titers are less than that of C group. Also, from table 5, it indicates that PRRSV ORF5 or ORF6 have an antigen-specific allergy effect after immunization and virus challenged. Manifestly, it is difficult to use them as PRRS vaccine antigens.
[0000]
TABLE 6
Serum titers
coating antigen
PE(Δ III)
PQGAB
Group
IgG-ELISA titers (S/BK)
IFA titers
NT titers*
A
12
80
8–16
8–16
PE-ABCF-K3
PE-PQGF-K3
B
1
1
<8
<8
Negative CTL
C
17
30
32–64
16–64
PE-PQG1AB-K3
*The neutralization titer is determined by the inhibition growth and proliferation of PRRSV under serial dilution sample added in MAC-10A cells culture system.
[0066] Although the present invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the scope of the invention as hereinafter claimed.
|
The present invention provides a PRRSV subunit vaccine comprising a fusion protein having neutralization titers evoked, PE-PQGAB-K3, which comprises a chimeric polypeptide containing N-terminal portions of PRRSV ORF5 and ORF6 structure proteins; a portion of Pseudomonas exotoxin A binding and translocation domain; and a carboxyl terminal domain containing KDEL-KDEL-KDEL(K3) sequence. Less inflammation of PE-PQGAB-K3 vaccine group in their lungs post being PRRSV-challenged indicates that PQGAB without an antigen-specific allergy effect. Importantly, PE-PQGAB-K3 vaccine presents a good protection against PRRSV infection than control groups in pig challenged experiment.
| 2
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This application is a division of application Ser. No. 373,944, filed May 2, 1982 now U.S. Pat. No. 4,483,986.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention belongs to the field of synthetic organic chemistry, and provides a process for selectively sulfonating one of the two unsubstituted amino groups on a 4-acyl-o-phenylenediamine. The products of the invention are intermediates in the preparation of antiviral benzimidazoles; some of them are new to chemistry.
2. State of the Art
Paget et al., U.S. Pat. No. 4,118,742, teaches the 1-sulfonylbenzimidazoles which are the ultimate products of the present process. The patent teaches a number of variations in the process used to prepare its compounds. In general, it first forms the benzimidazole with the 1-position unsubstituted, and then sulfonates it.
The patent explains (column 5 of the specification) that the sulfonation of the benzimidazole produces a mixture of isomers, which must ordinarily be separated. The problem arises from the fact that the desired antiviral benzimidazoles have a single substituent on the phenyl ring, usually preferably at the 6-position. The molecule is therefore asymmetric. Sulfonation of the benzimidazole by ordinary techniques is equally likely to sulfonate either of the nitrogen atoms, resulting in a mixture of isomers.
The advantage of the present invention, compared to the prior art processes, is that its ability to sulfonate selectively one of the amino groups of the phenylenediamine provides, after ring-closure, an excellent yield of the desired isomeric benzimidazole.
Some of the products of the present invention are taught and claimed by S. J. Dominianni in an application entitled Process of Preparing Chemical Intermediates, filed on the same day as the present application Ser. No. 373,945, now U.S. Pat. No. 4,483,986. Dominianni's process is only functional to make benzoyl compounds, where R is a phenyl group.
SUMMARY OF THE INVENTION
The present invention is a process for preparing a compound of the formula ##STR1## wherein
R is C 1 -C 7 alkyl, C 3 -C 7 cycloalkyl, C 3 -C 7 cycloalkylmethyl, 1-(C 3 -C 7 cycloalkyl)ethyl, benzyl, phenyl, or phenyl mono- or disubstituted with C 1 -C 4 alkyl, C 1 -C 4 alkoxy, chloro, bromo, iodo, nitro or trifluoromethyl;
R 1 is C 1 -C 5 alkyl, C 3 -C 7 cycloalkyl, phenyl, furyl, thienyl, thiazol-2-yl, 2-acetamido-4-methylthiazol-5-yl, 1,3,4-thiadiazol-2-yl, 2-methyl-1,3,4-thiadiazol-5-yl or R 2 R 3 N-;
R 2 and R 3 are independently C 1 -C 3 alkyl, or combine with the nitrogen atom to which they are attached to form pyrrolidino, piperidino or morpholino; comprising sulfonating a phenylenediamine of the formula ##STR2## with BrSO 2 R 1 or ClSO 2 R 1 in the presence of at least about one mole of a pyridine base chosen from pyridine, the lutidines and the picolines.
The invention also provides the new compounds of the formula ##STR3## wherein
R 4 is C 1 -C 7 alkyl, C 3 -C 7 cycloalkyl, C 3 -C 7 cycloalkylmethyl, 1-(C 3 -C 7 cycloalkyl)ethyl or benzyl;
R 1 is C 1 -C 5 alkyl, C 3 -C 7 cycloalkyl, phenyl, furyl, thienyl, thiazol-2-yl, 2-acetamido-4-methylthiazol-5-yl, 1,3,4-thiadiazol-2-yl, 2-methyl-1,3,4-thiadiazol-5-yl or R 2 R 3 N-;
R 2 and R 3 are independently C 1 -C 3 alkyl, or combine with the nitrogen atom to which they are attached to form pyrrolidino, piperidino or morpholino.
DESCRIPTION OF THE PREFERRED EMBODIMENT
All temperatures in this document are expressed in degrees Celsius.
The general terms in the above description have their usual meanings in the organic chemical art. The phenyl R group may be unsubstituted, or substituted with one or two groups from the list shown, which groups may be the same or different and may be placed anywhere on the phenyl ring which is not prevented by steric considerations.
The groups C 1 -C 4 alkyl, C 1 -C 4 alkoxy, C 1 -C 5 alkyl, C 1 -C 7 alkyl, C 3 -C 7 cycloalkyl and C 1 -C 3 alkyl include such typical chemical groups as methyl, ethyl, isopropyl, s-butyl, butyl, t-butyl, pentyl, 1-ethylpropyl, 3-methylbutyl, methoxy, ethoxy, isopropoxy, butoxy, i-butoxy, cyclopropyl, cyclobutyl, cyclohexyl, cycloheptyl, hexyl, heptyl, 2,3-dimethylbutyl; 3-ethylpentyl, 1-ethylbutyl and 1,1-dimethylbutyl.
The following group of products of the process of this invention is mentioned to assure that the reader fully understands the invention.
5-benzoyl-N 1 -methylsulfonyl-o-phenylenediamine
5-(3-methylbenzoyl)-N 1 -propylsulfonyl-o-phenylenediamine
5-(4-t-butylbenzoyl)-N 1 -(1-methylbutylsulfonyl)-o-phenylenediamine
N 1 -t-butylsulfonyl-5-(2-methoxybenzoyl)-o-phenylenediamine
5-(3-butoxybenzoyl)-N 1 -cyclopropylsulfonyl-o-phenylenediamine
5-(2-chlorobenzoyl)-N 1 -cyclopentylsulfonyl-o-phenylenediamine
5-(4-bromobenzoyl)-N 1 -cyclohexylsulfonyl-o-phenylenediamine
N 1 -cycloheptylsulfonyl-5-(4-iodobenzoyl)-o-phenylenediamine
5-(3-nitrobenzoyl)-N 1 -phenylsulfonyl-o-phenylenediamine
N 1 -(2-furylsulfonyl)-5-(4-trifluoromethylbenzoyl)-o-phenylenediamine
5-benzoyl-N 1 -(3-thienylsulfonyl)-o-phenylenediamine
5-(3,5-diethylbenzoyl)-N 1 -(thiazol-2-ylsulfonyl)-o-phenylenediamine
N 1 -(2-acetamido-4-methylthiazol-5-ylsulfonyl)-5-(2,4-dipropoxybenzoyl)-o-phenylenediamine
5-(2,6-dichlorobenzoyl)-N 1 -(1,3,4-thiadiazol-2-ylsulfonyl)-o-phenylenediamine
5-(2,5-dibromobenzoyl)-N 1 -(2-methyl-1,3,4-thiadiazol-5-ylsulfonyl)-o-phenylenediamine
N 1 -dimethylaminosulfonyl-5-(3,5-dinitrobenzoyl)-o-phenylenediamine
5-[2,4-bis(trifluoromethyl)benzoyl]-N 1 -methylpropylaminosulfonyl-o-phenylenediamine
5-(3-butoxy-5-butylbenzoyl)-N 1 -ethylisopropylaminosulfonyl-o-phenylenediamine
5-(4-chloro-2-ethylbenzoyl)-N 1 -pyrrolidinosulfonyl-o-phenylenediamine
5-(4-chloro-3-propoxybenzoyl)-N 1 -piperidinosulfonyl-o-phenylenediamine
5-(5-bromo-2-isopropylbenzoyl)-N 1 -morpholinosulfonyl-o-phenylenediamine
5-(3-bromo-5-chlorobenzoyl)-N 1 -isopropylsulfonyl-o-phenylenediamine
N 1 -neopentylsulfonyl-5-(3-nitro-4-trifluoromethylbenzoyl)-o-phenylenediamine
5-(2-chloro-4-nitrobenzoyl)-N 1 -(1-ethylpropylsulfonyl)-o-phenylenediamine
5-(2-bromo-4-trifluoromethylbenzoyl)-N 1 -s-butylsulfonyl-o-phenylenediamine
5-acetyl-N 1 -dimethylaminosulfonyl-o-phenylenediamine
N 1 -ethylmethylaminosulfonyl-5-propionyl-o-phenylenediamine
N 1 -s-butylsulfonyl-5-(2-methylpropionyl)-o-phenylenediamine
N 1 -isopropylsulfonyl-5-(2,2-dimethylpropionyl)-o-phenylenediamine
N 1 -t-butylsulfonyl-5-hexanoyl-o-phenylenediamine
5-(3,3-dimethylbutyryl)-N 1 -methylpropylamino-o-phenylenediamine
5-heptanoyl-N 1 -pyrrolidinosulfonyl-o-phenylenediamine
N 1 -cyclopropylsulfonyl-5-(3-ethyl-2-methylvaleryl)-o-phenylenediamine
5-(2,2-dimethylvaleryl)-N 1 -isopropylsulfonyl-o-phenylenediamine
N 1 -isobutylsulfonyl-5-(3-ethylhexanoyl)-o-phenylenediamine
N 1 -(1-methylbutylsulfonyl)-5-(2-methylheptanoyl)-o-phenylenediamine
N 1 -dimethylaminosulfonyl-5-octanoyl-o-phenylenediamine
5-(2-ethylvaleryl)-N 1 -diethylaminosulfonyl-o-phenylenediamine
5-cyclopropylcarbonyl-N 1 -isopropylsulfonyl-o-phenylenediamine
5-cyclobutylcarbonyl-N 1 -morpholinosulfonyl-o-phenylenediamine
5-cyclohexylcarbonyl-N 1 -phenylsulfonyl-o-phenylenediamine
5-cycloheptylcarbonyl-N 1 -cyclohexylsulfonyl-o-phenylenediamine
5-cyclopropylacetyl-N 1 -piperidinosulfonyl-o-phenylenediamine
5-cyclopentylacetyl-N 1 -dimethylaminosulfonyl-o-phenylenediamine
5-cycloheptylacetyl-N 1 -cyclopentylsulfonyl-o-phenylenediamine
N 1 -t-butylsulfonyl-5-(2-cyclopropylpropionyl)-o-phenylenediamine
5-(2-cyclobutylpropionyl)-N 1 -methylsulfonyl-o-phenylenediamine
5-(2-cycloheptylpropionyl)-N 1 -propylsulfonyl-o-phenylenediamine
5-benzylcarbonyl-N 1 -isopropylsulfonyl-o-phenylenediamine
It will be understood that the above products where the 5-position group is other than a benzoyl group are also new compounds of this invention.
The 4-acyl-o-phenylenediamines which are the starting compounds for the present process are known compounds and chemists can obtain them at will. The Paget et al. patent discussed above gives some discussion of their synthesis, at column 8.
The selective sulfonation of this invention is unexpectedly easy to carry out. The phenylenediamine is merely contacted with the appropriate sulfonyl bromide or chloride, preferably the chloride, in any convenient solvent in the presence of at least about 1 mole of a pyridine base chosen from pyridine, the lutidines and the picolines, preferably pyridine.
The sulfonyl halides are readily obtained or prepared. The amount of the sulfonyl halide used in the reaction is of some importance. It has been observed that the use of a substantial excess of sulfonyl halide is likely to produce the undesired bissulfonyl compound, or the wrong mono-sulfonyl compound. Accordingly, only a modest excess of sulfonyl halide should be used, to assure that the phenylenediamine is fully consumed. It is preferred to use an amount of the sulfonyl halide from about 1 to about 1.2 mole per mole of the phenylenediamine, most preferably from about 1 to about 1.1 mole.
The type of organic solvent is not critical to the success of the process. The choice of solvent, of course, is intimately linked with the desired temperature of operation, and with the concentration at which the reaction is to be run. The best solvents for the process are the halogenated alkanes, such as chloroform, dichloromethane, 1,2-dichloroethane and the like. Dichloromethane is a particularly preferred solvent. Other types of solvents, however, including aromatics, halogenated aromatics, esters, amides and nitriles may be used as is convenient. Aromatics, such as benzene, toluene and the xylenes, should be used only when the concentration of the reactants is to be low, because their solvency for the starting compound is not great. Esters such as ethyl acetate, ethyl formate, propyl acetate and the like are useful solvents, as are nitriles such as acetonitrile and propionitrile.
It is also entirely possible to use a sufficient amount of pyridine base to dissolve the reactants and operate without any other solvent. Such operation is not preferred, because of the difficulty of handling the basic wastes after the process is completed.
The process is run in the presence of at least about 1 mole of pyridine base per mole of phenylenediamine. It is preferred to use at least about 2 moles of the pyridine base, and still more preferred to use from about 4 to about 10 moles of the pyridine base per mole of phenylenediamine. Greater amounts of pyridine base may be used as desired. In general, it is found that the yield of the desired sulfonation product tends to increase slowly with greater amounts of the pyridine base in the reaction mixture, and so the choice of the optimum amount of the pyridine base for a given process depends upon the relative costs of the pyridine base, compared to the other reactants, at the time and place in question.
The contrast of this process with similar processes run without a pyridine base is remarkable. When other inorganic or organic bases are used, the yield of sulfonated products is only in the range of about 10%, and about equal amounts of the possible isomers are produced
The process is most preferably carried out at about the ambient temperature, which is considered to be from about 15° to about 35°. It may also be carried out effectively at temperatures in the preferred range from about 0° to about 50°, and temperatures in a range from about 0° to about 100° may be used if desired in the circumstances. In general, it is observed that elevated temperatures tend to produce more of the undesired isomeric product, where the sulfonyl has added to the amino group para to the acyl group. However, operation even at elevated temperatures gives a substantial yield of the desired isomer.
The most preferred product of the process of this invention is 5-benzoyl-N 1 -isopropylsulfonyl-o-phenylenediamine, because of the exceptional antiviral activity of the benzimidazole formed from that compound.
Further preferred products of the process of this invention include those compounds described by the following partial definitions. It will be understood that the definitions below may be combined to form additional, narrower preferred classes.
(a) R is phenyl;
(b) R is mono-substituted-phenyl;
(c) R is phenyl mono-substituted with chloro, C 1 -C 4 alkyl or C 1 -C 4 alkoxy;
(d) R is 4-alkoxyphenyl;
(e) R 1 is C 1 -C 5 alkyl;
(f) R 1 is C 3 -C 5 branched alkyl;
(g) R 1 is isopropyl;
(h) R 1 is C 3 -C 7 cycloalkyl;
(i) R 1 is phenyl;
(j) R 1 is thienyl.
Preferred novel compounds of this invention include those described by the following limitations, which may be combined as mentioned above.
(a) R 4 is alkyl;
(b) R 4 is C 1 -C 4 alkyl;
(c) R 4 is cycloalkyl;
(d) R 4 is C 5 -C 6 cycloalkyl;
(e) R 1 is C 1 -C 5 alkyl;
(f) R 1 is C 3 -C 5 branched alkyl;
(g) R 1 is isopropyl;
(h) R 1 is C 3 -C 7 cycloalkyl;
(i) R 1 is phenyl;
(j) R 1 is thienyl.
The antiviral benzimidazoles are prepared from the products of the present process by the usual synthetic methods, especially by reaction with cyanogen bromide to form the 2-aminobenzimidazoles, which are a particularly preferred class of the antiviral compounds. See the Paget et al. patent, column 8. It is particularly advantageous to form the benzimidazoles by forming the sodium salt of the product of this process, as by contact with concentrated aqueous sodium hydroxide, removing the water and adding cyanogen bromide, which forms the benzimidazole upon stirring at ambient temperature.
The following examples are given to assure that a chemist who reads this document can fully understand the nature of the invention, and can carry it out to prepare products of his choice. In all cases, the desired isomeric sulfonated product and the undesired ones have different melting points and different retention times on high performance liquid chromatography (HPLC) columns, and can easily be recognized. The amounts of products given in the examples below, therefore, are known to be amounts of the desired isomer. In some cases, the amounts of the other isomer were analytically determined and are indicated. The preferred chromatographic analytical method is run by using a C 18 reverse phase column, and eluting with aqueous methanol at about 5.6 kg./cm 2 . In all cases studied, the desired isomer came off the column before the undesired 4-isomer.
EXAMPLE 1
5-benzoyl-N 1 -isopropylsulfonyl-o-phenylenediamine
Twenty g. of 4-benzoyl-o-phenylenediamine was suspended in 150 ml. of dichloromethane and 30 ml. of pyridine, and 11 ml. of isopropylsulfonyl chloride was added dropwise while the temperature of the mixture was held between 25° and 30°. The mixture was then stirred about 24 hours at 25°, and was washed with 150 ml. of 2N hydrochloric acid. The organic layer was then extracted with 190 ml. of 0.6N sodium hydroxide, and 100 ml. of isopropanol was added to the aqueous phase. The pH of the aqueous layer was adjusted to about 7.0 with concentrated hydrochloric acid, and the mixture was heated to reflux. The mixture was then stirred while it cooled overnight to 25°. It was then filtered and the solids were washed with 60 ml. of 33% aqueous isopropanol. The solids were dried in a vacuum oven at 50° for 8 hours to obtain 20.2 g. of the desired product, m.p. 150°-152°. High performance liquid chromatographic analysis indicated that the product was 98+% pure, showing a yield of 67.4% of the theoretical yield. The product was identified by its mass spectroscopic molecular ion, having a weight of 318, and by nuclear magnetic resonance (NMR) analysis on a 60-mHz instrument in CDCl 3 plus DMSOd 6 , showing characteristic peaks at δ1.3-1.4 (d, 6H, (CH 3 ) 2 ); 2.9-3.5 (m, 1H, CH), 5.5 (s, 2H, NH 2 ); 6.7-7.8 (m, 9H, aromatic).
EXAMPLE 2
5-benzoyl-N 1 -methylsulfonyl-o-phenylenediamine
Ten g. of 4-benzoyl-o-phenylenediamine was combined with 75 ml. of dichloromethane and 15 ml. of pyridine and 3.8 ml. of methylsulfonyl chloride was added slowly while the temperature was held below 30°. The mixture was then stirred for 4 hours at 25°, and was worked up by washing with 75 ml. of 2N hydrochloric acid, and then extracting the organic layer with 100 ml. of 0.6N sodium hydroxide. The aqueous layer was neutralized to pH 7.0-7.5 with concentrated hydrochloric acid, and was extracted with ethyl acetate. The organic extract was evaporated to dryness under vacuum to obtain 11.9 g. of a crude product which was found to contain more than 90% of the desired isomer. The product was recrystallized from 35 ml. of methanol and 110 ml. of toluene to obtain 6.3 g. of 99% pure product, m.p. 184°-186°. The calculated yield, based on the analysis of the crude product, was 87.5% of theoretical, and the purified isolated yield was 46.2% of theoretical. The product's identity was confirmed by its molecular ion of 290, and by NMR analysis, run as described in Example 1: δ2.93 (s, 3H, CH 3 ); 5.1 (s, 2H, NH 2 ); 6.7- 7.7 (m, 9H, aromatic).
EXAMPLE 3
5-benzoyl-N 1 -(2-thienylsulfonyl)-o-phenylenediamine
Ten g. of 4-benzoyl-o-phenylenediamine was slurried in 75 ml. of dichloromethane and 15 ml. of pyridine, and to it was added 9 g. of 2-thienylsulfonyl chloride. A mild exotherm occurred and the reaction mixture became a deep red solution. The mixture was stirred for 24 hours, and to it was added 75 ml. of 2N hydrochloric acid. The mixture was poured into 200 ml. of water, and the solids were filtered off and dried to obtain 16.75 g., 99% of theoretical, of crude product which was found to be more than 90% pure by HPLC analysis. A portion of the product was recrystallized from methanol and was found to have a melting point of 183°-186°. The product's identity was confirmed by its molecular ion of 358, and by its NMR spectrum, run as described above: δ5.4 (s, 2H, NH 2 ); 6.7-7.7 (m, 11H, aromatic and thienyl).
EXAMPLE 4
5-benzoyl-N 1 -dimethylaminosulfonyl-o-phenylenediamine
Ten g. of 4-benzoyl-o-phenylenediamine was suspended in 75 ml. of dichloromethane and 15 ml. of pyridine at 15°. To the mixture was added 5.3 ml. of dimethylsulfamoyl chloride in one portion, and the reaction mixture was stirred at 25° for 20 hours. The pH was then adjusted to 2.0 with 2N hydrochloric acid, and the organic layer was separated and washed with 200 ml. of water. It was then extracted with 80 ml. of 0.75N sodium hydroxide solution, and the aqueous layer was neutralized to pH 7.1 with hydrochloric acid. It was then extracted with dichloromethane, and the organic extract was concentrated under vacuum and the residue was triturated with diethyl ether. A total of 10.5 g. of crude product was collected, corresponding to a crude yield of 69.6% of theoretical. Analysis of the crude product by HPLC indicated that it contained more than 90% of the desired isomer. The product was recrystallized from 60 ml. of isopropanol to obtain 8.76 g. of pure product, m.p. 147°-149°, a yield of 58.2% of theoretical. Its identity was confirmed by NMR analysis, run as described above: δ4.4 (s, 6H, (CH 3 ) 2 ); 5.3 (s, 2H, NH 2 ); 6.6-7.7 (m, 8H, aromatic); 8.5 (s, 1H, NH); and by mass spectroscopy, which showed a molecular ion of weight 319.
EXAMPLE 5
5-propionyl-N 1 -isopropylsulfonyl-o-phenylenediamine
A 2.46 g. portion of 4-propionyl-o-phenylenediamine was suspended in 50 ml. of dichloromethane and 4.8 ml. of pyridine at 25°, and 1.8 ml. of isopropylsulfonyl chloride was added. The mixture was stirred at 25° for about 24 hours, and 70 ml. of 1.2N hydrochloric acid was added. The organic layer was separated and washed with 80 ml. of water, and was then extracted with 60 ml. of 0.4N sodium hydroxide. The aqueous layer was neutralized to pH 7.2 with hydrochloric acid, and was extracted with dichloromethane. The organic extract was concentrated under vacuum to obtain 2.6 g. of oil, which was found by HPLC analysis to contain more than 90% of the desired product. The crude yield was 65.2% of theoretical. Thirty ml. of diethyl ether was added, the mixture was heated to reflux and enough dichloromethane was added to dissolve all of the residue. The solution was cooled and 1.54 g. of 98% pure product was obtained by crystallization. Its melting point was 104°-106°, and the purified yield was 38% of theoretical. The product was identified by NMR analysis, run in CDCl 3 on a 60-mHz instrument: δ1.13 (t, 3H, CH 3 ); 1.4 (d, 6H, (CH 3 ) 2 ); 2.8 (q, 2H, CH 2 ); 3.3 (m, 1H, CH); 4.9 (s, 2H, NH 2 ); 6.67 (d, 1H, aromatic); 7.0 (s, 1H, NH); 7.5-7.8 (m, 2H, aromatic); and by mass spectroscopy, which showed a molecular ion of weight 270.
EXAMPLE 6
5-cyclohexylcarbonyl-N 1 -isopropylsulfonyl-o-phenylenediamine
A 8.7 g. portion of 4-cyclohexylcarbonyl-o-phenylenediamine was dissolved in 75 ml. of dichloromethane and 15 ml. of pyridine. To it was added 4.8 ml. of isopropylsulfonyl chloride while the temperature was held between 25° and 30°. The mixture was then stirred overnight, and to it was added 75 ml. of 2N hydrochloric acid and the mixture was stirred for 30 minutes. The aqueous layer was then washed with about 25 ml. of dichloromethane, and the organic layer was added to the first organic layer. To the combined organics was added 90 ml. of 0.7N sodium hydroxide solution, and to the aqueous layer was added 50 ml. of isopropanol and its pH was adjusted to about 7. The mixture was stirred overnight, and was extracted with 250 ml. of dichloromethane.
The product of this example was identified by converting it to the corresponding benzimidazole.
PREPARATION 1
2-amino-6-cyclohexylcarbonyl-1-isopropylsulfonylbenzimidazole
To the extract obtained above was added 6.72 g. of 50% aqueous sodium hydroxide, and the water was removed from the mixture by azeotropic distillation. The mixture was then cooled to ambient temperature, and 4.8 g. of cyanogen bromide was added. The mixture was stirred at ambient temperature for 2 days, and then the dichloromethane was distilled off and replaced with 120 ml. of methanol. The mixture was stirred under reflux for 3 hours, and was then chilled in an ice bath for 3 hours. The mixture was then concentrated under vacuum to a solid residue, which was dissolved in hot toluene. The mixture was chilled and cooled until a precipitate formed, which was identified as 8.4 g. of 2-amino-6-cyclohexylcarbonyl-1-isopropylsulfonylbenzimidazole. The product was identified by its NMR spectrum, run on a 60-mHz instrument: δ1.25 (d, 6H, (CH 3 ) 2 ); 2-1 (m, 11H, cyclohexyl).
EXAMPLE 7
5-benzoyl-N 1 -isopropylsulfonyl-o-phenylenediamine
Ten g. of 4-benzoyl-o-phenylenediamine was combined with 85 ml. of dichloromethane and 4 ml. of pyridine, and the mixture was cooled to 20°. To the mixture was added 5.5 ml. of isopropylsulfonyl chloride in one portion, and it was then stirred at ambient temperature for 20 hours. To it was added 75 ml. of water, and the aqueous phase was then washed with a small amount of dichloromethane, which was combined with the original organic layer. The organic mixture was then extracted with 70 ml. of 0.9N sodium hydroxide, and 20 ml. of additional water was added to the aqueous phase. Forty ml. of isopropanol was added to the aqueous phase and its pH was adjusted to 7.2 with hydrochloric acid. The mixture was then stirred for one and one-half hours at ambient temperature and then in an ice bath for 2 hours. It was then filtered and the solids were washed with 30 ml. of 33% aqueous isopropanol and dried to obtain 6.9 g. of the desired product, which was 86.2% pure by HPLC analysis and contained 9.7% of the undesired isomer. The corrected yield was 39.8% of theoretical.
EXAMPLE 8
5-benzoyl-N 1 -isopropylsulfonyl-o-phenylenediamine
A mixture of 20 g. of 4-benzoyl-o-phenylenediamine, 165 ml. of dichloromethane and 15 ml. of pyridine was cooled to 5°. To it was added 11 ml. of isopropylsulfonyl chloride in one portion, and the mixture was stirred at constant temperature for 5 hours and then overnight at 25°. To the mixture was then added 150 ml. of 2N hydrochloric acid, and the mixture was stirred for 1 hour at ambient temperature. It was then filtered, the solids were washed with dichloromethane, and the aqueous layer of the combined filtrate was separated and washed with 30 ml. of dichloromethane. The combined organic layers were extracted with 170 ml. of 0.7N sodium hydroxide, and the aqueous layer was adjusted to 190 ml. volume by adding water. To it was added 100 ml. of isopropanol, and its pH was then adjusted to 7.0-7.5 with concentrated hydrochloric acid. The mixture was stirred for 90 minutes at ambient temperature, then in an ice bath for two and one-half hours. It was then filtered, and the solids were washed with 33% aqueous isopropanol and dried. The product was 18.3 g. of the desired product, found to be 96.0% pure by HPLC analysis and containing 2.5% of the undesired 4-benzoyl-N 1 -isopropylsulfonyl-o-phenylenediamine. The corrected yield of the desired product, substantially identical to the product of Example 1, was 58.7% of the theoretical yield.
EXAMPLE 9
5-benzoyl-N 1 -isopropylsulfonyl-o-phenylenediamine
A 20 g. portion of 4-benzoyl-o-phenylenediamine was dissolved in 143 ml. of dichloromethane and 37.5 ml. of pyridine and cooled to 5°. To the mixture was added 11 ml. of isopropylsulfonyl chloride in one portion, and the reaction was carried out and the product isolated as was described in Example 5 to obtain 24.6 g. of the desired product, which was 86.9% pure by HPLC analysis, containing 11.6% of the undesired 4-benzoyl isomer. The corrected yield was 71.2% of the theoretical yield.
EXAMPLE 10
5-benzoyl-N 1 -isopropylsulfonyl-o-phenylenediamine
Twenty g. of 4-benzoyl-o-phenylenediamine was dissolved in 120 ml. of dichloromethane and 60 ml. of pyridine and cooled to 5°. To the mixture was added 11 ml. of isopropylsulfonyl chloride in one portion, and the reaction was then carried out and the product isolated as described in Example 5 above. The product was 24.7 g. of the desired product, found to be 93.2% pure by HPLC analysis and containing 5.7% of the undesired 4-benzoyl isomer. The corrected yield was 76.7% of the theoretical yield.
EXAMPLE 11
5-benzoyl-N 1 -isopropylsulfonyl-o-phenylenediamine
A 5.02 g. portion of 4-benzoyl-o-phenylenediamine was combined with 100 ml. of toluene and 15 ml. of pyridine, and 2.25 ml. of isopropylsulfonyl chloride was added. The mixture was stirred overnight at ambient temperature. To it was added 75 ml. of 2N hydrochloric acid, and the mixture was stirred for 20 minutes. One hundred ml. of ethyl acetate was added, and the organic layer was separated. The solvents were removed under vacuum to obtain an oil, which was dissolved in dichloromethane and mixed with 30 ml. of 1N sodium hydroxide. The 2-phase mixture was stirred for 30 minutes, and the aqueous layer was separated and made acid with 2N hydrochloric acid. The acid mixture was then extracted with dichloromethane, and the organic layer was evaporated under vacuum to obtain a gummy solid, which was recrystallized from 25 ml. of isopropanol and 80 ml. of water, with cooling. The solids were recovered by filtration and washed with 33% aqueous isopropanol. After drying, the product was 2.4 g. of the desired product, 96.5% pure by HPLC analysis, containing 0.65% of the 4-benzoyl isomer. The yield was 31.2% of the theoretical yield; the low solvency of toluene is believed to be the reason for the relatively low yield.
EXAMPLE 12
5-benzoyl-N 1 -isopropylsulfonyl-o-phenylenediamine
Four g. of 4-benzoyl-o-phenylenediamine was dissolved in 45 ml. of pyridine, and 2.3 ml. of isopropylsulfonyl chloride was added dropwise while the temperature rose from 23° to 30°. The mixture was stirred for 2 hours at ambient temperature, and then 60 ml. of ethyl acetate was added to it. To it was then added 100 ml. of 4N hydrochloric acid, and the layers were separated. The organic layer was washed with 200 ml. of water, then with 100 ml. of 1N hydrochloric acid, then with saturated sodium chloride solution, and finally with potassium carbonate solution. All of the aqueous washes were extracted with small portions of ethyl acetate, and all the organic layers were then combined and dried over sodium sulfate. The ethyl acetate was removed under vacuum, isopropanol was added to the residue and it was removed under vacuum. Then the residue was dissolved in 30 ml. of isopropanol with heating, and 60 ml. of water was slowly added with heating. The mixture was cooled, seeded with small crystals of the desired product, chilled in an ice bath and filtered. The solids were washed with 33% isopropanol, and the product was dried under vacuum to obtain 3.8 g. of the desired product, which was 96.2% pure by HPLC analysis and contained 2.0% of the undesired 4-benzoyl isomer. The yield was 60.7% of theoretical.
EXAMPLE 13
5-benzoyl-N 1 -isopropylsulfonyl-o-phenylenediamine
Five g. of 4-benzoyl-o-phenylenediamine was dissolved in 45 ml. of acetonitrile and 7.5 ml. of pyridine, and the mixture was cooled to 10°. A 2.25 ml. portion of isopropylsulfonyl chloride was added in one portion, and the mixture was then stirred for 16 hours at ambient temperature. The mixture was then evaporated under vacuum to an oily residue, and 75 ml. of 0.7N hydrochloric acid was added, together with 50 ml. of dichloromethane. An intractable emulsion formed, which was broken by adding a small amount of ethyl acetate and adjusting the pH of the mixture to about 8 with 4N sodium hydroxide. The organic layer was evaporated to a gum, and to it was added 60 ml. of 0.7N sodium hydroxide, and the mixture was heated on the steam bath for 10 minutes and then cooled. The insoluble matter was filtered off, and the filtrate was extracted with 100 ml. of dichloromethane. The basic aqueous layer was neutralized to pH 7 with concentrated hydrochloric acid, and then extracted with dichloromethane. The solvent was removed from the extract under vacuum to obtain a gummy solid, which was dried in the vacuum oven for 2 hours. The crude weight of the product was 5.30 g., a crude yield of 70.6% of theoretical. HPLC analysis showed less than 10% of the 4-benzoyl isomer in the crude product.
EXAMPLE 14
5-benzoyl-N 1 -isopropylsulfonyl-o-phenylenediamine
Five g. of 4-benzoyl-o-phenylenediamine was dissolved in 40 ml. of ethyl acetate and 7.5 ml. of pyridine, and the solution was cooled to 10°. To it was added 2.25 ml. of isopropylsulfonyl chloride in 1 minute, and the ice bath was then removed and the mixture was stirred at ambient temperature overnight. To it was then added 40 ml. of 2N hydrochloric acid, and the layers were separated. The organic layer was then evaporated under vacuum to obtain about 5.6 g. of a dark solid, which was mixed with 100 ml. of 0.8N sodium hydroxide and heated on the steam bath for 10 minutes. The mixture was then cooled and filtered, and the filtrate was extracted with dichloromethane. To the aqueous layer was added concentrated hydrochloric acid to pH 7, and the acid solution was extracted with 100 ml. of dichloromethane. The organic layer was evaporated under vacuum to obtain 4.3 g. of a gummy solid, which was dried for 2 hours under vacuum. HPLC analysis of the crude product showed that it contained less than 10% of the undesired 4-benzoyl isomer. The crude yield of the desired product was 56.8% of theoretical.
EXAMPLE 15
5-benzoyl-N 1 -isopropylsulfonyl-o-phenylenediamine
Ten g. of 4-benzoyl-o-phenylenediamine was dissolved in 75 ml. of tetrahydrofuran and 15 ml. of pyridine and the solution was cooled to 20°. To it was added 5.5 ml. of isopropylsulfonyl chloride in one portion, and the mixture was stirred overnight at ambient temperature. To it was then added 75 ml. of 2N hydrochloric acid, and the mixture was stirred for 10 minutes. The aqueous layer was removed and washed with 40 ml. of tetrahydrofuran, and the combined organics were washed with 100 ml. of water and 50 ml. of saturated sodium chloride solution. The organic layer was then removed and evaporated under vacuum, and 75 ml. of dichloromethane was added to the residue. To it was then added 75 ml. of 0.8N sodium hydroxide, and the mixture was stirred for 30 minutes. The organic layer was then washed with 50 ml. of water, and the combined aqueous layers were adjusted to pH 7.5 with concentrated hydrochloric acid. The mixture was then extracted with dichloromethane, and the organic extraet was dried over magnesium sulfate and evaporated under vacuum to an oil. Isopropyl alcohol was added to the oil, and was evaporated away under vacuum. To the residue was then added 150 ml. of 33% isopropanol, and the mixture was heated and then cooled slowly to about 15°. The mixture was then filtered and the solids were washed with 90 ml. of 33% aqueous isopropanol and dried to obtain 6.65 g. of the desired product, m.p. 155°-157°, which was 99.55% pure by HPLC analysis. The yield was 44.5% of theoretical.
EXAMPLE 16
5-benzoyl-N 1 -isopropylsulfonyl-o-phenylenediamine
Studies were carried out to determine the optimum reaction time at various temperatures. The reaction mixtures contained 10 g. of 4-benzoyl-o-phenylenediamine, 75 ml. of dichloromethane, 15 ml. of pyridine and 5.5 ml. of isopropylsulfonyl chloride. However, the 86° study was carried out with 1,2-dichloroethane as the solvent instead of dichloromethane. Samples were withdrawn from the reaction mixture at hourly or 2-hourly intervals up to 8 hours and then at 24 hours, and the samples were analyzed by HPLC to determine the approximate amount of the desired product present. Before analysis, the 2.5-ml. samples were mixed with 2 ml. of diethylamine and 20 ml. of dichloromethane, and the solvents were removed from the sample under vacuum. The residue was then dissolved in ethyl acetate, and the insolubles were filtered off. The ethyl acetate was then removed under vacuum, a small amount of methanol was added to the residue and removed under vacuum, and then 20 ml. of methanol was added to the residue to prepare the analytical sample.
At 25°, it was found that the maximum yield of the desired product was obtained at 24 hours, but that the 8-hour yield was very close to optimum. The amount of the undesired 4-benzoyl isomer did not increase as the reaction went on, but reached its maximum at about 3 hours and did not change appreciably thereafter.
At 45°, the yield of the desired product appeared to be optimum at about 6 hours. Again, the amount of the undesired isomer was small and did not increase after about 3 hours reaction time.
At 86°, the optimum reaction time was about 2 hours, and the amount of the undesired isomer, compared to the amount of product, was relatively high.
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A 4-acyl-o-phenylenediamine is selectively sulfonated on the amino group meta to the acyl group to provide an important intermediate for benzimidazole pharmaceuticals. Some of the intermediates are new to organic chemistry.
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TECHNICAL FIELD
[0001] The present invention relates to a substrate for use in analysis of nucleic acid, a flow cell for use in analysis of nucleic acid, and a nucleic acid analysis device.
BACKGROUND ART
[0002] In recent years, as a method of analyzing base sequences of nucleic acid, there is known a method of concurrently analyzing base sequences of multiple DNA fragments. In this method, an absorbent portion capable of absorbing DNA fragments or the like and a non-absorbent portion not capable of the DNA fragment are formed on a substrate, for example, by photolithography or an etching technique. Then, DNA fragments or the like serving as an analysis target are absorbed in the absorbent portion to perform the analysis (for example, see PTL 1).
[0003] In the analysis method described above, excitation light is irradiated onto an analysis area including multiple DNA fragments where fluorochrome-labelled matrices corresponding to bases are introduced, and fluorescence emitted from each DNA fragment is detected to determine the base (for example, see NPL 1).
[0004] In this analysis method, typically, a plurality of analysis areas are provided on a single substrate, and the analysis is performed for overall analysis areas by changing the analysis area whenever the irradiation is performed. Then, a new fluorochrome-labelled matrix is introduced on the basis of a polymerase extension reaction, and each analysis area is analyzed through the aforementioned operation. By repeating this procedure, it is possible to effectively determine the base sequence.
CITATION LIST
Patent Literature
[0000]
PTL 1: US 2009/0270273 A1
NPL 1: Science, 2005, Vol. 309, Pages 1728 to 1732
SUMMARY OF INVENTION
Technical Problem
[0007] However, in the background art described above, when the same analysis area is repeatedly analyzed, a positional deviation may occur in the analysis area at every cycle. This positional deviation makes it difficult to map the DNA fragments in every cycle, so that it may be difficult to obtain a suitable base sequence.
[0008] In view of the aforementioned problems, the present invention provides a substrate for use in analysis of nucleic acid, a flow cell for use in analysis of nucleic acid provided with this substrate for use in analysis of nucleic acid, and a nucleic acid analysis device, capable of reproducibly obtaining a position of the analysis area even when the positioning is performed repeatedly for the same analysis area.
Solution to Problem
[0009] The invention to solve the above issue is a substrate for use in analysis of nucleic acid having a plurality of analysis areas partitioned on a substrate to perform measurement by sequentially changing each analysis area,
[0010] wherein the analysis area has an absorbent portion capable of absorbing a DNA fragment or a vector where the DNA fragment is borne and a non-absorbent portion other than the absorbent portion, and
[0011] a marker portion having a predetermined shape to calculate a position of the analysis area is provided in at least a part of the non-absorbent portion.
[0012] Furthermore, another invention to solve the above issue is a flow cell for use in analysis of nucleic acid including:
[0013] the substrate for use in analysis of nucleic acid;
[0014] a light-transmitting cover placed to face the substrate for use in analysis of nucleic acid to transmit light;
[0015] a plurality of spacers provided between the substrate for use in analysis of nucleic acid and the light-transmitting cover and separated substantially in parallel with each other;
[0016] a flow passage formed in a portion interposed between the neighboring spacers between the substrate for use in analysis of nucleic acid and the light-transmitting cover to circulate a fluid;
[0017] an inlet port opened in one end of the flow passage to inject the fluid; and
[0018] an outlet port opened in the other end opposite to the inlet port of the flow passage to discharge the fluid.
[0019] In addition, another invention to solve the above issue is a nucleic acid analysis device including:
[0020] the flow cell for use in analysis of nucleic acid;
[0021] a circulation unit that circulates a fluid in a flow passage of the flow cell for use in analysis of nucleic acid;
[0022] a temperature control unit that controls a reactive temperature of the DNA fragment;
[0023] an irradiation unit that irradiates excitation light onto an analysis area serving as an analysis target through the light-transmitting cover;
[0024] a detection unit that detects fluorescence emitted from the DNA fragment by irradiating the excitation light using the light-transmitting cover and detects a position of the marker portion in the analysis area from the detected fluorescence; and
[0025] a carriage unit that carries the flow cell for use in analysis of nucleic acid and shifts the analysis area to a predetermined position with respect to the marker portion.
[0026] Note that, herein, a “predetermined shape” refers to a predefined shape (such as a cross shape) as seen in a plan view, used to determine a position inside the analysis area. In addition, herein, a “predetermined position” refers to a predefined position where the analysis area as an analysis target is shifted. Furthermore, herein, “a plurality of spacers” conceptually include a spacer provided with a single member such as a blanked sheet on which a plurality of spacers are formed by punching as well as a spacer provided with a plurality of members.
Advantageous Effects of Invention
[0027] According to the present invention, it is possible to provide a substrate for use in analysis of nucleic acid, a flow cell for use in analysis of nucleic acid having the substrate for use in analysis of nucleic acid, and a nucleic acid analysis device, capable of reproducibly obtaining a position of the analysis area even when the positioning is repeatedly performed for the same analysis area.
BRIEF DESCRIPTION OF DRAWINGS
[0028] FIG. 1 is a schematic plan view illustrating a substrate for use in analysis of nucleic acid according to a first embodiment of the present invention.
[0029] FIG. 2 is a schematic plan view illustrating a substrate for use in analysis of nucleic acid according to a second embodiment of the present invention.
[0030] FIG. 3( a ) is a schematic plan view illustrating a substrate for use in analysis of nucleic acid according to a third embodiment of the present invention, and FIG. 3( b ) is a schematic diagram illustrating an exemplary fluorescent image.
[0031] FIG. 4 is a schematic plan view illustrating a substrate for use in analysis of nucleic acid according to a fourth embodiment of the present invention, in which a single analysis area is enlargedly illustrated.
[0032] FIGS. 5( a ) to 5( c ) are schematic diagrams illustrating a state that the fluorescent image obtained from the substrate for use in analysis of nucleic acid of FIG. 4 is distorted, in which FIG. 5( a ) shows a deformed state of fluorescent image, FIG. 5( b ) shows a rotated state of the fluorescent image, and FIG. 5( c ) shows another rotated state of the fluorescent image.
[0033] FIGS. 6( a ) to 6( f ) are schematic diagrams illustrating a method of manufacturing the substrate for use in analysis of nucleic acid of FIG. 1 , in which FIG. 6( a ) shows a state before a hydrophilic membrane is formed, FIG. 6( b ) shows a state after a hydrophilic membrane is formed, FIG. 6( c ) shows a state after a resist film is formed, FIG. 6( d ) shows a state after development, FIG. 6( e ) shows a state after etching, and FIG. 6( f ) shows a state after removal of the resist film.
[0034] FIG. 7 is a schematic perspective view illustrating an exemplary flow cell for use in analysis of nucleic acid according to the present invention, in which the light-transmitting cover is partially cut away.
[0035] FIG. 8 is a schematic diagram illustrating an exemplary nucleic acid analysis device according to the present invention.
[0036] FIG. 9 is a flowchart illustrating a control process of the nucleic acid analysis device of FIG. 8 .
[0037] FIGS. 10( a ) to 10( c ) are schematic diagrams illustrating an exemplary analysis method using the nucleic acid analysis device according to the present invention, in which FIG. 10( a ) shows a positional relationship of the marker portion in the fluorescent image before movement, FIG. 10( b ) shows a positional relationship between the target location range and the marker portion before movement, and FIG. 10( c ) shows a positional relationship between the target location range and the marker portion after the movement.
[0038] FIG. 11 is a schematic diagram illustrating an exemplary fluorescent image using the substrate for use in analysis of nucleic acid of FIG. 1 .
DESCRIPTION OF EMBODIMENTS
[0039] <Substrate for Use in Analysis of Nucleic Acid>
[0040] A substrate for use in analysis of nucleic acid according to the present invention has a plurality of analysis areas partitioned on a substrate, so that measurement is performed by sequentially changing each analysis area. The analysis area includes an absorbent portion capable of absorbing a DNA fragment or a vector where the DNA fragment (hereinafter, the DNA fragment and the vector will be collectively referred to as an “analysis sample”) is borne and a non-absorbent portion other than the absorbent portion. The non-absorbent portion has a marker portion having a predetermined shape for obtaining a position of the analysis area in at least a part thereof.
[0041] Substrates for use in analysis of nucleic acid according to first to fourth embodiments of the present invention will now be described with reference to the accompanying drawings. The present invention is not limited to the first to fourth embodiments and relating drawings.
First Embodiment
[0042] FIG. 1 is a schematic plan view illustrating the substrate for use in analysis of nucleic acid according to the first embodiment of the present invention. As illustrated in FIG. 1 , the substrate for use in analysis of nucleic acid 100 according to this embodiment substantially includes a substrate 10 , a reaction area 11 , an analysis area 12 , an absorbent portion 13 , and a non-absorbent portion 14 . Note that, in FIG. 1 , the reaction area 11 , the analysis area 12 , and a marker portion 15 (which will be described below) on the substrate 10 are enlargedly illustrated in a hierarchical manner.
[0043] The substrate 10 is a plate-like base material having the reaction area 11 formed on its one surface. This substrate 10 may include a plate having a hydrophobic thin film on its surface, such as a quartz plate, a silicon plate, and a synthetic resin plate. The reaction area 11 is partitioned into a plurality of analysis areas 12 as described below. Note that, in this embodiment, the reaction area 11 is partitioned into one hundred forty analysis areas 12 .
[0044] The analysis area 12 is an area for absorbing an analysis sample s. The analysis area 12 includes a plurality of absorbent portions 13 capable of absorbing the analysis sample s and a non-absorbent portion 14 other than the absorbent portions 13 .
[0045] The absorbent portion 13 is formed of a hydrophilic membrane or the like laminated on the substrate 10 and exposed to the surface in order to allow absorption of the analysis samples s. This hydrophilic membrane may include, for example, a film of inorganic oxide or the like into which a functional group capable of fixing the analysis sample s (such as an amino group) is introduced. This specific inorganic oxide may include, for example, aminosilane.
[0046] As illustrated in FIG. 1 , each analysis area 12 has a plurality of absorbent portions 13 having a circular shape as seen in a plan view, and each absorbent portion 13 is arranged in a grid-like manner. In this manner, since each analysis area 12 has a plurality of absorbent portions 13 , and each absorbent portion 13 is arranged in a grid-like manner, it is possible to easily and reliably recognize positions of the absorbent portions 13 within the analysis area 12 .
[0047] Note that the absorbent portion 13 typically has a diameter of 0.01 to 10 μm as seen in a plan view. A lower limitation of this diameter is preferably set to 0.05 μm, more preferably 0.1 μm, and most preferably 0.2 μm in terms of easiness in formation of the absorbent portion 13 and improvement of absorbance of the analysis sample. Meanwhile, an upper limitation of the diameter is preferably set to 5 μm, more preferably 1 μm, and most preferably 0.5 μm in terms of improvement of an arrangement density of the absorbent portion 13 .
[0048] The diameter of the absorbent portion 13 as seen in a plan view is preferably set depending on a spatial resolution (pixel dimension) of a detection unit of the nucleic acid analysis device provided with this substrate for use in analysis of nucleic acid 100 . In this case, the diameter is preferably set to one pixel in terms of improvement of the arrangement density of the absorbent portion 13 .
[0049] A pitch of the absorbent portion 13 is typically set to 0.05 to 50 μm. A lower limitation of the pitch is preferably set to 0.1 μm, more preferably 0.5 μm, and most preferably 1 μm in terms of improvement of an anti-interference property between the absorbent portions 13 neighboring in the analysis. Meanwhile, an upper limitation of the pitch is preferably set to 10 μm, more preferably 5 μm, and most preferably 2 μm in terms of improvement of the arrangement density of the absorbent portion 13 .
[0050] Similar to the diameter, the pitch of the absorbent portion 13 is preferably set depending on a spatial resolution (pixel dimension) of a detection unit of the nucleic acid analysis device. In this case, the pitch is preferably set to four to five pixels, and more preferably five pixels in terms of the fluorescence resolution and improvement of the arrangement density of the absorbent portion 13 .
[0051] The non-absorbent portion 14 includes a hydrophobic membrane laminated on the substrate 10 to prevent absorption of the analysis sample s. A compound for forming this hydrophobic membrane may include, for example, a multivalent organic compound, a carboxylic acid compound, a phosphate compound, a sulfate compound, a nitryl compound, and salts thereof. Note that the compound may be employed solely or as a combination of two or more compounds.
[0052] The non-absorbent portion 14 has a marker portion 15 having a cross shape for computing a position of the analysis area 12 in its part. Since a DNA fragment capable of emitting fluorescence is not easily absorbed in this marker portion 15 , the marker portion 15 can be easily distinguished from the absorbent portion 13 using a fluorescent image of the analysis area 12 .
[0053] Next, positioning of the analysis area 12 using the substrate for use in analysis of nucleic acid 100 according to the first embodiment will be described.
[0054] If the substrate for use in analysis of nucleic acid 100 is employed, and excitation light emitting a particular wavelength is irradiated onto the analysis area 12 including the absorbent portion 13 absorbed with the DNA fragment (analysis sample) where a fluorochrome-labelled matrix corresponding to the base is introduced, fluorescence is emitted from an absorbent portion 13 where a particular dye excited by this excitation light exists (hereinafter, also referred to as a “particular absorbent portion”). Note that, for example, in the case of four color fluorescence detection (detection for four different types of fluorescence corresponding to four types of bases), a fluorescence probability caused by irradiation of excitation light having a particular wavelength in an arbitrary absorbent portion 13 becomes about 25%.
[0055] Here, since a marker portion 15 having a predetermined shape for obtaining a position of the analysis area 12 (no fluorescent portion) is provided in at least a part of the non-absorbent portion 14 , the position of the analysis area 12 is determined by finding the marker portion 15 by searching the obtained fluorescent image. Then, the substrate for use in analysis of nucleic acid 100 is shifted on the basis of the determined position of the analysis area 12 to match this analysis area 12 with the fluorescent image range. As a result, it is possible to obtain a fluorescent image of the analysis area 12 serving as an analysis target.
[0056] In this manner, on the substrate for use in analysis of nucleic acid 100 , at least a part of the non-absorbent portion 14 of the analysis area 12 has the marker portion 15 having a predetermined shape for obtaining a position of the analysis area 12 . Therefore, even when the positioning is repeated, it is possible to reproducibly obtain the position of the analysis area 12 . As a result, it is possible to reliably and rapidly analyze base sequences of DNA fragments.
Second Embodiment
[0057] FIG. 2 is a schematic plan view illustrating a substrate for use in analysis of nucleic acid according to a second embodiment of the present invention. As illustrated in FIG. 2 , the substrate for use in analysis of nucleic acid 200 according to the second embodiment substantially includes a substrate 10 , a reaction area 11 , an analysis area 12 , an absorbent portion 13 , and a non-absorbent portion 14 . The substrate for use in analysis of nucleic acid 200 according to the second embodiment is different from that of the first embodiment in that the shape of the marker portion 15 of the non-absorbent portion 14 as seen in a plan view is different depending on the analysis area 12 . Note that the substrate 10 , the reaction area 11 , the analysis area 12 , and the absorbent portion 13 are similar to those of the first embodiment. Therefore, like reference numerals denote like elements as in the first embodiment, and they will not be described repeatedly.
[0058] According to this embodiment, the shape of the marker portion 15 as seen in a plan view is different between at least the neighboring analysis areas 12 . Specifically, as illustrated in FIG. 2 , the substrate for use in analysis of nucleic acid 200 has two types of analysis areas 12 a and 12 b having different shapes of the marker portions 15 as seen in a plan view. The different types of analysis areas 12 a and 12 b are alternately arranged (the shape of the marker portion 15 is different between the odd-numbered analysis area 12 a and the even-numbered analysis area 12 b ). In this embodiment, while the analysis area 12 a has a marker portion 15 a, the analysis area 12 b has a marker portion 15 b (refer to the shapes of the marker portions 15 in FIG. 2 ).
[0059] Next, positioning of the analysis area 12 using the substrate for use in analysis of nucleic acid 200 according to the second embodiment will be described.
[0060] If the substrate for use in analysis of nucleic acid 200 is employed, the shapes of the marker portions 15 a and 15 b of the odd-numbered analysis area 12 a and the even-numbered analysis area 12 b are stored in an external computer (not illustrated) in advance. Then, similar to the positioning of the first embodiment, the positioning is performed for the initial analysis area 12 .
[0061] Then, detection of fluorescence is performed by irradiating excitation light. In this detection of fluorescence, the shape of the marker portion 15 is recognized when the fluorescent image of the target analysis area 12 is obtained. On the basis of the recognized shape, whether this analysis area 12 is the odd-numbered analysis area 12 a or the even-numbered analysis area 12 b is determined. For example, if the initial analysis area 12 is set as an odd number, the next analysis area 12 shifted after the analysis of the analysis area 12 a recognizes the even-numbered marker portions 15 b unless an erroneous operation such as misalignment occurs in a carriage unit (described below) of the substrate for use in analysis of nucleic acid 200 . If the odd-numbered marker portion 15 a is recognized instead of the even-numbered marker portion 15 b, or if no fluorescence is detected from the obtained fluorescent image at all, this means that the corresponding area is not the target analysis area 12 .
[0062] In this manner, the shape of the marker portion 15 on the substrate for use in analysis of nucleic acid 200 as seen in a plan view is different at least between the neighboring analysis areas 12 . Therefore, it is possible to distinguish each analysis area 12 on the basis of the shape of the marker portion 15 and reliably analyze the target analysis area 12 .
[0063] Note that the planar shape of the marker portion 15 is preferably different between overall analysis areas 12 . Specifically, the shape of the marker portion 15 may include, for example, a numeric shape, a shape obtained by modeling a distinguishable symbol, or the like (not shown).
[0064] In this manner, since the planar shape of the marker portion 15 is different between overall analysis areas 12 , it is possible to clearly distinguish each analysis area 12 on the basis of the shape of the marker portion 15 and more reliably analyze the target analysis area 12 .
Third Embodiment
[0065] FIGS. 3( a ) and 3( b ) are schematic diagrams illustrating a substrate for use in analysis of nucleic acid according to a third embodiment of the present invention. As illustrated in FIG. 3( a ) , the substrate for use in analysis of nucleic acid 300 according to the third embodiment substantially includes a substrate 10 , a reaction area 11 , an analysis area 12 , an absorbent portion 13 , and a non-absorbent portion 14 . The substrate for use in analysis of nucleic acid 300 according to the third embodiment is different from that of the first embodiment in the absorbent portion 13 and the non-absorbent portion 14 . Note that the substrate 10 , the reaction area 11 , and the analysis area 12 are similar to those of the first embodiment. Therefore, like reference numerals denote like elements as in the first embodiment, and they will not be described repeatedly. In addition, the positioning of the analysis area 12 using the substrate for use in analysis of nucleic acid 300 according to the third embodiment is similar to that of the first embodiment, and it will not also be described repeatedly.
[0066] According to this embodiment, the entire area of the non-absorbent portion 14 is the marker portion 15 , and the remaining area of the analysis area 12 other than the marker portion 15 is the absorbent portion 13 . Specifically, as illustrated in FIG. 3( a ) , the non-absorbent portion 14 having a cross shape and serving as the marker portion 15 is formed in an approximate center of the analysis area 12 , and the entire remaining area of this analysis area 12 other than the non-absorbent portion 14 (marker portion 15 ) is the absorbent portion 13 . Note that FIG. 3( b ) illustrates an exemplary fluorescent image k obtained from the substrate for use in analysis of nucleic acid 300 according to this embodiment. In this drawing, white dots indicate portions corresponding to the analysis samples s emitting fluorescence.
[0067] In this manner, in the substrate for use in analysis of nucleic acid 300 , the entire area of the non-absorbent portion 14 is the marker portion 15 , and the remaining area of the analysis area 12 other than marker portion 15 is the absorbent portion 13 . Therefore, it is possible to densely arrange the analysis sample s and analyze an amount of images at once.
Fourth Embodiment
[0068] FIG. 4 is a schematic plan view illustrating a substrate for use in analysis of nucleic acid 400 according to a fourth embodiment of the present invention, in which a single analysis area 12 is enlargedly illustrated. The substrate for use in analysis of nucleic acid 400 according to the fourth embodiment substantially includes a substrate 10 , a reaction area 11 , an analysis area 12 , an absorbent portion 13 , and a non-absorbent portion 14 . As illustrated in FIG. 4 , the substrate for use in analysis of nucleic acid 400 according to the fourth embodiment is different from that of the first embodiment in that the marker portion 15 is arranged in each of four corners in addition to the center of the analysis area 12 . Note that, since the substrate 10 , the reaction area 11 , and the analysis area 12 are similar to those of the first embodiment, they will not be described repeatedly. Furthermore, the absorbent portion 13 is similar to that of the first embodiment, and a plurality of absorbent portions 13 are not illustrated intentionally in FIG. 4 for simplicity purposes.
[0069] According to this embodiment, the marker portion 15 is used in positional correction of each absorbent portion 13 in the analysis area 12 . Specifically, the substrate for use in analysis of nucleic acid 400 includes a marker portion 15 c placed in the center of the analysis area 12 and L-shaped marker portions 15 d provided in each of four corners of the analysis area 12 . In addition, the marker portions 15 d placed in the four corners are arranged such that straight lines obtained by linking the neighboring marker portions 15 d of each corner are separated from the marker portion 15 c placed in the center at the same distance “a.” Furthermore, although not shown in the drawing, each absorbent portion 13 is arranged in a grid shape at an interval of five pixels on the analysis area other than the marker portion 15 .
[0070] Next, positional correction of each absorbent portion 13 in the analysis area 12 using the substrate for use in analysis of nucleic acid 400 according to the fourth embodiment will be described with reference to FIGS. 5( a ) to 5( c ) .
[0071] For example, positional correction of the absorbent portion 13 may be performed through the following method if a fluorescent image obtained from the substrate for use in analysis of nucleic acid 400 has a distortion. Specifically, as illustrated in FIG. 5( a ) , due to a distortion of the fluorescent image k 1 , a portion 15 c ′ corresponding to the marker portion 15 c in the center of the fluorescent image k 1 (hereinafter, referred to as a “marker mapping portion 15 c ′”) is separated from straight lines obtained by linking portions corresponding to the marker portions 15 d in the neighboring corners (marker mapping portions 15 d ′) at distances b, c, d, and e. In this case, as a method of estimating the position of the absorbent portion 13 in practice, for example, an interpolation technique such as a linear interpolation technique may be employed, in which interpolation is performed for each of the upper left, upper right, lower left, and lower right regions with respect to the marker mapping portion 15 c′.
[0072] For example, as an example of such a linear interpolation method, an actual pitch is calculated by obtaining a proportion of the distance “a” (refer to FIG. 4 ) against each of the distance “b, c, d, and e” and multiplying the proportions by five pixels. Specifically, an actual pitch of the BD direction in the B-side region from the marker mapping portion 15 c ′ in FIG. 5( a ) becomes “b/a×five pixels.” An actual pitch of the CE direction in the E-side region from the marker mapping portion 15 c ′ becomes “e/a×five pixels.” An actual pitch of the BD direction in the D-side region from the marker mapping portion 15 c ′ becomes “d/a×five pixels.” An actual pitch of the CE direction in the C-side region from the marker mapping portion 15 c ′ becomes “c/a×five pixels.” Using these values, positional correction of each absorbent portion 13 is performed.
[0073] Since a distortion of the fluorescent image depends on a detector of the nucleic acid analysis device, the aforementioned calculation may be performed only for the initial analysis area 12 of the first cycle. The correction is performed for the analysis areas 12 to be analyzed after using this calculation result. In addition, if two or more detectors are used in analysis, the calculation and the correction are performed in each detector.
[0074] Meanwhile, for a distortion (deviation) of the fluorescent image in the rotational direction with respect to the optical axis of the excitation light irradiated onto the substrate for use in analysis of nucleic acid 400 , the positional correction of the absorbent portion 13 can be performed in the following way. Specifically, as illustrated in FIG. 5( b ) , an inclination θ 1 is calculated from the marker mapping portion 15 d ′ of the fluorescent image k 2 obtained by the detector. Then, correction in the rotational direction is performed on the basis of the calculated inclination θ 1 . Note that, since the distortion of the rotational direction in the fluorescent image k depends on the detector of the nucleic acid analysis device, the aforementioned calculation may be performed only for the initial analysis area 12 of the first cycle, and the correction is performed for the analysis areas 12 to be analyzed after using this calculation result. In addition, if two or more detectors are used in the analysis, the calculation and the correction are performed in each detector. For example, FIG. 5( c ) illustrates a fluorescent image k 3 (inclination θ 2 ) detected from another detector different from the aforementioned detector.
[0075] In this manner, since the marker portion 15 is used in positional correction of each absorbent portion 13 in the analysis area 12 , it is possible to accurately recognize a position of each absorbent portion 13 in the analysis area 12 .
[0076] <Method of Manufacturing Substrate for Use in Analysis of Nucleic Acid>
[0077] Next, a method of manufacturing the aforementioned substrate for use in analysis of nucleic acid will be described. FIGS. 6( a ) to 6( f ) are schematic diagrams illustrating a method of manufacturing the substrate for use in analysis of nucleic acid 100 of FIG. 1 . This substrate for use in analysis of nucleic acid 100 may be manufactured, for example, using a method described in JP 2011-99720 A. That is, a substrate 10 having one surface where a hydrophobic membrane is laminated in advance (refer to FIG. 6( a ) ) is prepared. On this hydrophobic membrane, a hydrophilic membrane 16 formed of specific inorganic oxide or the like is deposited, for example, through vacuum deposition, sputtering, chemic vapor deposition (CVD), physical vapor deposition (PVD), or the like (refer to FIG. 6( b ) ).
[0078] Then, a resist 17 is coated on the obtained hydrophilic membrane 16 (refer to FIG. 6( c ) ). Then, predetermined patterning is performed using a photolithographic technique (refer to FIG. 6( d ) ). An unnecessary part of the hydrophilic membrane is removed through etching by using the patterned resist 17 as a mask (refer to FIG. 6( e ) ), and the remaining resist 17 is removed by dissolving (refer to FIG. 6( f ) ). As a result, it is possible to manufacture a substrate for use in analysis of nucleic acid 100 having a desired absorbent portion 13 provided with the hydrophilic membrane 16 . Note that, since the hydrophobic membrane is exposed on a part of the analysis area 12 other than the absorbent portion 13 , this part serves as the non-absorbent portion 14 .
[0079] <Flow Cell for Use in Analysis of Nucleic Acid>
[0080] The flow cell for use in analysis of nucleic acid according to the present invention includes the substrate for use in analysis of nucleic acid, a light-transmitting cover disposed to face the substrate for use in analysis of nucleic acid to transmit light, a plurality of spacers arranged between the substrate for use in analysis of nucleic acid and the light-transmitting cover and separated substantially in parallel with each other, a flow passage formed in a portion interposed by the neighboring spacers between the substrate for use in analysis of nucleic acid and the light-transmitting cover to circulate a fluid, an inlet port opened in one end of the flow passage to inject the fluid, and an outlet port opened in the other end opposite to the inlet port of the flow passage to discharge the fluid.
[0081] The flow cell for use in analysis of nucleic acid according to the present invention will now be described with the accompanying drawings. However, the present invention is not limited to the embodiments illustrated in the drawings.
[0082] FIG. 7 is a schematic perspective view illustrating an exemplary flow cell for use in analysis of nucleic acid according to the present invention, in which the light-transmitting cover is partially cut away. As illustrated in FIG. 7 , the flow cell for use in analysis of nucleic acid 500 substantially includes a substrate for use in analysis of nucleic acid 100 , a light-transmitting cover 21 , spacers 22 , and a flow passage 23 . Note that, since the substrate for use in analysis of nucleic acid 100 described above is employed as the substrate for use in analysis of nucleic acid in this embodiment, like reference numerals denote like element, and they will not be described repeatedly.
[0083] The light-transmitting cover 21 is a flat cover placed to face the substrate for use in analysis of nucleic acid 100 to transmit light. The light-transmitting cover may be formed of, for example, glass such as soda glass, quartz glass, or sapphire glass, light-transmitting resin such as transparent polyimide resin, or polycarbonate resin, and the like.
[0084] The spacers 22 are placed between the substrate for use in analysis of nucleic acid 100 and the light-transmitting cover 21 and are separated substantially in parallel with each other. The flow cell for use in analysis of nucleic acid 500 has a plurality of spacers 22 . The spacers 22 may be formed of, for example, thermosetting or photosetting epoxy resin, acrylic resin, silicon resin, and the like as disclosed in JP 2006-87974 A. Out of these materials, in terms of improvement of a bonding strength with the glass or the light-transmitting resin, silicon resin is preferable, polysiloxane is more preferable, and polydimethylsiloxane (PDMS) is most preferable. In addition, the spacers 22 preferably have a thickness of 0.05 to 2 mm, and more preferably 0.2 to 1 mm, but not particularly limited thereto.
[0085] The flow passage 23 is a flow passage formed in a portion interposed between the neighboring spacers 22 between the substrate for use in analysis of nucleic acid 100 and the light-transmitting cover 21 to flow a fluid. For example, a fluid such as a reagent that can react with the DNA fragment flows through this flow passage 23 . Specifically, the flow passage 23 is surrounded by the substrate for use in analysis of nucleic acid 100 , the light-transmitting cover 21 , and the spacers 22 to form a rectangular cross section as seen in the flow direction and a substantially rectangular parallel-piped space extending in the flow direction. The flow passage 23 has an inlet port 23 a opened in one end to inject the fluid and an output port 23 b opened in the other end opposite to the inlet port 23 a to discharge the fluid.
[0086] In this manner, since the flow cell for use in analysis of nucleic acid 500 has the substrate for use in analysis of nucleic acid 100 , it is possible to reproducibly obtain the position of the analysis area 12 even when positioning is repeatedly performed during the nucleic acid analysis. As a result, it is possible to reliably and rapidly analyze base sequences of DNA fragments.
[0087] <Method of Manufacturing Flow Cell for Use in Analysis of Nucleic Acid>
[0088] Next, a method of manufacturing the flow cell for use in analysis of nucleic acid 500 will be described. For the flow cell for use in analysis of nucleic acid 500 , for example, a pair of spacers 22 are bonded to the substrate for use in analysis of nucleic acid 100 described above in parallel with each other using an adhesive. Then, the light-transmitting cover 21 is bonded to the bonded spacers 22 using an adhesive. Note that any type of adhesive may be employed without a particular limitation as long as it does not affect the nucleic acid analysis. Through the aforementioned process it is possible to manufacture the flow cell for use in analysis of nucleic acid 500 according to the present invention.
[0089] <Nucleic Acid Analysis Device>
[0090] The nucleic acid analysis device according to the present invention includes the flow cell for use in analysis of nucleic acid, a circulation unit that circulates the fluid in the flow passage of the flow cell for use in analysis of nucleic acid, a temperature control unit that controls an reactive temperature of the DNA fragment, an irradiation unit that irradiates excitation light onto the analysis area as an analysis target through the light-transmitting cover, a detection unit that detects the fluorescence emitted from the DNA fragment by irradiating the excitation light through the light-transmitting cover and detects a position of the marker portion in the analysis area from the detected fluorescence, and a carriage unit that carries the flow cell for use in analysis of nucleic acid and shifts the analysis area to a predetermined position with respect to the marker portion.
[0091] A nucleic acid analysis device according to the present invention will now be described with reference to the accompanying drawings. However, the present invention is not limited to the embodiments illustrated in the drawings.
[0092] FIG. 8 is a schematic diagram illustrating an exemplary nucleic acid analysis device according to the present invention. As illustrated in FIG. 8 , the nucleic acid analysis device 600 substantially includes a flow cell for use in analysis of nucleic acid 500 , a circulation unit 31 , a temperature control unit 32 , an irradiation unit 33 , a detection unit 34 , and a carriage unit 35 . Note that the flow cell for use in analysis of nucleic acid 500 is similar to the flow cell for use in analysis of nucleic acid 500 described in the paragraph <Flow Cell for Use in Analysis of Nucleic Acid> described above. Therefore, like reference numerals denote like elements, and they will not be described repeatedly.
[0093] The circulation unit 31 circulates the fluid in the flow passage 23 of the flow cell for use in analysis of nucleic acid 500 . The circulation unit 31 has a reagent cooling storage chamber 312 that houses a plurality of reagent containers 311 containing the reagent, a nozzle 313 that accesses the reagent container 311 , a pipe 314 that introduces the reagent into the flow cell for use in analysis of nucleic acid 500 , and a waste liquid reservoir 315 that disposes the reagent reacting with the DNA fragments.
[0094] The temperature control unit 32 controls a reaction temperature of the DNA fragment. The temperature control unit 32 has a temperature control substrate 321 provided on an XY-stage 351 described below to promote a reaction between the DNA fragment (analysis sample s) to be analyzed and the reagent. The temperature control substrate 321 is embedded with, for example, a peltier device.
[0095] The irradiation unit 33 has a light source 331 such as a light emitting diode (LED) serving as the excitation light, a filter switching mechanism 332 capable of selecting an arbitrary wavelength from the excitation light emitted from the light source 331 , a dichroic mirror 333 that reflects the excitation light and transmits the fluorescence described below, an objective lens 334 that irradiates the excitation light onto the analysis sample s to be analyzed, and a Z-stage 335 that drives the objective lens 334 in the Z-axis direction perpendicular to both the X-axis and the Y-axis to adjust a focus of the excitation light.
[0096] The detection unit 34 detects the fluorescence emitted from the DNA fragment by irradiating the excitation light through the light-transmitting cover 21 and a position of the marker portion 15 in the analysis area 12 from the detected fluorescence. The detection unit 34 has an objective lens 334 that recovers the fluorescence emitted from the analysis sample s, a fluorescence separation dichroic mirror 341 that divides parallel light from the objective lens 334 on a wavelength basis, a tube lens 342 that focuses the parallel light, and a detector 343 provided with a sensor such as a complementary metal oxide semiconductor (CMOS) sensor for detecting the focused image. Note that, since the objective lens 334 of the detection unit 34 is shared with the irradiation unit 33 , the same reference numerals are used.
[0097] The carriage unit 35 carries the flow cell for use in analysis of nucleic acid 500 and shifts the analysis area 12 to a predetermined position with respect to the marker portion 15 . The carriage unit 35 has an XY-stage 351 capable of delivering the flow cell for use in analysis of nucleic acid in each of the X-axis and Y-axis directions coplanarly perpendicular to each other and a driving motor (not shown) that drives the XY-stage 351 . Note that the XY-stage 351 is controlled in an open loop manner.
[0098] <Analysis Method>
[0099] Next, a method of analyzing base sequences of the DNA fragments using the nucleic acid analysis device 600 according to the present invention will be described with reference to FIGS. 8 to 11 . Note that, here, a case where the analysis sample s is a vector that contains the DNA fragment, and the flow cell for use in analysis of nucleic acid 500 provided with the substrate for use in analysis of nucleic acid 100 according to the first embodiment described above is employed will be described by way of example.
[0100] The analysis using the nucleic acid analysis device 600 may be performed, for example, by combining processes described below, including “Preparation of Flow Cell,” “Installation of Flow Cell,” “Introduction of Reagent,” “Temperature Control,” “Shift of Stage,” and “Positioning of Stage.” While each process will be described in details hereinafter, the analysis using the nucleic acid analysis device 600 is not limited to the following aspects.
[0101] <Preparation of Flow Cell>
[0102] In this process, a flow cell for use in analysis of nucleic acid 500 (refer to FIG. 7 ) where the analysis sample s is borne in advance is prepared. The substrate for use in analysis of nucleic acid 100 of the flow cell for use in analysis of nucleic acid 500 has an absorbent portion 13 and a non-absorbent portion 14 in each analysis area 12 on the substrate 10 , and a marker portion 15 having a cross shape is formed in the center of the non-absorbent portion 14 as illustrated in FIG. 1 . Note that the analysis sample s is borne only in the absorbent portion 13 .
[0103] <Installation of Flow Cell>
[0104] In this process, the flow cell for use in analysis of nucleic acid 500 prepared in the process <Preparation of Flow Cell> is fixed to the temperature control substrate 321 provided on the XY-stage 351 of the nucleic acid analysis device 600 .
[0105] <Introduction of Reagent>
[0106] In this process, the nozzle 313 of the circulation unit 31 accesses the reagent container 311 of the reagent cooling storage chamber 312 to suction the reagent. Then, the suctioned reagent is injected into the flow passage of the flow cell for use in analysis of nucleic acid 500 through the pipe 314 and the inlet port 23 a, and the injected reagent comes into contact with the analysis sample s borne in the absorbent portion to generate reaction. Note that the reagent subjected to the aforementioned reaction is disposed to the waste liquid reservoir 315 through the pipe.
[0107] <Temperature Control>
[0108] In this process, a temperature control is performed for the flow cell for use in analysis of nucleic acid 500 using the temperature control substrate 321 to allow the analysis sample s to have a predetermined temperature. Through this temperature control, the reagent reacts with the analysis sample s of the flow cell for use in analysis of nucleic acid 500 . In this case, DNA elongation is performed by suitably repeating the aforementioned processes “Introduction of Reagent” and “Temperature Control.” This elongation is performed by reacting polymerase with four types of nucleotide labeled with different fluorochromes. The nucleotide includes FAM-dCTP, Cy3-dATP, Texas Red-dGTP, or Cy5-dTsTP. The reagent contains polymerase, and only one base of complementary fluorescence nucleotide is incorporated into the DNA fragment.
[0109] <Shift of Stage>
[0110] In this process, in order to observe the reacted analysis sample s, the XY-stage 351 is driven by a driving motor (not shown) to shift the flow cell for use in analysis of nucleic acid 500 to a preset position. Here, the “preset position” refers to an initial target position of the analysis area 12 where the marker portion 15 is to be placed within a fluorescence detection range of the detection unit 34 . Note that the accurate positioning of the stage will be described below in more details in the following paragraph “Positioning of Stage.”
[0111] <Positioning of Stage>
[0112] In this process, first, a focus position of the analysis sample s in the objective lens 334 is adjusted by driving the Z-stage 335 of the detection unit 34 . Then, after shifting the objective lens 334 to the focus position, excitation light having a particular wavelength is irradiated onto the analysis sample s using the filter switching mechanism 332 . In this case, through the irradiation of excitation light, only an analysis sample s corresponding to an excitation wavelength out of the analysis samples s borne in the absorbent portion 13 emits fluorescence. Meanwhile, the marker portion 15 does not emit fluorescence.
[0113] Then, a fluorescent image k is obtained using the detection unit 34 . In this case, for example, when the four colors of fluorescence described above are detected, the analysis sample s emits fluorescence with a probability of “¼.” Therefore, it is possible to perceive a shape of the marker portion 15 that does not emit fluorescence out of the obtained fluorescent image k. Then, as illustrated in FIGS. 10 ( a ) to 10 ( c ), for the detection range of the fluorescent image k, a marker portion 15 having a shape stored in a computer (not shown) in advance is searched. In this case, if the marker portion 15 is searched, pixel values of the X-axis and the Y-axis in the center of the marker portion 15 (coordinates converted into pixels of the marker portion 15 in the fluorescent image k) are calculated (refer to FIG. 10( a ) ). If the marker portion 15 is not searched, the search area moves to the next analysis area by driving the XY-stage 351 . Note that, if the calculated pixel value is within a target location range 344 , the positioning of the XY-stage 351 is not performed. Meanwhile, if the calculated pixel value is out of the target location range 344 , relative pixel numbers Xa and Ya for this pixel values for the center position within the target location range 344 are calculated (refer to FIG. 10( b ) ). Then, the pixel numbers Xa and Ya are converted into the number of pulses necessary in the positioning, and the number of pulses is transmitted to the carriage unit 35 . After this transmission, the XY-stage 351 is moved by driving the driving motor of the carriage unit 35 (refer to FIG. 10( c ) ).
[0114] Then, irradiation of the excitation light and position detection of the marker portion 15 using the detection unit 34 are performed again to check whether or not the marker portion 15 is shifted to the target location range 344 . In this case, if the marker portion 15 is within the target location range 344 , the positioning of the XY-stage 351 is completed. Meanwhile, if the marker portion 15 is out of the target location range 344 , the positioning is performed again. Then, after this positioning is completed, this position (the aforementioned number of pulses) is stored. Note that, if the position of the marker portion 15 does not change after the positioning of the XY-stage 351 , it is considered as misalignment of the driving motor, and the analysis is interrupted by outputting an alarm.
[0115] <Detection of Fluorescence>
[0116] In this process, a focus position is adjusted by driving the objective lens 334 of the detection unit 34 again. Note that this re-adjustment of the focus position is performed to correct a deviation in the vertical direction caused by the movement of the XY-stage. However, if the detection unit 34 and the analysis samples have a sufficient depth of field, this adjustment is not necessary.
[0117] Then, using the filter switching mechanism 332 , the excitation light is irradiated onto the analysis area 12 by switching the excitation light between two wavelength bands of 490 nm and 595 nm as a median, and the fluorescence is detected on each occasion. Here, the excitation light having a wavelength of 490 nm as a median is used to detect fluorescence of FAM-dCTP and Cy3-dATP, and the excitation light having a wavelength of 595 nm as a median is used to detect fluorescence of Texas Red-dGTP and Cy5-dTsTP.
[0118] The fluorescence emitted from the analysis sample 12 is input to a pair of detectors 343 through the fluorescence separation dichroic mirror 341 . Here, since the fluorescence separation dichroic mirror 341 has a smooth reflection characteristic for the four color fluorescence wavelength regions, it is possible to calculate a ratio of the fluorescence intensity at a bright spot emitted from the analysis sample s using a pair of detectors 343 . For this reason, by calculating an intensity ratio on the image planes of a pair of detectors 343 , it is possible to determine which one of the four colors of fluorescence the fluorescence of the analysis sample s belongs to. Note that several ten thousands to several hundred thousands of analysis samples s are borne on the analysis sample 12 , and which position of the analysis samples s emits which fluorescence is detected in a batch through the fluorescence detection.
[0119] Next, an exemplary fluorescent image k detected through the fluorescence detection is illustrated in FIG. 11 . In FIG. 11 , reference numeral “ 345 ” denotes pixels of the fluorescent image k, reference numeral “ 13 ′” denotes a portion on the fluorescent image k corresponding to the absorbent portion 13 , and reference numeral “ 15 ′” denotes a portion on the fluorescent image k corresponding to the marker portion 15 . FIG. 11 illustrates an exemplary fluorescent image when each absorbent portion 13 is arranged at an interval of 1.4 μm, a spatial resolution of the detection unit 34 is set to 0.28 μm/pixel, and the absorbent portion 13 is arranged at the same interval as five pixels of the fluorescent image k. In this example, the analysis sample s has a size of 0.28 μm or larger. For this reason, when the fluorescence of the analysis sample s is detected, a sample position is specified at an interval of five pixels from the edge of the marker portion 15 , and fluorescence of nine pixels (three pixels in each direction) is detected for each position of each analysis sample s.
[0120] After completing the detection of fluorescence for a single analysis area 12 , the detection range is shifted to the next analysis area 12 . Then, the positioning on the XY-stage 351 is performed again, and fluorescence is detected from this analysis area 12 . The movement of the XY-stage 351 , the positioning of the analysis sample s, the storing of the position of the analysis sample s, and the fluorescence detection are repeated until detection is completed for all of the analysis areas 12 . Note that, in order to reduce the analysis time, the positioning of the analysis sample s is performed only for an arbitrary analysis area 12 , and the position information stored as described above may be used for the other analysis areas 12 . Hereinbefore, an operation for a single cycle in this analysis has been described in brief.
[0121] Next, the analysis is performed for the second and subsequent cycles. In the stage movement of the second and subsequent cycles, the positioning is performed by shifting to the position of the initial analysis area 12 obtained in the positioning of the first cycle. This positioning is performed to correct thermal expansion caused by an internal temperature change of the nucleic acid analysis device 600 . After this positioning is completed, the corrected position is stored.
[0122] For the subsequent analysis area 12 , the analysis is performed by shifting to a relative position from the initial analysis area 12 obtained in the first cycle. For example, it is assumed that the initial analysis areas 12 of the first cycle and the subsequent two analysis areas 12 are positioned in 1,000 μm, 2,000 μm, and 3,000 μm, respectively. If the initial analysis area 12 of the second cycle is positioned in 950 μm, the next two analysis areas 12 are positioned in 1,950 μm and 2,950 μm.
[0123] Note that, in this operation, an error or a positional deviation may occur in accuracy of the repeated positioning of the XY-stage 351 . If the accuracy of the repeated positioning of the XY-stage 351 is sufficiently low, a detection loss is not easily generated. However, if the accuracy of the repeated positioning of the XY-stage 351 is high, it is not negligible. If the accuracy of repeated positioning is high, it is necessary to increase the analysis areas 12 for the positioning considering the detection loss and the detection time.
[0124] By repeating the aforementioned cycles, the DNA base sequences of the analysis sample s are analyzed. For example, assuming that a certain analysis sample s emits fluorescence for each cycle in order of Cy3→Texas Red→FAM→Cy5→ . . . , the base sequence of the sample can be determined as “A→G→C→T→ . . . ” from the dNTP corresponding to the fluorochrome. In this manner, fluorescence is detected from several ten thousands to hundred thousands of analysis samples s in a batch, and all of the base sequences of the analysis samples s are determined in parallel.
[0125] Note that, although the analysis of the DNA base sequences of the analysis samples s starts from the first cycle in this example, the first cycle may be a mapping operation of the analysis area 12 . In this mapping operation, if, for example, Texas Red-dGTP is incorporated into the DNA fragments of all of the analysis samples, all of the analysis samples emit fluorescence using excitation light having a wavelength of 595 nm. As a result, it is possible more reliably detect the marker portion. Therefore, it is possible to reduce the analysis area 12 where the positioning is not performed.
[0126] In this manner, the nucleic acid analysis device 600 has the flow cell for use in analysis of nucleic acid 500 provided with this substrate for use in analysis of nucleic acid 100 . Therefore, even when the repeated positioning is performed, it is possible to reproducibly obtain the position of the absorbent portion 13 . As a result, it is possible to reliably and rapidly analyze the base sequences of the DNA fragments.
[0127] Note that the substrate for use in analysis of nucleic acid, the flow cell for use in analysis of nucleic acid, and the nucleic acid analysis device according to the present invention are not limited to the embodiments described above, but the scope of the invention may encompass those described in the claims, their equivalents, and all possible changes.
[0128] For example, although the marker portion 15 has a cross shape or a hook shape by way of example in the aforementioned embodiments, any shape of the marker portion, such as a star shape or a circular shape, may be employed as long as the position of the marker portion 15 can be specified in the analysis area 12 .
[0129] Although the substrate for use in analysis of nucleic acid 400 having the marker portions 15 formed in the center and the four corners of the analysis area 12 has been described in FIGS. 4 and 5 ( a ) to 5 ( c ), the scope of the invention may also include a substrate having no marker portion 15 in the center or having the marker portions 15 formed in only in opposite corners.
[0130] Although the flow cell for use in analysis of nucleic acid 500 provided with the substrate for use in analysis of nucleic acid 100 has been described in the aforementioned embodiments, any substrate for use in analysis of nucleic acid may also be employed as long as it satisfies the configuration of the substrate for use in analysis of nucleic acid according to the present invention.
[0131] Although the flow cell for use in analysis of nucleic acid 500 provided with a pair of spacers 22 separated substantially in parallel with each other has been described in FIG. 7 , the flow cell for use in analysis of nucleic acid may have three or more spacers 22 to provide a plurality of lines of flow passages 23 . For example, a flow cell for use in analysis of nucleic acid formed of polydimethylsiloxane (PDMS) or the like and provided with a blanked sheet obtained by blanking the flow passage portion may also be employed.
[0132] While the nucleic acid analysis device 600 provided with the flow cell for use in analysis of nucleic acid 500 has been described in the aforementioned embodiments, any flow cell for use in analysis of nucleic acid may also be employed as long as it satisfies a configuration of the flow cell for use in analysis of nucleic acid according to the present invention.
[0133] While the nucleic acid analysis device 600 having the detection unit 34 provided with a pair of detectors 343 has been described in FIG. 8 , the nucleic acid analysis device may be additionally provided with a fluorescence separation dichroic mirror, and the nucleic acid analysis device may have the detection unit 34 having three or four detectors.
REFERENCE SIGNS LIST
[0000]
10 substrate
11 reaction area
12 analysis area
13 absorbent portion
14 non-absorbent portion
15 marker portion
21 light-transmitting cover
22 spacer
23 flow passage
23 a inlet port
23 b outlet port
31 circulation unit
32 temperature control unit
33 irradiation unit
34 detection unit
35 carriage unit
100 , 200 , 300 , 400 substrate for use in analysis of nucleic acid
500 flow cell for use in analysis of nucleic acid
600 nucleic acid analysis device
s analysis sample
k fluorescent image
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The substrate 100 for use in the analysis of a nucleic acid according to the present invention has multiple analysis areas 12 which are partitioned on a substrate 10, and enables the measurement of the analysis areas 12 while interchanging the analysis areas 12 in turn, said substrate 100 being characterized in that each of the analysis areas 12 consists of an adsorption part 13 onto which a DNA fragment or a carrier having the DNA fragment carried thereon can be adsorbed and a non-adsorption part 14 which is a part outside of the adsorption part 13, and the non-adsorption part 14 has, formed on at least a part thereof, a marker part 15 that has a specified shape and helps to identify the positions of the analysis areas 12.
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The present application claims the priority of U.S. Provisional Patent Application Ser. No. 61/100,484 filed Sep. 26, 2008, which application is incorporated in its entirety herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to document and media storage and in particular large scale storage requiring periodic reallocation of storage capabilities.
Both open slot storage and container storage are commonly utilized to store documents and media at offsite vaults. Open slot storage generally comprises vertical drawers individually horizontally drawn from a common cabinet and is commonly used for storing media such as data tapes and disks. The vertical drawers are configurable to allow creation of vertically spaced apart shelves holding rows of common sized media (e.g. tape or disk) containers and the media is accessible by horizontally drawing the drawer containing the media from the cabinet. U.S. Pat. No. 4,657,317 discloses a very efficient open slot storage unit manufactured by Russ Bassett, Corp. in Whittier, Calif. under the trademark Gemtrac™. The '317 patent is herein incorporated by reference in its entirety.
Container storage includes vertically spaced apart horizontal shelves for containers. The containers hold multiple media, for example, tapes, typically 20-40 per container. Known container storage is constructed using common pallet racks as a frame. Unfortunately, the cabinets of open slot storage are very different from the pallet racking used to support container storage and share no common structure. For example, the vertically spaced apart horizontal shelves required for known container storage are not compatible with the full height vertical drawers of the open slot storage systems. Both storage systems require major installation expenditure decisions made years in advance as to the mix of open slot or case storage which will be needed in the future. When storage needs change, costs of converting from one to another are prohibitive, resulting in inefficient use of storage space.
A need thus exists for storage allowing convenient conversion between open slot and container storage.
BRIEF SUMMARY OF THE INVENTION
The present invention addresses the above and other needs by providing a convertible media and document storage system which uses elements of common pallet rack framing and is convertible between open slot and container storage. The container storage includes pilasters hanging from existing horizontal beam elements of the framing, and vertically spaced apart pairs of adjustable wireform racks engage the pilasters and provide horizontal ledges for supporting containers of various sizes. The use of hanging pilasters minimizes strength and material requirements. The open slot storage includes tall vertical drawers riding on overhead rails attachable to the same horizontal beam elements and individually horizontally drawn for access to the stored material such as data tape and disk media. The storage system optimizes utilization of space and allows large facilities to reconfigure storage between open slot and container storage when demands change.
In accordance with one aspect of the invention, there is provided a reconfigurable hanging storage system. The hanging storage system includes framing having upper horizontal beams and laterally spaced apart pairs of pilasters hanging from the upper horizontal beams. The pilasters are adjustable laterally for positioning on the upper horizontal beams and for different width containers. Pairs of racks are attached to the pilasters for carrying containers and the racks are independently adjustable vertically for different height containers. Using hanging pilasters reduces both material requirements, because the pilasters are in tension versus compression, and less space consumed by the pilasters, because less material is required. Using the hanging pilasters further overcomes a need for fixed shelves which would interfere with conversion to open slot storage.
In accordance with another aspect of the invention, there is provided a configurable storage system. The configurable storage system includes a multiplicity of rectangular frames residing in parallel facing pairs, open slot storage units attached to the frames, and container storage attached to the frames. Each pair of the frames is separated by an aisle providing spacing S between the pairs frames of approximately one frame depth D. Each frame includes uprights, horizontal beams, and end bracing. The uprights comprise four horizontally spaced apart vertical uprights, one of the uprights at each corner of the frame, the uprights forming a rectangular horizontal footprint having the width W and the depth D. The beams comprise lower and upper horizontal beams. The lower horizontal beams are attached to the uprights along the width dimension at the same height. The upper horizontal beams are vertically spaced apart above each of the at least one pairs of lower horizontal beams and are attached to the uprights along the length dimension at the same height. The pair of lower horizontal beams and the pair of upper horizontal beams separated vertically by a section height Hs. The end bracing connects the uprights along the depth dimension and the length L, the width W, and the height Hs define a section of the storage system. The open slot storage units each include a horizontal overhead rail, a bottom drawer guide, and drawers. The horizontal overhead rails are configured for clamping attachment to one of the pairs of upper horizontal beams and reaching across the pair of upper horizontal beams and across the aisle to an adjacent pair of upper horizontal beams. The bottom drawer guide configured for clamping attachment to one of the pair of lower horizontal beams and reaching across the pair of lower horizontal beams. The drawers are slidably carried by the overhead rails and guided by the bottom drawer guides and are slidable into the aisle for providing access to stored material. The container storage includes laterally spaced apart pairs of pilasters adjustably configured for clamping attachment to one of the pairs of horizontal beams and having a multiplicity of vertically spaced apart holes, and pairs of opposing wireform racks configured for attachment to the pilasters using the multiplicity of vertically spaced apart holes and having opposing ledges for receiving containers. The pilaster separation is adjustable for different width containers.
In accordance with another aspect of the invention, there is provided a configurable hanging storage system. The configurable hanging storage system includes at least two rectangular frames and container storage. Each frame has a width dimension with width W and a depth dimension with depth D. Pairs of the frames reside in parallel with faces along the width dimension facing each other and separated by an aisle providing spacing S between the frames. Each frame includes uprights, horizontal beams, and end bracing. The uprights comprise four horizontally spaced apart vertical uprights, one of the uprights at each corner of the frame, the uprights forming a rectangular horizontal footprint having the width W and the depth D. The beams comprise lower and upper horizontal beams. The lower horizontal beams are attached to the uprights along the width dimension at the same height. The upper horizontal beams are vertically spaced apart above each of the at least one pairs of lower horizontal beams and are attached to the uprights along the length dimension at the same height. The pair of lower horizontal beams and the pair of upper horizontal beams are separated vertically by a section height Hs. The end bracing connects the uprights along the depth dimension and the length L, the width W, and the height Hs define a section of the storage system. The container storage resides in one of the sections of the storage system and comprises pairs of laterally (i.e, along the width dimension of the frame) pilasters hanging from the upper horizontal beams and pairs of opposing racks attached to the pilasters and providing ledges receiving containers. Pilaster top bars and top clamping fingers are attached at each end of the top bars for tightly sandwiching a horizontal bottom edge of the upper horizontal beams between the top bars and top clamping fingers to attach the pilasters to the upper horizontal beams. Pilaster bottom bars reaching the length of the bottoms of the pilasters and bottom clamping fingers are attached to bottom surfaces at each end of the bottom bars. A top horizontal edge of the lower horizontal beams is sandwiched between the bottom clamping fingers and the bottom bar to attach the pilasters to the bottom horizontal beams.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The above and other aspects, features and advantages of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
FIG. 1 is a perspective view of a multi-level convertible media and document storage system according to the present invention.
FIG. 2A is a perspective view of a pair of single level side by side frames positioned to provide support for the convertible media and document storage system according to the present invention.
FIG. 2B is a perspective view of a pair of two level side by side frames positioned to provide support for the convertible media and document storage system according to the present invention.
FIG. 2C is a perspective view of a pair of three level side by side frames positioned to provide support for the convertible media and document storage system according to the present invention.
FIG. 3 is a perspective view of a single three level frame suitable for supporting the convertible media and document storage system according to the present invention.
FIG. 3A is a side view of one of the three level frames suitable for supporting the convertible media and document storage system according to the present invention.
FIG. 3B is an end view of one of the three level frames suitable for supporting the convertible media and document storage system according to the present invention.
FIG. 3C is a top view of one of the three level frames suitable for supporting the convertible media and document storage system according to the present invention.
FIG. 4A is a front view of a first half of the document storage system according to the present invention including a top open slot storage section, an empty center section, and a bottom container storage section configured for storing tubs.
FIG. 4B is a front view of a second half of the document storage system according to the present invention including a top open slot storage section, a center empty section, and a bottom container storage section configured for storing small containers.
FIG. 5A shows the small storage container according to the present invention.
FIG. 5B shows a large storage container according to the present invention.
FIG. 5C shows the tub according to the present invention.
FIG. 6 shows a pilaster configured for clamping to a pair of upper horizontal beams, and racks attached to the pilaster, according to the present invention.
FIG. 6A shows detail 6 A of FIG. 6 .
FIG. 7 shows details of top clamping apparatus according to the present invention.
FIG. 7A shows a cross-sectional view of the clamping apparatus according to the present invention.
FIG. 7B shows details of bottom clamping apparatus according to the present invention.
FIG. 8 shows the rack according to the present invention.
FIG. 9A shows an opposing pair of vertical drawers used with the open slot storage section according to the present invention.
FIG. 9B shows a single vertical drawer used with the open slot storage section according to the present invention.
FIG. 10 shows an end view of a storage facility including adjacent rows of the convertible media and document storage system according to the present invention.
Corresponding reference characters indicate corresponding components throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
The following description is of the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing one or more preferred embodiments of the invention. The scope of the invention should be determined with reference to the claims.
A perspective view of a convertible media and document storage system 10 according to the present invention is shown in FIG. 1 . The convertible media and document storage system 10 includes side by side cooperating halves 10 a and 10 b . The halves 10 a and 10 b each include a top open slot storage section 12 , a center empty section 16 , and a bottom container storage section 14 . The container storage bottom section 14 of the first half 10 a is configured to carry small containers 32 a (see FIG. 5A ) and the container storage bottom section 14 of the second half 10 b is configured to carry tub containers 32 c (see FIG. 5C ). All of the sections of the convertible media and document storage system 10 according to the present invention may be reconfigured into open slot storage sections, container storage sections, or empty sections as needs change. A walkway 13 is provided for access to the open slot storage section 12 .
A perspective view of a pair of side by side single level pallet rack frames 18 a positioned to provide support for the convertible media and document storage system 10 according to the present invention is shown in FIG. 2A , a perspective view of a pair of side by side two level pallet rack frames 18 b positioned to provide support for the convertible media and document storage system 10 according to the present invention is shown in FIG. 2B , and a perspective view of a pair of side by side three level pallet rack frames 18 c positioned to provide support for the convertible media and document storage system 10 according to the present invention is shown in FIG. 2C . The pallet rack frames 18 a , 18 b , and 18 c include upper horizontal beams 22 a and lower horizontal beams 22 b attached to vertical uprights 20 , and end bracing comprising horizontal end braces 24 and diagonal end braces 24 . Additionally, “X” bracing 21 is provided on rear faces of the bottom level in the two level frames 18 a and on the bottom and middle level of the three level frames 18 c . The pallet rack frames 18 a , 18 b , and 18 c may comprise common pallet rack frames which are easily obtained. The “X” bracing is required in many cases because the frames have fewer horizontal beams to provide stability than typical pallet frames.
The upper horizontal beams 22 a carry a large load and are preferably approximately eight inch high beams. The lower most lower horizontal beam 22 b is preferably approximately three inches high and carries the least load of all the horizontal beams. The remaining lower horizontal beams 22 b are preferably approximately five inches high and carry a moderate load due to supporting the walkway 13 .
A perspective view of one of the frames 18 c is shown in FIG. 3 , a side view of one of the frames 18 c is shown in FIG. 3A , a rear view of one of the frames 18 c is shown in FIG. 3B , and a top view of one of the frames 18 c is shown in FIG. 3C . Rails 40 (see FIG. 9A ) for open slot storage units 30 and pilasters 38 (see FIG. 6 ) for container storage are hung from the upper horizontal beams 22 a . The lower horizontal beams 22 b provide support for the walkways 13 , for bottom guides 56 for open slot storage 30 or bottom attachment of the container storage 38 .
The frames 18 c further have a width W and a depth D, and each section has a section height Hs. The lateral dimension in the following description is aligned with the width W, and the longitudinal dimension with the depth D as viewed by a user accessing the stored material. The depth D is preferably approximately 38 inches and the width W is preferably approximately ten feet. The preferred depth D facilitates using elements of existing vertical drawer systems which are a large component of the cost of constructing a convertible media and document storage system. For example, the Gemtrac™ vertical drawer system manufactured by Russ Bassett, Corp. in Whittier, Calif. and described in U.S. Pat. No. 4,657,317 incorporated by reference above.
A front view (i.e., as viewed from the center aisle) of the first half 10 a of the document storage system 10 according to the present invention, including the top open slot storage section 12 , the center empty section 16 , and the bottom container storage section 14 configured for tub containers 32 c is shown in FIG. 4A and a side view of a second half 10 b of the document storage system according to the present invention including the top open slot storage section 12 , the center empty section 16 , and the bottom container storage section 14 configured for small storage containers 32 a is shown in FIG. 4B .
The small storage container 32 a according to the present invention is shown in FIG. 5A , the large storage container 32 b according to the present invention is shown in FIG. 5B , and the tub container 32 c according to the present invention is shown in FIG. 5C . The container storage sections 14 of the document storage system 10 according to the present invention are easily convertible to store any of the containers 32 a , 32 b , and 32 c . As described below, the container storage sections 14 may also be configured for other containers. The document storage system 10 may be configured with open slot storage sections 12 in any position, but preferably are opposite another open slot storage section 12 . Further, each section may be reconfigured from open slot storage to container storage and from container storage to open slot storage.
A pilaster 38 of a container storage section is shown in FIG. 6 , details of the pilaster 38 are shown in FIG. 6A , a clamping system according to the present invention for attaching the pilaster 38 to the upper horizontal beam 22 a are shown in FIG. 7 , a cross-sectional view of the clamping system is shown in FIG. 7A . The pilasters 38 include top bars 36 which clamp onto the bottom horizontal edges 23 of the upper horizontal beams 22 a allowing infinite adjustment of the lateral separation of pilasters 38 to accommodate containers of various widths.
The clamping attachment is preferably performed by top clamping fingers 40 a . The fingers 40 a have a bent tab 41 which pass through a slot 36 a in the top bar 36 of the pilaster 38 . A tightening stud 39 is used to tightly sandwich the bottom horizontal edge 23 of the upper horizontal beam 22 a between the top bar 36 and the finger 40 a.
Details of a preferred bottom clamping apparatus according to the present invention are shown in FIG. 7B . A bottom clamping finger (or bar) 40 b is attached to the bottom bar 37 of the pilaster 38 by two screws 45 . The top horizontal edge 25 of the lower horizontal beam 22 b is sandwiched between the finger 40 b and the bottom bar 37 to secure the pilaster 38 to the frame.
The storage system according to the present invention includes the clamping attachments described in FIGS. 7 , 7 A, and 7 B to provide for simple conversion between container storage and open slot storage, and the pilasters and the open slot storage units are preferably attached only using the clamping attachments and require no additional attaching structure.
The racks 35 used with the pilasters 38 are shown in FIG. 8 . The pilasters 38 includes vertical members 34 having vertically spaced apart holes 34 ′. The ranks 35 includes bent elements 41 which are insertable into the hold 34 ′ to attach the racks 35 to the pilasters 38 . The racks 35 further include opposing ledges 42 for carrying the containers 23 a , 32 b , and 32 c (see FIGS. 5A , 5 B, and 5 C). The multiplicity of holes 34 ′ allow adjustment of the racks 35 for different height containers.
A pair of vertical drawer elements 60 for use with slot storage sections according to the present invention are shown in FIG. 9A and a single vertical drawer element 60 according to the present invention is shown in FIG. 9B . Details of a vertical drawer element are disclosed in U.S. Pat. No. 4,657,317 incorporated by reference above. Pairs of the slot storage sections generally face each other, and handle 48 are preferably alternated on opposing drawers to allow maximum opening. The drawers include rollers carried in horizontal overhead rails 50 a and 50 b connecting opposing slot storage sections for both carrying the drawers and providing support to the document storage system 10 . The rails 50 a are attached to second top bars 52 which are preferably clamped to the upper horizontal members 22 a as shown in FIGS. 7A and 7B . The vertical drawer elements 60 further include bottom guides 56 attached to second bottom bars 54 . The bottom bars 54 are preferably clamped to the top horizontal edges of the lower horizontal beams 22 b in the same manner as shown in FIG. 7B for the pilaster 38 . The rails and top bars may be a single piece and the guides and bottom bars may also be a single piece. Because the rails 50 a and 50 b attach to the second top bars 52 in the same manner as the top bars 36 (see FIG. 7 ), the vertical draw storage and the container storage are interchangeable, and may reside side by side in a single container storage.
An end view of a storage facility including adjacent rows of the convertible media and document storage system 10 according to the present invention is shown in FIG. 10 . Commonly, the document storage system 10 is used in very large storage areas having many rows of storage. Each section has the depth D and the sections are separated by aisles providing a separation S approximately equal to the depth D. Walkways 13 are provided to access the center and top sections.
The present invention thus includes storage units, either container storage, or open slot storage, supported by hanging from a frame or other overhead support structure. Substantially all of the weight of the storage is supported in tension from the overhead structure, and while the storage may be attached to a frame at the bottom of the storage unit, such bottom attachment is primarily for stabilizing the storage unit, and does not provide substantial or required vertical support. Such method of supporting from above the storage facilitates the convertible storage system of the present invention and because columns in tension require much less strength than column in compression, the weight and size of the storage units is minimized.
While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.
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A convertible media and document storage system uses elements of common pallet rack framing and is convertible between open slot and container storage. The container storage includes pilasters hanging from horizontal beam elements of the framing, and vertically spaced apart pairs of adjustable wireform racks engage the pilasters and provide horizontal ledges for supporting containers of various sizes. The use of hanging pilasters minimizes strength and material requirements. The open slot storage includes tall vertical drawers riding on overhead rails attachable to the same horizontal beam elements and individually horizontally drawn for access to the stored material such as data tape and disk media. The storage system optimizes utilization of space and allows large facilities to reconfigure storage between open slot and container storage when demands change.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of International Application No. PCT/US04/37743 filed on Nov. 12, 2004, which designated the United States of America, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a dispenser for serially dispensing folded absorbent sheet products through an upwardly oriented opening, and more preferably relates to an improved top-dispensing paper towel dispenser.
2. Description of Related Art
Paper towel dispensers used in commercial establishments generally are wall-mounted and dispense downwardly. Dispensers in which the towels can be removed from above tend not to be dispensers as such, but rather open trays such as the INSIGHT® Counter Top Folded Towel Dispenser marketed by Kimberly-Clark. Such open tray dispensers permit users to take more than one towel at a time, and thus do not curtail waste as effectively as a dispenser in which the towels are removed one-at-a-time. Also, with most of the towels being exposed in such trays, there is a danger that a large part of the stack could get wet or otherwise contaminated by a previous user.
One-at-a-time top-dispensing dispensers, sometimes referred to as “pop-up” dispensers, are most often used for facial tissues, in which a bolt of discrete, separated tissues is dispensed one-at-a-time, although the one-at-a-time dispensing is not entirely reliable. That is, the tissues have a tendency to fall back down into the dispenser, particularly when there is a relatively small portion of the tissues remaining, such that a tissue suspended from the top opening is draped over a longer distance before resting on the remaining tissues within the dispenser. This gives rise to the disadvantage of a next user having to reach into the dispenser in order to get the tissues coming out again, which is all the more undesirable if the dispenser is in a public place.
When the tissues in such a dispenser are an interfolded stack, it is particularly difficult to prevent fallback when the height of the dispenser exceeds the length of one panel of the folded tissue. Therefore, pop-up tissue dispensers are frequently no taller than they are wide, which plays a limiting role in their capacity and increases the frequency with which they must be refilled.
Also on the market are top-dispensing cardboard boxes of “wipers” (high basis weight disposable utility towels), sold by Kimberly-Clark under the trade name WypAll®, in which two webs of interfolded and pre-perforated wipers are dispensed through a relatively large diamond-shaped opening in the top of the box. In that product, however, if it is attempted to remove a wiper from the box upwardly in a one-handed operation, the wiper being pulled does not separate from the next adjacent wiper on the same web (which is actually the third sheet in the order of dispensing, the second sheet being that on the overlapped adjacent web). It is instead necessary for the user to hold the third wiper in order to tear off the first, after which not only the second wiper but also a rather large portion of the third wiper project upwardly through the opening.
U.S. Pat. No. 5,810,200 describes a pop-up dispenser in which a single web of pre-perforated tissues may be dispensed serially, by use of a spring-loaded tab 18 that registers within each line of perforations as a tissue is being withdrawn. This patent does not appear to address the above-described fallback problems, and entails a somewhat more complicated structure to deal with the tissues being initially interconnected within the dispenser.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to address and alleviate, at least in part, the disadvantages described above in connection with the prior art, by providing a dispenser for absorbent sheet products, comprising a body that covers a stack of paper products to be disposed within the dispenser, the body comprising an opening on an upper surface thereof, in which the opening has a size and shape such that a stack of absorbent sheet products to be disposed within the dispenser and formed of at least two interfolded webs of perforated absorbent sheet material in which the perforations of one web are not aligned with the perforations of an adjacent web may be withdrawn through the opening one sheet at a time, by a user pulling on a first sheet of the one web protruding through the opening without the user needing to touch a next sheet on the adjacent web or a subsequent sheet on the one web, the next sheet on the adjacent web protruding through the opening each time a first sheet on the one web is withdrawn and detached from the one web, without the adjacent sheet falling downwardly from the opening back into the body.
The invention is embodied not only in the dispenser itself, but also in the combination of the dispenser filled with a stack of absorbent sheet products housed therein, the absorbent sheet products having a structure and arrangement particularly well suited for serial dispensing in the dispenser of the invention, as will be discussed hereinbelow in the context of several preferred embodiments.
The invention also relates to the use of a stack of interfolded absorbent sheet products as described hereinbelow, in a dispenser according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of the invention will become more apparent after reading the following detailed description of preferred embodiments of the invention, given with reference to the accompanying drawings, in which:
FIG. 1 is a perspective view showing an embodiment of a dispenser according to the present invention;
FIG. 2 is a view showing how the dispenser of FIG. 1 opens for loading of absorbent sheet products therein;
FIG. 3 is a cross sectional view of the dispenser of FIG. 1 taken along its long side, showing a stack of paper products disposed therein;
FIGS. 4( a ) and 4 ( b ) schematically depicts two preferred interfolded arrangements of a stack of towels for use in combination with the dispenser of the invention, viewed from the short side of the FIG. 1 dispenser; and
FIG. 5 is a fragmentary sectional view showing a preferred shape of the dispenser top opening.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 1 , the dispenser 1 is generally parallelepiped in shape, comprising four sides and a top, housing as it does a rectangular stack of absorbent sheet products. The dispenser need not have a bottom, as the stack of absorbent sheet products could simply rest directly on a countertop; however, that possibility is less preferred to a dispenser that includes its own bottom, as shown in the depicted embodiments.
The dispenser includes an opening 2 in its top, which in this embodiment is generally circular. The shape of the opening is not critical, although circular is preferred. The opening could also be of octagonal shape, or of oblong shape, for example. It is preferred that the aspect ratio of the opening not exceed about 5:1, that is, that the opening not have a long dimension greater than about five times its shorter dimension.
It has been found that the area of the opening contributes to the one-at-a-time operation of the dispenser while preventing fallback of the paper towel stack disposed therein. In particular, it is preferred that the opening has a surface area in the range from about 0.78 in 2 to about 2.40 in 2 , with a surface area of about 1.10 in 2 being particularly preferred. Tests on prototype dispensers having openings in this range of surface areas, using paper towel stacks as described hereinbelow, confirmed that one-handed serial dispensing could be performed consistently, and without fallback of the towels, even when the stack of towels was nearing the end.
It should be noted that the fallback avoidance provided according to the invention can be achieved without resorting to the use of a spring plate or other means urging the stack of towels upwardly within the dispenser. Thus, although the possible presence of such urging means is not disclaimed unless an appended claim so states, nevertheless, the structure of the inventive dispensers is such that urging means of this type are not essential.
The term Aabsorbent sheet products@ as used herein embraces not only paper products such as paper towels, but also absorbent nonwoven materials not normally classed as papers or tissues. Such nonwoven materials include pure nonwovens and hybrid nonwoven/pulp webs.
In FIG. 2 , the dispenser is shown open for receiving a fresh stack of absorbent sheet products therein. As can be seen in FIG. 2 , the dispenser is preferably formed of two main parts, each of which is preferably injection molded plastic. The front part 3 includes the top and front side, whereas the rear part 4 includes the bottom and the three other sides. The front part is pivotally connected to the rear part via integrally molded pins (not shown) received in corresponding openings 5 on the rear part. Integrally molded tabs 6 depend downwardly from the rear of the top side, and snap fit into corresponding openings 7 formed toward the rear of the side walls of the rear part 4 , by virtue of the intrinsic resiliency of the plastic material and the thinned webs with which the tabs 6 are connected to the front part 3 .
Another aspect relevant to the one-handed serial dispensing is that the dispenser not lift off the surface of the countertop when a towel is being withdrawn. One way of avoiding this is by gluing or otherwise fastening the container body to the countertop. However, the inventors' experimentation has shown that the container will be intrinsically heavy enough not to lift off a countertop surface, when its weight is at least about 24 oz. If the dispenser body does not already have at least that much weight, it can be made heavier, for example, by placing a metal plate in its bottom.
In FIG. 3 , the dispenser is shown with a stack of interfolded paper towels disposed therein, according to an embodiment of the dispenser/absorbent sheet combination of the present invention. The stack 8 terminates upwardly in a sheet 9 that is projecting outwardly through the opening 2 , but which remains attached via tabs 15 to the web of which it forms a part.
FIG. 4( a ) shows an example of a paper towel stack preferred for use in the present invention. This can be a stack such as is sold commercially by SCA Tissue North America under the trade name “Tork Xpress Plus, 3-panel.” In that product, each web is a two-ply series of interconnected towels in which each ply has a basis weight of about 13 lb per 3000 square feet, for an aggregate basis weight of about 26 lb. Alternatively, it is contemplated that each web may be a one-ply TAD (through-air dried) web having a basis weight of about 24 lb. More generally, it is contemplated that the towels for use in combination with the dispenser according to the invention will have a basis weight in the range form about 10 to about 40 lb per 3000 square feet.
FIG. 4( a ), like FIG. 4( b ), is exaggerated to show the interfolding of the dual webs. Whereas FIG. 4( a ) shows only six absorbent sheets for ease of understanding, in reality a pack of towels having that interfold structure might typically include 144 towels in a 5.5″ tall stack.
The dispenser itself of this embodiment has an interior height of about 6.5″, such that there is about a one-inch gap from the opening 2 to the top of the fresh stack 8 of towels loaded therein. The length of the panel (short horizontal dimension of the stack 8 ) in this embodiment is 3¼″, with the corresponding interior depth of the dispenser being slightly larger, about 3.625″. The width of the sheets (long horizontal dimension of the stack 8 ) is about 9 inches in this embodiment, with the corresponding interior dimension of the dispenser 1 being about 9½″.
As can be seen in FIG. 4( a ), the stack is formed from two interfolded webs 10 and 11 . Each web is continuous, in the sense that perforations or tabs interconnect all adjacent sheets within a given web. In the cross sectional view, the adjacent sheets within each web 10 , 11 are shown separately for ease of understanding, but it is understood that the gaps between adjacent sheets on a given web thus merely fall between tabs in the sectional plane of the figure. In FIG. 4( a ), it can be seen that each sheet, e.g. 9 a , on a first web 10 overlaps by about 1½ panel lengths with the next sheet, e.g. 9 b , on the adjacent web, which in turn overlaps about 1½ panel lengths with the subsequent sheet 9 c on the first web.
A peculiarity of the three-panel towel of FIG. 4( a ) in combination with a 1½ panel overlap between the adjacent webs, is that, whereas the sheet 9 a , 9 c of web 10 truly have three panels, the sheets 9 b of web 11 actually have four panels with the end panels being half the length of the middle panels.
The sheets of the adjacent webs 10 and 11 can overlap to a greater or lesser extent, although it is preferred that they overlap by greater than one panel length. The sheets in the depicted embodiments are all of the same size on both webs, but it is possible, although less preferred, that the sheets could be of different lengths on different webs, or even of different lengths on a given web. Whatever the sheet lengths, however, the perforations of two consecutive sheets on adjacent webs should not be in alignment with one another.
In use, the dispenser 1 is loaded with a stack 8 of paper towels or other absorbent sheet product, with the dispenser open as in FIG. 2 . Owing to the rather small size of opening 2 , it is preferred to feed the first sheet 9 up through the opening 2 with the dispenser open, and then to close it, to achieve the starting condition shown in FIG. 3 . The sheets may thereafter be withdrawn serially in a one-handed manner. In particular, with reference to FIG. 4( a ), after a first sheet 9 a is fed up through the opening 2 , the sheet 9 a is grasped by a user and pulled upwardly. The overlapping relationship between webs 10 and 11 causes the two webs to be pulled up together toward and through the opening, such that the frictional force opposing withdrawal causes the tabs interconnecting sheets 9 a and 9 c of web 10 to sever only after sheet 9 b is projecting a sufficient distance through opening 2 as to be easily grasped by a next user, and as not to fall back down into the housing of the dispenser 1 . The size and shape of the opening 2 according to the invention ensures that the withdrawal is not so easy that the tabs do not break between sheets 9 a and 9 c , but not so hard that the tabs break prematurely or that the sheet tears somewhere other than at the tabs.
In FIG. 4( b ), a four-panel towel stack is shown, in which the towels of adjacent webs overlap by two panels. This embodiment is otherwise the same as that of FIG. 4( a ), except that a four-panel stack of the same height as a three-panel stack provides only 108 panels for the same height as 144 towels in the three-panel stack.
FIG. 5 shows a fragmentary cross section of the opening 2 . FIG. 5 emphasizes that the underside of the opening 2 , which is the region of greatest frictional contact between the towels 9 being withdrawn and the dispenser, is preferably formed as a gradually rounded surface so as to minimize resistance to pulling as the towels 9 are withdrawn. A more abrupt corner would not necessarily disable the serial one-handed operation, which is more a function of the area of the opening, but would likely result in a less smooth and pleasing fell to the user as the towels are withdrawn.
While the present invention has been described in connection with various preferred embodiments thereof, it is to be understood that those embodiments are provided merely to illustrate the invention, and should not be used as a pretext to limit the scope of protection conferred by the true scope and spirit of the appended claims.
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A pop-up type dispenser is provided for paper towels, in which a specially sized and shaped hole in the dispenser top cooperates with a stack of paper towels housed in the dispenser. The towel stack has at least two interfolded webs of perforated absorbent sheet material in which the perforations of one web are not aligned with the perforations of an adjacent web. The towels may be withdrawn through the opening one sheet at a time, by a user pulling on a first sheet of said one web protruding through said opening without needing to touch a next sheet on the adjacent web or a subsequent sheet on the one web.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based upon and claims the benefit of priority of the prior Japanese Patent Application No. 2008-330700, filed on Dec. 25, 2008, the entire contents of which are incorporated herein by reference.
FIELD
[0002] The embodiments discussed herein are related to techniques for managing logical volumes in storage devices.
BACKGROUND
[0003] Storage virtualization is known as a technique for centrally managing storage volumes of multiple storage devices included in a system as virtual volumes. According to the storage virtualization technique, arbitrary areas carved from multiple volumes in storage devices are defined as virtual volumes. Such virtual volumes provide a host system (an upper system) or the like requesting storage resources with a requested storage capacity at a requested time.
[0004] In the following, such virtual volumes will be described with reference to FIG. 15 . FIG. 15 illustrates a conventional system for providing virtual volumes to host systems.
[0005] The system illustrated in FIG. 15 includes a plurality of storage devices 200 ( 200 a to 200 d ), a plurality of host systems 300 ( 300 a to 300 c ), and a plurality of virtualization devices connected between the storage devices 200 and the host systems 300 . In such a system (hereinafter referred to as a virtualized system), a virtual switch 100 registers storage volumes of the storage devices 200 a to 200 d as LUNs (logical unit numbers) 201 a to 201 g . Further, the virtual switch 100 provides the host systems 300 a to 300 c with these LUNs 201 a to 201 g as virtual volumes (VLUN (virtual logical unit numbers)) 301 a to 301 c , respectively, each having a specified capacity. This causes each of the host systems 300 a to 300 c to recognize the storage volumes configured with the multiple LUNs as a single volume. Data written to the virtual volumes are substantially written to the storage volumes of the storage devices that constitute the virtual volumes.
[0006] According to the system described above, when the capacity of each of the storage devices is 1 Tbyte, and the capacity requested by one of the host systems is 1.5 Tbytes, it does not need to allocate two or more storage devices to the host system. In this case, the virtual switch combines three 0.5-Tbyte LUNs to be provided to the host system as one volume of 1.5 Tbytes.
[0007] Techniques related to the technique which will be discussed include a data processing system, a data processing method, and a storage apparatus. According to the system, when a failure occurs in a part of a plurality of first memory areas and there is no spare second memory area to migrate data in the faulty part of the first memory areas, another part of the first memory areas is dynamically reserved as a second memory area. There is Japanese Laid-open Patent Publication No. 2008-009767 as a reference document.
[0008] However, in order to overcome degradation of storage devices in such a virtualized system as illustrated in FIG. 15 , hot spare storage devices may be prepared for the individual storage devices to maintain redundancy. That is, when the scale of the virtualization system increases, the number of storage devices increases. Proportionally to the increase in the number of storage devices, the number of requested hot spare storage devices also increases. In addition, the storage capacity of a hot spare storage device needs to be larger than that of a corresponding storage device. Thus, the amount of storage resources that may not be effectively used increases with increasing capacity of each storage device in a virtualized system.
SUMMARY
[0009] According to an aspect of the embodiment, a storage area managing apparatus for managing a plurality of storage drive groups each of which has a plurality of storage drives providing redundancy for each other, the storage area managing apparatus includes a managing unit for managing a plurality of logical volumes provided by the plurality of storage drive groups for storing the data redundantly, a rebuilding controller for generating recovery data, when at least one of the storage drive groups is degraded on the basis of the data stored in the degraded storage drive group, and generating a selected logical volume on the basis of the capacity of the recovery data, the rebuilding controller controlling the management unit for managing first logical volumes to correspond to a part of the plurality of storage drive groups except for the degraded storage drive group, and a first transferring unit for transferring the recovery data to the part of the plurality of storage drive groups as indicated by the selected logical volume.
[0010] The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.
[0011] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF DRAWINGS
[0012] FIG. 1 illustrates a virtualized system.
[0013] FIG. 2 illustrates a functional configuration of a virtualized system.
[0014] FIG. 3 illustrates an outline of operations of a virtualized system according to an embodiment.
[0015] FIG. 4 illustrates an outline of operations of a virtualization switch.
[0016] FIG. 5 illustrates a bitmap table.
[0017] FIG. 6 is a flowchart illustrating an overall operation procedure in a virtualized system according to an embodiment.
[0018] FIG. 7 is a flowchart illustrating the overall operation procedure in the virtualized system.
[0019] FIG. 8 is a flowchart illustrating an operation procedure of free capacity verification processing.
[0020] FIG. 9 is a flowchart illustrating an operation procedure of hot spare space candidate selection processing.
[0021] FIG. 10 is a flowchart illustrating an operation procedure of hot spare space candidate selection processing.
[0022] FIG. 11 is a flowchart illustrating an operation procedure of data copying to a copying destination virtual volume.
[0023] FIG. 12 illustrates a bitmap table corresponding to a virtual volume in which a hot spare space has been set.
[0024] FIG. 13 illustrates a bitmap table corresponding to a virtual volume in which the setting of the hot spare space has been released.
[0025] FIG. 14 is a flowchart illustrating processing of copying of data which has been written to a copying source virtual volume.
[0026] FIG. 15 illustrates a conventional system providing virtual volumes to host system.
DESCRIPTION OF EMBODIMENTS
[0027] In the following, a preferred embodiment of the present technique will be described with reference to the drawings. Firstly, a virtualized system according to the present embodiment and hardware configurations of devices constituting the system will be described. FIG. 1 illustrates a virtualized system according to the present embodiment.
[0028] As illustrated in FIG. 1 , the virtualized system according to the present embodiment includes a virtualization switch 10 , a plurality of storage devices 20 (storage devices 20 A and 20 B), and a host system 30 .
[0029] The virtualization switch (storage area managing apparatus) 10 comprises hardware components including a CPU 101 , a memory 102 , a port 103 a , a port 103 b , and a port 103 c . The port 103 a is an input/output interface for the storage device 20 A. The port 103 b is an input/output interface for the storage device 20 B. The port 103 c is an input/output interface to the host system 30 .
[0030] Each of the storage devices 20 A and 20 B comprises hardware components including a CPU 214 and a memory 202 . The storage device 20 A includes a port 203 a which is an input/output interface for the virtualization switch 10 . The storage device 20 A also includes RAID (Redundant Array of Inexpensive Disks) groups (storage drive groups) A- 0 , A- 1 , and A- 2 each including a plurality of disk drives. The storage device 20 B includes a virtualization port 203 b which is an input/output interface for the virtualization switch 10 and RAID groups B- 0 and B- 1 each including a plurality of disk drives. Note that the multiple disk drives in the RAID groups provide redundancy to each other. Although the disk drives in each of the RAID group are configured as RAID 5 in the present embodiment, any other configurations may be applied as long as multiple disk drives provide redundancy to each other (e.g., RAID 1 ).
[0031] The host system 30 comprises hardware components including a CPU 314 , a memory 302 , and a host bus adapter 303 serving as an input/output interface for the virtualization switch 10 .
[0032] In the following, functional configurations of the individual devices in the virtualized system according to the present embodiment will be described. FIG. 2 illustrates a functional configuration of the virtualized system according to the present embodiment.
[0033] As illustrated in FIG. 2 , in the virtualized system according to the present embodiment, the virtualization switch 10 includes functional components including a virtual target 105 , a virtualization controller 106 (including a managing unit, a rebuilding controller, a first transferring unit, and a second transferring unit), a virtualization pool 107 , and a bitmap table 108 . Each of the storage devices 20 includes a RAID controller 204 as a functional component. Note that the individual functions in the virtualization switch 10 and the storage devices 20 are substantially realized by the CPUs provided therein. In addition, disk volumes in each of the storage devices 20 are presented as LUNs or logical volumes. The storage device 20 A contains logical volumes of the RAID group A- 0 (LUN 0 and LUN 1 ), logical volumes of the RAID group A- 1 (LUN 0 , LUN 1 , and LUN 2 ), and logical volumes of the RAID group A- 2 (LUN 0 , LUN 1 , and LUN 2 ). The storage device 20 B contains logical volumes of the RAID group B- 0 (LUN 0 , LUN 1 , LUN 2 , and LUN 3 ) and logical volumes of the RAID group B- 1 (LUN 0 , LUN 1 , and LUN 2 ).
[0034] The virtual target 105 in the virtualization switch 10 is a virtual interface adapter for causing the host system 30 to recognize virtual volumes which will be described below. The virtualization pool 107 is a virtual area into which a LUN in the storage devices 20 connected to the virtualization switch 10 is to be loaded. In copying of a virtual volume described below, the virtual volume is partitioned into area, and the bitmap table 108 serves to store records as to whether or not each of the partitioned areas of a virtual volume has been copied. The virtualization controller 106 manages and controls the LUNS using the virtual target 105 and the virtualization pool 107 . In addition, using the bitmap table 108 , the virtualization controller 106 manages the status of the progress of copying of data in a virtual volume. The RAID controller 204 in each of the storage devices 20 manages the multiple disk drives contained in the storage device as RAID groups having redundancy and on the basis of the RAID groups constructs logical volumes having arbitrary capacities as LUNs.
[0035] Now, an outline of operations of the virtualized system according to the present embodiment will be described with reference to FIG. 3 .
[0036] As illustrated in FIG. 3 , a RAID group 205 in the storage device 20 A becomes degraded due to failure of a disk drive belonging to the RAID group 205 , for example, the RAID controller 204 requests the virtualization switch 10 for a hot spare (HS) space 21 . In response to the request, the virtualization switch 10 selects and reserves LUN 21 a and LUN 21 b which belong to a RAID group other than the degraded RAID group 205 for the hot spare space 21 . Further, the virtualization switch 10 sends the reserved hot spare space 21 (the address of the LUNs constituting the hot spare space 21 ) to the RAID controller 204 of the storage device 20 A as a response to the request. Upon receiving the hot spare space 21 , the RAID controller 204 transfers rebuilding data (recovery data) to the virtualization switch 10 . This rebuilding data is data reconstructed from data stored in a normal disk drive in the RAID group 205 to which the fault disk drive belongs and corresponding parity data. Using this rebuilding data, the degraded RAID group is rebuilt. Further, upon receiving the rebuilding data, the virtualization switch 10 transfers the rebuilding data to the LUN 21 a and LUN 21 b which have been set as the hot spare space 21 . When the fault disk drive is recovered, the rebuilding data transferred and written to the hot spare space 21 is written back to the recovered disk drive by copyback processing. In the following description, the above-described processing is referred to as “rebuilding”. In the manner described above, RAID redundancy of a RAID group to which a fault disk drive belongs may be maintained by writing rebuilding data to a virtual hot spare space.
[0037] Now, an outline of operations of the virtualization switch 10 in the virtualized system will be described. FIG. 4 illustrates an outline of operations of the virtualization switch 10 . FIG. 5 illustrates a bitmap table. Note that in FIG. 4 , individual LUNS are distinguished from each other by providing RAID volumes names to the LUNs such as a LUN 0 (A- 0 ).
[0038] As illustrated in FIG. 4 , the virtualization controller 106 of the virtualization switch 10 registers all LUNs of the storage devices 20 connected thereto in the virtualization pool 107 . At this time, each LUN is provided with a hot spare attribute (first attribute information). This hot spare attribute is represented by “2”, “1”, or “0”. “2” indicates that the LUN is dedicated for use as a hot spare space. “1” indicates that the LUN is available for use as a hot spare space. “0” indicates that the LUN is not to be used as a hot spare space.
[0039] The virtualization controller 106 may combine two or more of the registered LUNs and defines them as one virtual volume. The virtualization controller 106 may also partition one LUN into a plurality of parts to be defined as virtual volumes. Among the defined virtual volumes, a virtual volume 0 which is allocated to a host is recognized by the host system 30 via the virtual target 105 . Note that the virtual target 105 is a virtual port, and a plurality of such ports may be created regardless of the number of the physical ports 103 of the virtualization switch 10 . The virtualization controller 106 includes a replication function for mirroring the content of the virtual volume 0 ( 109 ) recognized by the host system 30 onto a virtual volume 1 ( 110 ) which is set as a copying destination (copying destination virtual volume). In such a copying destination virtual volume, either a “copying destination priority flag” or a “rebuilding priority flag” is set as attribute information (second attribute information). When a “copying destination priority flag” is set in a copying destination virtual volume, the copying destination virtual volume is not to be set as a hot spare space. On the other hand, when a “rebuilding priority flag” is set, the copying destination virtual volume may be set as a hot spare space. Further, the virtualization controller 106 includes a function of duplicating data from a LUN defined as a virtual volume in one of the storage devices 20 to a LUN in another one of the storage devices 20 . A virtual volume 2 ( 111 ) is a volume which has neither been allocated by the host nor defined as a copying destination volume.
[0040] In data copying between virtual volumes by means of the functions described above, the virtualization switch 10 uses the bitmap table 108 . As mentioned above, the bitmap table 108 is a table for storing records as to whether or not data in each of the partitioned fields in the virtual volume 0 , serving as the copying source, has been copied to the corresponding fields in virtual volume 1 serving as the copying destination. As illustrated in FIG. 5 , each record is represented by a flag value, and “1” indicates that data has not been copied at a corresponding field (uncopied) and “0” indicates that data has been copied. Using the flag values (“0” and “1”), the virtualization controller 106 determines the status of progress of copying data to the corresponding fields.
[0041] In the following, overall operations of the virtualized system according to the present embodiment will be described. FIG. 6 and FIG. 7 are flowcharts each illustrating a procedure of the overall operations of the virtualized system according to the present embodiment.
[0042] At Operation S 101 , the RAID controller 204 of the storage device 20 A or the storage device 20 B determines whether RAID degradation has occurred in disk drives in the device.
[0043] If it is determined in Operation S 101 that RAID degradation has occurred in the device, at Operation S 102 the RAID controller 204 determines whether there is a data area used for rebuilding in the device. That is, it is determined whether there is a sufficient capacity for performing restoration of a disk drive causing the RAID degradation (capacity equal to or larger than the size of the rebuilding data).
[0044] If it is determined in Operation S 102 that there is no data area used for rebuilding in the device, at Operation S 103 the RAID controller 204 sends the virtualization controller 106 of the virtualization switch 10 a request for a hot spare space as a data area allowing rebuilding.
[0045] In response to the request, at Operation S 104 , the virtualization controller 106 performs free capacity verification processing which will be described below. At Operation S 105 , the virtualization controller 106 determines whether there is free capacity for rebuilding, for each of all LUNs registered in the virtualization pool 107 .
[0046] When it is determined in Operation S 105 that there is free capacity for rebuilding, the virtualization controller 106 performs hot spare space candidate selection operation at Operation S 106 , which will be described below, to determines if there is a candidate for a hot spare space at Operation S 107 .
[0047] If it is determined in Operation S 107 that there is a candidate for a hot spare space, at Operation S 108 the virtualization controller 106 sends the RAID controller 204 hot spare volume information corresponding to a reserved hot spare space, as a response to the request.
[0048] Upon receiving the response, the RAID controller 204 transfers rebuilding data to the virtualization controller 106 at Operation 109 , and determines whether the transfer of the rebuilding data has been completed at Operation S 111 . At Operation S 110 , the virtualization controller 106 sends the rebuilding data transferred from the RAID controller 204 to the hot spare space and writes the rebuilding data to a LUN that has been reserved for the hot spare space. Note that the status of progress of data writing to the hot spare space is managed by a storage device that contains the LUNs constituting the virtual volume 1 .
[0049] If it is determined in Operation S 111 that the transfer of the rebuilding data has been completed, the RAID controller 204 notifies the virtualization controller 106 of the completion of rebuilding data transfer at Operation S 112 . Then, at Operation S 114 , the RAID controller 204 determines whether the fault disk drive has been recovered by replacement or the like, i.e., whether the degraded RAID group has been rebuilt. Having received the notification, at Operation S 113 , the virtualization controller 106 saves the rebuilding data written to the hot spare space until a request is received.
[0050] If it is determined in Operation S 114 that the fault disk has been recovered, at Operation S 115 the RAID controller 204 requests the virtualization controller 106 for the rebuilding data.
[0051] Upon receiving the request for the rebuilding data, at Operation S 116 the virtualization controller 106 transfers the rebuilding data saved in the hot spare space to the RAID controller 204 . Specifically, the virtualization controller 106 sends the storage device that contains the LUN which has been reserved for the hot spare space a request for the rebuilding data and transfers the requested rebuilding data to the RAID controller 204 of the storage device to which the degraded RAID group belongs.
[0052] Upon receiving the rebuilding data, at Operation S 117 the RAID controller 204 performs copyback of the rebuilding data to the recovered disk. In other words, data is restored by writing the rebuilding data back to the recovered disk. Subsequently, at Operation S 118 , the RAID controller 204 determines whether the copyback has been completed.
[0053] If it is determined in Operation S 118 that the copyback has been completed, at Operation S 119 the RAID controller 204 notifies the virtualization controller 106 of the completion of the copyback.
[0054] Upon receiving the notification, the virtualization controller 106 releases the hot spare space at Operation 5120 .
[0055] If it is determined in Operation S 118 that the copyback has not been completed, at Operation S 117 the RAID controller 204 continues the copyback of the rebuilding data to the recovered disk.
[0056] If it is determined in Operation S 114 that the fault disk has not been recovered, the RAID controller 204 again determines if the fault disk has been recovered at Operation 5114 .
[0057] If it is determined in Operation S 111 that the transfer of the rebuilding data has not been completed, the RAID controller 204 again transfers the rebuilding data to the virtualization controller 106 at Operation S 109 .
[0058] If it is determined in Operation 5107 that there is no candidate for a hot spare space, the virtualization controller 106 terminates the operation procedure.
[0059] If it is determined in Operation S 105 that there is no free capacity used for rebuilding, the virtualization controller 106 terminates the operation procedure.
[0060] It is determined in Operation S 102 that there is a data area for rebuilding in the device, the RAID controller 204 performs reconstruction processing in the device at Operation S 121 and notifies the virtualization controller 106 of the completion of the reconstruction processing at Operation S 122 . Note that in this reconstruction processing, data is reconstructed from a normal disk drive in the device without using a hot spare space, stored in a data space for rebuilding set in the device, and then written back to the disk drive.
[0061] If it is determined in Operation S 101 that no RAID degradation has occurred in the device, the RAID controller 204 again determines whether RAID degradation has occurred in RAID groups in the device at Operation S 101 .
[0062] In the following, free capacity verification processing will be described. FIG. 8 is a flowchart illustrating a procedure of free capacity verification processing.
[0063] At Operation S 201 , the virtualization controller 106 verifies the total capacity of LUNs which have not been used (which have not been allocated to a virtual volume) (unallocated LUNs) among the LUNs registered in the virtualization pool 107 . Then, at Operation S 202 , the virtualization controller 106 determines whether the capacity of the unallocated LUNs is equal to or larger than a capacity used for rebuilding.
[0064] If it is determined in Operation S 202 that the total capacity of the unallocated LUNs is smaller than the capacity used for rebuilding, at Operation 203 the virtualization controller 106 determines whether there is a virtual volume which has not been used (which has neither been allocated to the host system 30 nor set as a copying destination) (an allocated virtual volume).
[0065] If it is determined in Operation 203 that there is an unallocated virtual volume, at Operation S 204 the virtualization controller 106 determines whether the capacity of the unallocated virtual volume is equal to or larger than the capacity used for rebuilding.
[0066] If it is determined in Operation S 204 that the capacity of the unallocated virtual volume is smaller than the capacity used for rebuilding, at Operation S 205 the virtualization controller 106 determines whether the sum of the total capacity of the unallocated LUNs and the capacity of the unallocated virtual volume (combined capacity) is equal to or larger than the capacity used for rebuilding.
[0067] If it is determined in Operation S 205 that the combined capacity is smaller than the capacity used for rebuilding, at Operation S 206 the virtualization controller 106 determines if there is a virtual volume serving as a copying destination in which a “rebuilding priority” flag has been set (copying destination volume).
[0068] If it is determined in Operation S 206 that there is a copying destination volume with a “rebuilding priority” flag, at Operation S 207 the virtualization controller 106 determines whether the capacity of the copying destination volume with the “rebuilding priority” flag is equal to or larger than the capacity used for rebuilding.
[0069] If it is determined in Operation S 207 that the total capacity of the copying destination volume with the “rebuilding priority” flag is smaller than the capacity used for rebuilding, at Operation S 208 the virtualization controller 106 determines that there is no free capacity to meet the request from the RAID controller 204 .
[0070] On the other hand, if it is determined in Operation S 207 that the total capacity of the copying destination volume with the “rebuilding priority” flag is equal to or larger than the capacity used for rebuilding, at Operation S 209 the virtualization controller 106 determines that there is free capacity to meet the request from the RAID controller 204 .
[0071] If it is determined in Operation S 206 that there is no copying destination volume with a “rebuilding priority” flag, at Operation S 208 the virtualization controller 106 determines that there is no free capacity to meet the request from the RAID controller 204 .
[0072] If it is determined in Operation S 205 that the combined volume is equal to or larger than the capacity used for rebuilding, at Operation S 209 the virtualization controller 106 determines that there is free capacity to meet the request form the RAID controller 204 .
[0073] If it is determined in Operation S 204 that the capacity of the unallocated virtual volume is equal to or larger than the capacity used for rebuilding, at Operation S 209 the virtualization controller 106 determines that there is free capacity to meet the request from the RAID controller 204 .
[0074] If it is determined in Operation S 203 that there is no unallocated virtual volume, at Operation S 206 the virtualization controller 106 determines whether there is a virtual volume serving as a copying destination in which a “rebuilding priority” flag has been set (copying destination volume).
[0075] If it is determined in Operation S 202 that the total capacity of the unallocated LUNs is equal to or larger than the capacity used for rebuilding, at Operation S 209 the virtualization controller 106 determines that there is an available capacity to meet the request from the RAID controller 204 .
[0076] As described above, when degradation of a RAID group occurs, a LUN in a RAID group other than the degraded RAID group is dynamically allocated as a hot spare space. With this arrangement, it does not need to prepare storage devices used for hot spare spaces for the individual storage devices 20 constituting the virtualized system, making it possible to efficiently use the existing resources.
[0077] In the following, hot spare space candidate selection processing will be described. FIG. 9 and FIG. 10 are flowcharts illustrating an operation procedure of hot spare space candidate selection processing.
[0078] At Operation S 301 , the virtualization controller 106 refers to the hot spare attributes of target LUNs. Note that target LUNs refer to LUNs from among which one is to be selected as a hot spare space. All LUNs except those connected to the host system 30 by the virtual target 105 such as the LUNs used as the virtual volume 0 and LUNs that belong to a degraded RAID group may be set as target LUNs. It is also possible to select target LUNs on the basis of the free capacity verification processing described above. For instance, when the result of determination in Operation S 204 is positive, LUNs in the unallocated virtual volume may be set as candidate LUNs.
[0079] Subsequently, at Operation S 302 , the virtualization controller 106 determines whether the total capacity of target LUNs of which the hot spare attributes are “2” and “1” is equal to or larger than the capacity used for rebuilding.
[0080] If it is determined in Operation S 302 that the total capacity of the target LUNs of which the hot spare attributes are “2” and “1” is equal to or larger than the capacity used for rebuilding (the size of the rebuilding data), at Operation S 303 the virtualization controller 106 determines whether the total capacity of the target LUNs with the hot spare attribute “2” is equal to or larger than the capacity used for rebuilding.
[0081] If it is determined in Operation S 303 that the total capacity of the target LUNs with the hot spare attribute “2” is equal to or larger than the capacity used for rebuilding, at Operation S 304 the virtualization controller 106 limits the target LUNs to the LUNs with the hot spare attribute “2”. Subsequently, at Operation S 305 the virtualization controller 106 selects a RAID group with the lowest utilization rate from among RAID groups containing the target LUNs. Note that the utilization rate of a RAID group is obtained by subtracting the capacity of LUNs in the RAID group which has been allocated to a virtual volume from the capacity of all LUNs in the RAID group. Further, at Operation S 306 , the virtualization controller 106 determines whether there is a plurality of such RAID groups in the multiple storage devices 20 . That is, it is determined whether there is another RAID group having the same utilization rate as the selected RAID group in the storage devices 20 .
[0082] If it is determined in Operation S 306 that there is a plurality of RAID groups having the same utilization rate in the storage devices 20 , at Operation S 307 the virtualization controller 106 selects, from among the storage devices 20 containing the selected RAID groups, the one with the lowest utilization rate. The utilization rate of a storage device is obtained by subtracting LUNs allocated to a virtual volume from all LUNs in the device. At Operation S 308 , the virtualization controller 106 determines whether two or more of the selected storage devices have the same utilization rate.
[0083] If it is determined in Operation S 308 that two or more of the selected storage devices have the same utilization rate, at Operation S 309 the virtualization controller 106 selects from among the storage devices having the same utilization rate one having the largest total capacity of unallocated LUNs. Subsequently, at Operation S 310 , the virtualization controller 106 determines whether there is a plurality of RAID groups having the same utilization rate in the selected storage device.
[0084] If it is determined in Operation S 310 that there is a plurality of RAID groups having the same utilization rate in the selected storage device, at Operation S 311 the virtualization controller 106 selects, from among the RAID groups, the one having the largest total capacity of unallocated LUNs. Subsequently, at Operation S 312 , the virtualization controller 106 determines whether there is a LUN in the selected RAID group of which the capacity is equal to or larger than the capacity used for rebuilding.
[0085] If it is determined in Operation S 312 that there is no LUN with a capacity equal to or larger than the capacity used for rebuilding, at Operation S 313 the virtualization controller 106 selects LUNs for which the number allocated thereto is the greatest from among the LUNs in the selected RAID group. Subsequently, at Operation S 314 , the virtualization controller 106 determines whether the total capacity of the selected LUNs is equal to or greater than the capacity used for rebuilding.
[0086] If it is determined in Operation S 314 that the total capacity of the selected LUNs is equal to or greater than the capacity used for rebuilding, at Operation S 315 the virtualization controller 106 defines the selected LUNs as a hot spare space.
[0087] On the other hand, if it is determined in Operation S 314 that the total capacity of the selected LUNs is smaller than the capacity used for rebuilding, at Operation S 313 the virtualization controller 106 selects a LUN for which the number allocated thereto is the largest from among the LUNs in the selected RAID group except for those which have been selected in Operation S 311 .
[0088] If it is determined in Operation S 312 that there is a LUN of which the capacity is equal to or larger than the capacity used for rebuilding, at Operation S 316 the virtualization controller 106 selects a LUN with a capacity closest to the capacity used for rebuilding. This makes it possible to allocate a LUN with the minimum capacity to a hot spare space.
[0089] If it is determined in Operation S 310 that there is not a plurality of RAID groups having the same utilization rate in the selected storage device (NO, in Operation S 310 ), the virtualization controller 106 executes the processing of Operation S 312 .
[0090] If it is determined in Operation S 308 that the selected storage devices do not include two or more storage devices having the same utilization ratio, the virtualization controller 106 performs the processing of Operation S 310 .
[0091] If it is determined in Operation S 306 that there is not a plurality of RAID groups having the same utilization rate in the multiple storage devices 20 , the virtualization controller 106 performs the processing of Operation S 310 .
[0092] If it is determined in Operation S 303 that the total capacity of the target LUNs of which the hot spare attributes is “2” is smaller than the capacity used for rebuilding, at Operation S 317 the virtualization controller 106 sets LUNs of which the hot spare attributes are “2” and “1” as target LUNs.
[0093] If it is determined in Operation S 302 the total capacity of the target LUNs of which the hot spare attributes are “2” and “1” is smaller than the capacity used for rebuilding, at Operation S 318 the virtualization controller 106 determines that there is not a candidate for a hot spare area and terminates the operation procedure.
[0094] As described above, in selection of a LUN to be used as a hot spare space, the virtualization controller 106 preferentially selects a LUN in a RAID group with a low utilization rate or a LUN in a storage device with a low utilization rate. This permits defining of a hot spare space with minimum influence on normal operations. In addition, the virtualization controller 106 selects a LUN to be used as a hot spare space on the basis of the attribute allocated to the LUN. This makes it possible to exclude a LUN which would cause inconvenience when used as a hot spare space from the candidates for the hot spare space.
[0095] In the following, processing to be performed when a LUN in a virtual volume serving as a copying destination, such as a virtual volume 1 illustrated in FIG. 4 , is set as a hot spare space. FIG. 11 is a flowchart illustrating an operation procedure of copying of data to a virtual volume serving as a copying destination virtual volume. FIG. 12 illustrates a bitmap table corresponding to a virtual volume in which a hot spare space is set. FIG. 13 illustrates a bitmap table corresponding to a virtual volume in which the setting of the hot spare space has been released. In the following description with reference to FIG. 11 to FIG. 13 , a copying destination virtual volume is called the virtual volume 1 as in FIG. 4 . Likewise, a virtual volume serving as a copying source is called the virtual volume 0 . In FIG. 11 , it is assumed that either one of LUNs constituting the virtual volume 1 has been set as a hot spare spaces.
[0096] As illustrated in FIG. 11 , at Operation S 401 the virtualization controller 106 determines whether data has been written to the virtual volume 0 .
[0097] If it is determined in Operation S 401 that data has been written to the virtual volume 0 , at Operation S 402 the virtualization controller 106 determines whether data copying to the virtual volume 1 is suspended.
[0098] If it is determined in Operation S 402 that copying to the virtual volume 1 is not being suspended, at Operation S 403 the virtualization controller 106 determines whether or not a copying destination in the virtual volume 1 is a hot spare space. More specifically, in the bitmap table 108 corresponding to the virtual volume 1 , fields corresponding to a region to which the data is to be copied are referred to, so that it is determined if the copying destination is included in the hot spare space. Fields corresponding to a region set as the hot spare space are each forcedly fixed to “1” indicating that no data has been copied thereto (not copied). Writing and copying of data to the region corresponding to the bit fields fixed to “1” is inhibited until the setting of the hot spare space is released. To define a hot spare space in the bitmap table 108 , it is possible to employ a technique in which another bitmap table 108 is prepared and fields corresponding to an undefined region are each set to “0” and fields corresponding to a region defined as a hot spare space are each set to “1”. This technique allows the virtualization controller 106 to determines whether or not a field is included in a hot spare space by adding flags in corresponding bit fields in the two bitmap tables 108 . Specifically, a field may be determined to be included in a hot spare space when the sum of corresponding flags is 2 and may be determined to be included in an undefined region when the sum is equal to or less than 1.
[0099] If it is determined in Operation S 403 that the copying destination in the virtual volume 1 is not a hot spare space, at Operation S 404 the virtualization controller 106 copies data in the virtual volume 0 to the virtual volume 1 . When the copying is completed, the procedure returns to Operation S 401 and the virtualization controller 106 again determines whether data has been written to the virtual volume 0 .
[0100] If it is determined in Operation S 403 that the copying destination in the virtual volume 1 is a hot spare space, at Operation s 405 the virtualization controller 106 skips the hot spare space. Subsequently, at Operation S 401 the virtualization controller 106 again determines whether data has been written to the virtual volume 0 .
[0101] If it is determined in Operation S 402 that the copying to the virtual volume 1 is being suspended, at Operation S 406 the virtualization controller 106 updates the bitmap table 108 with respect to the fields to which the data has been written to the virtual volume 0 . Then, the procedure returns to Operation S 401 and the virtualization controller 106 again determines whether data has been written to the virtual volume 0 .
[0102] If it is determined in Operation S 401 that no data has been written to the virtual volume 0 , the virtualization controller 106 again determines whether data has been written to the virtual volume 0 at Operation S 401 .
[0103] As described above, an undefined region and a region defined as a hot spare space are managed and distinguished using the bitmap table 108 . This allows the virtualization controller 106 to write data in a copying source virtual volume and rebuilding data to a copying destination virtual volume.
[0104] Now, processing of copying data which has been written to a copying source virtual volume will be described. This processing includes copying of data corresponding to a released hot spare space from a copying source virtual volume to a copying destination virtual volume. FIG. 14 illustrates an operation procedure of copying processing of data which has been written to the copying source virtual volume. In the following description with reference to FIG. 14 , as in the description with reference to FIG. 11 , a copying destination virtual volume is called the virtual volume 1 and a copying source virtual volume is called the virtual volume 0 .
[0105] At Operation S 501 , the virtualization controller 106 determines whether data copying to the virtual volume 1 is suspended.
[0106] If it is determined in Operation S 501 that copying to the virtual volume 1 is not suspended, at Operation S 502 the virtualization controller 106 refers to the bitmap table 108 to determine whether there is a field to which no data has been copied (uncopied field). Note that when a hot spare space is released, flags of the fields in the bitmap table 108 corresponding to the released hot spare space are set to “1”, so that the fields are recognized as an uncopied region. That is, the released hot spare space is included in the uncopied region.
[0107] If it is determined in Operation in Operation S 502 that there is an uncopied field, at Operation S 503 the virtualization controller 106 reads data corresponding to the uncopied field from the virtual volume 0 and writes the read data to the virtual volume 1 at Operation S 504 . Then, the procedure returns to Operation S 501 and the virtualization controller 106 again determines whether data copying to the virtual volume 1 is suspended.
[0108] On the other hand, if it is determined in Operation S 502 that there is no uncopied field, the procedure returns to Operation S 501 and the virtualization controller 106 again determines whether data copying to the virtual volume 1 is suspended.
[0109] If it is determined in Operation S 501 that data copying to the virtual volume 1 is suspended, at Operation S 505 the virtualization controller 106 updates the bitmap table 108 with respect to the fields to which data has been copied from the virtual volume 0 to the virtual volume 1 . Then, the procedure returns to Operation S 501 and the virtualization controller 106 again determines whether data copying to the virtual volume 1 is suspended.
[0110] As described above, when a hot spare space is released, the flags in the fields corresponding to the released hot spare space in the bitmap table 108 are set to “1”. Thus, copying of data to the released hot spare space is resumed.
[0111] The present technique may be embodied in various modifications without departing from the essence or essential characteristics thereof. Thus, the embodiment described above is merely illustrative in all respects and should not be restrictively construed. The scope of the present technique is defined by the appended claims but not restrained by the specification at all. Further, modifications, improvements, substitutions, and reformations belonging to the equivalent of the scope of the claims are all within the scope of the present technique.
[0112] According to the present technique, effective use of storage resources may be achieved in allocation of hot spare space in a system.
[0113] All examples and conditional language recited herein are intended for pedagogical purposes to aid the reader in understanding the invention and the concepts contributed by the inventor to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions, nor does the organization of such examples in the specification relate to a showing of the superiority and inferiority of the invention. Although the embodiment of the present invention has been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention.
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A storage area managing apparatus includes a managing unit for managing a plurality of logical volumes provided by a plurality of storage drive groups for storing data redundantly, and a rebuilding controller for generating recovery data when at least one of the drive groups is degraded on the basis of the data stored in the degraded drive group and generating a selected logical volume on the basis of the capacity of the recovery data, the rebuilding controller controlling the management unit for managing first logical volumes to correspond to a part of the plurality of storage drive groups except for the degraded drive group. The storage area managing apparatus includes a first transferring unit for transferring the recovery data to the part of the plurality of storage drive groups as indicated by the selected logical volume.
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This is a Continuation-in-part Application of pending Application No. 07/474,516; filed on Feb. 2, 1990 (abandoned), in the name of George D. Preston.
BACKGROUND OF THE INVENTION
The present invention relates to practice device in which a ball is used, and more particularly to practice wherein a ball is struck after delivery to a player standing at a particular point.
In games utilizing a ball, including cricket, bounders, tennis, racquetball, and in particular for example, baseball, every player on a team, with some exceptions, takes a turn at striking the ball. In baseball, practice batting usually entails a pitcher throwing balls to the practice batter. Given the large number of players needing batting practice with respect to the relatively smaller number of pitchers, a typical batting practice might unduly tire or even injure pitcher's pitching arm. Therefore, the need for a suitable pitching apparatus and method for pitching is especially acute, and such a device, if available, would be of tremendous benefit for batting practice.
Art relating to the use of batting practice devices includes U.S. Pat. No. 3,540,726 to Richard S. Davis, entitled, "Batting Practice Apparatus" and discloses a rotary vertical pole having a drill-type handle to swing a horizontal member in a circle. At the end of the horizontal member, a ball flies in a circular arc within the reach of a batter U.S. Pat. No. 3,658,330 to Maestracci et al, entitled, "Device for Lawn Tennis Training" discloses a tennis ball suspended in a "Y" fashion between two poles. The player hits the ball which swings over the top and back into the player's field of play. U.S. Pat. No. 4, 127,268 to Thomas E. Lindgren, entitled, "Tethered ball and Method of Manufacture" discloses a ball tethered at the end of an elastic tape which is attached to the wrist of the player. Another device, embodied in U.S. Pat. No. 4,057,248 to William J. Stoecker, entitled, "Baseball Practice Device" includes a pair of ground engaging panels forming a pitcher's mound and batter's plate which are connected by cords to mark a known distance between the panels, for manual pitching practice. In U.S. Pat. No. 4,032,145 to Max M. Tami entitled, "Action Batter-Up Game Apparatus" a hand held rope with ball attached is swung over the trainer's head. The ball is swung into the vicinity of a trainee who attempts to strike the ball. A similar type apparatus is disclosed in U.S. Pat. No. 4,186,921 to Daniel W. Fox, entitled "Method of Making a Tethered Ball Apparatus," which discloses a whiffle type ball mounted at the end of a cord having a handle. The ball is then swung overhead, within the reach of a practice batter.
The use an elastic or resilient means for devices propelling a ball include U.S Pat. No. 2,017,720 issued to Philip Lake, entitled, "Apparatus for Practicing Ball Games" and discloses a rotatable member having an obtuse angle which is swivelable in a horizontal plane. At the upper end of the swiveling member is attached an elastic cord having a ball at its end. U.S. Pat. No. 3,788,297 to Walter Borst, entitled "Ball Pitching Device," discloses a tethered ball with the tether anchored to the ground, and a catapult type pitching apparatus to propel the ball at a batter.
British Patent No. 434,143 discloses a right angle pole which forms a suitable wicket and captive ball which, if hit by a cricket bat, will enable the ball to rebound back to the batsman. If the batsman is not vigilant in continuing to hit the ball swingable in a circle, the bails included in the apparatus will be knocked off, causing him to be out. U.S. Pat. No. 3,297,321 to V. D. Kuhnes, entitled "Baseball Batting Trainer," discloses a ball tethered at the end of a series combination of a cord, weight, and spring. The end of the spring is attached into the ground. A pitcher throws the ball at a batter, but in the event the batter strikes the ball, its range of flight is limited due to its being tethered to the ground.
In U.S. Pat. No. 3,767,198 to Ralph C. Boyer, entitled "Batting Practice Device and Method," an elastic trampoline shock cord is fixed at one end to the ground and at the other end to a cord having a ball attached. A pitcher pulls the cord and ball, releasing it in the direction of the batter. U.S. Pat. No. 3,011,784 to Angelo Segretto discloses a backstop, batter's box, and an elastic cord tethered to the back of home plate. An optional tethering pole is disclosed, which may be positioned between the pitcher and batter. The patent also discloses a drilled hole into a stitched baseball as a means to attach the ball to the end of the tether. By changing the location of the point of entry of the hole on the ball's surface, the ability to produce a curved pitch may be possible.
In view of the shortcomings inherent in the foregoing, what is needed is an accurate, resilient pitching apparatus and method which will provide a convenient, portable means to provide simulated pitching. Also needed is a pitching apparatus and method which will not necessitate the continual remeasurement of the dimensions necessary for setting up the device. What is also needed is a method whereby curve balls can be produced without the need for a collection of separate balls, each one having a hole drilled therein at a different angle with respect to the stitching. Also needed is a pitching apparatus and method utilizable on a concrete, paved or other hard surfaces. Also needed is a pitching apparatus and method which will enable an inexperienced person to pitch a ball to consistently reach a selected location near the strike zone of a batter or other ball hitter, which is relatively inexpensive and which limits the flight of a hit baseball to facilitate retrieval.
SUMMARY OF THE INVENTION
In accordance with one embodiment of the present invention, an apparatus and method are provided for pitching a ball to a batter, said pitching controllable according to the point from which the ball is released. In one embodiment, the apparatus includes a base portion having a tapering center spike for insertion into the ground with a planar center portion to facilitate the driving of the spike into the ground such as with a mallet or the like. The planar portion forms a hilt having a plurality of vertical teeth, which also are pushed into the ground to add rigidity and stability and to prevent rotation about the center of the spike. A davit-shaped upper member has a vertical and a horizontal portion, the horizontal portion terminating in a tapered end and having an aperture. One end of an elastic cord is connected to a ring which extends through the aperture of the tapered end. The other end of the elastic cord is connected to a ball. A home plate, or batting marker, and a pitching marker each locatable with a measuring cord of pre-specified length, is also included. An alternate embodiment includes a rectangular shaped container which can be filled with water, sand, or other dense material. The container forms a base upon which a davit-shaped upper member is affixed. The elastic cord is connected to the davit-shaped upper member in the same manner as in the first embodiment.
The method of the present invention includes the carriage of the ball to the pitching marker area causing the stretchable extension of the elastic cord. The pitcher may release the ball at various distances from the davit-shaped member and therefore at various point horizontal to the pitching marker. The ball may be released at various heights above the ground and at various angles with respect to the point of attachment of the elastic cord to the davit shaped upper member. The stitching on the ball may be adjusted with regard to its angle of attachment on the elastic cord in order to yield straight or curved flight towards the batting marker. The elastic cord is stretched, usually to about 90% of its maximum length. Upon release of the ball, it travels to an area near the batter, or batting marker.
The novel features of the invention are set forth with particularity in the appended claims. The invention would be best understood from the following description read in conjunction with accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the pitching apparatus of the present invention, illustrating the relative location of its components;
FIG. 2 is a front view of the pitching apparatus illustrated in FIG. 1;
FIG. 3 illustrates the detail of fit of bottom swaged portion of the upper davit shaped member into the upper end of the base portion, as was previously shown in FIG. 2;
FIG. 4 is an enlarged view of the base portion of the apparatus shown in FIG. 1 from the back side;
FIG. 5 is a side view of the base portion as was previously shown in FIGS. 2 and 4;
FIG. 6 is a top view of the base portion of FIGS. 2, 4, and 5 with the upper davit-shaped member removed;
FIG. 7 illustrates the lower swaged section of the upper davit shaped member shown in FIG. 1;
FIG. 8 is a detailed view of horizontal tapered end portion of the upper davit shaped member shown in FIG. 1;
FIG. 9 illustrates the details of the attachment of the elastic cord shown in FIGS. 1 and 2 to the attachment ring shown in FIGS. 2 and 7 and the ball of FIGS. 1 and 2;
FIG. 10 illustrates an alternate embodiment of the pitching apparatus shown in FIGS. 1-9.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a perspective view of davit-shaped support 11 extending upwardly from the ground and to the right. An elastic cord 13 having a ball 15 at the end thereof is connected to the support 11. A pitching marker 17 and a batting marker 19 are spaced at distances 21 and 23, respectively, from davit-shaped support 11. Note that the upper end of davit-shaped support 11 extends vertically over the junction of distances 21 and 23. A pre-specified length of line 25 is attachable to the base of davit-shaped support 11 to measure out the locations of pitching marker 17 and batting marker 19. Measuring line 25 has colored links or other markings schematically indicated by cross-hatched bar 27 and transverse hatched bar 29 to indicate the preferred location of batting marker 19 and pitching marker 17, respectively. To the upper left of FIG. 1 the measuring line 25 and the transverse hatched bar 29 is fully extended to locate the pitching marker 17. To the lower right of FIG. 1 the measuring line 25 and the cross-hatched bar 27 is extended to locate the batting marker 19. In the second case, note that the part of the measuring line 25 between the markers 27 and 29 is not extended because distance 23 is not as long as distance 21.
Measuring line 25 may be further subdivided to indicate the proper distances, for example in the sport of baseball, for Little League, softball, and Major League ball. Similar marks may be had for subdivisions relating to tennis, squash, racquetball and the like.
Referring to FIG. 2, davit shaped support 11 is seen in partially exploded form consisting of a davit shaped upper member 31 and a vertically oriented base portion 33. Vertically oriented base portion 33 has a hilt portion 35 having three front teeth 37 vertically extending from the longer edge of hilt 35. Vertically oriented base portion 33 also includes a tapering center spike member 39 for insertion into the ground. Typically, spike portion 39 and teeth 37 all extend into the ground with only the upper planar portion of hilt 35 exposed. A wooden or hard rubber plate 41 lies atop hilt 35 to assist the driving of the hilt 35 and teeth 37 into the ground to achieve superior rigidity of davit-shaped support 11.
The davit shaped upper member 31 has an end section of swaged length 43 for close fittable insertion within the open upper end of base portion 33 generally designated by the numeral 45, and as also shown in FIG. 3. Davit-shaped upper member 31 has a horizontal portion terminating in a tapering portion 47. Attached to tapering portion 47 is a ring 49. Ring 49 extends through an aperture (not shown in FIG. 2). One end of the elastic cord 13 is secured to the ring, and the other end of elastic cord 13 is secured to ball 15.
FIG. 3 illustrates a detail of the swaged portion 43 of davit-shaped upper member 31 in close proximity to the upper open end 45 of vertically oriented base portion 33. The material from which the davit-shaped upper member 31, and vertically oriented base portion 33 are made, may be identical. This is because the swaged section 43 may be sufficiently reduced in dimension, to yield the resulting shape seen in FIG. 3, which is fittable within end 45. The swaged portion 43 prevents axial and rotatable movement of davit-shaped upper member 31 with respect to vertically oriented base portion 33.
Referring to FIG. 4, the back side of hilt 35 of vertically oriented base portion 33 is illustrated, showing a back tooth 51 in addition to the aforementioned three teeth 37, both of which are along both of the longer edges of hilt portion 35. Note that teeth 37 are longer than tooth 51. Also visible in FIG. 4 is the plate 41. Plate 41 rests atop a planar surface whose edge 53 is visible in FIG. 4. Teeth 37 and 51 extend from the longer edges of the planar surface.
Referring to FIG. 5, a side view of hilt portion 35, as was shown in FIG. 4 is illustrated. Teeth 37 and 51 can be seen spaced apart from tapering center spike member 39. From FIGS. 1-5 it can be seen that hilt 35 provides support for teeth 37 and 39 and has adequate spacing between the teeth 37 and 51 and the center spike 39 to form a close fit into the earth. Hilt 35 also sets the extent to which spike portion 39 is extended into the earth, and thereby defines the height of davit-shaped support 11 of FIG. 1 when it is in operating position. Such consistent definition of height contributes to the precision height of davit-shaped support 11 attainable with each successive ground installation.
Referring to FIG. 6, a top view of the hilt portion 35 of FIGS. 4 and 5 is shown truly illustrating the presence of plate 41 and the location of vertically oriented base portion 33.
FIG. 7 illustrates a detail of the swaged portion 43 of the upper davit shaped member 31 as was previously shown in FIGS. 2 and 3. All four surfaces are swaged inwardly at their centers to form a somewhat star-shaped pattern.
FIG. 8 illustrates the details of the attachment of elastic cord 13 to the ring 49, and connection of the ring 49 through an aperture 55 in the tapered portion 47 of the horizontal portion of the davit shaped upper member 31. The top view of FIG. 8 illustrates the extension of elastic cord through ring 45. There is a section of elastic cord 13 which extends through ring 49 and securely back onto itself by means of a clamp 57. Ring 49 allows elastic cord 13 to pivot freely about davit-shaped support 31 without tangling or becoming caught.
FIG. 9 illustrates the ring 49 and clamp 57 as was previously shown in FIG. 8, of elastic cord 13, shown in broken length format. Also shown is the extension of elastic cord 13 through a linear aperture or bore shown in dashed line format, generally designated by the numeral 59 extending into ball 15. Note that elastic cord 13 extends through a clamp 61, and along the surface of ball 15, entering one end of bore 59, extending through ball 15, exiting the other end of bore 59, and extending along the surface of ball 15 to finally terminate within clamp 61. The section of elastic cord 13 which extends from clamp 61 through bore 59 is generally kept in tension. The overall length of elastic cord, when not in tension, is insufficient to extend from davit-shaped support 11 to pitching marker 17. The length of elastic cord 13 may be sufficient to extend without stretching to batting marker 19, especially if no deceleration of ball 15 is desired before ball 15 reaches batting marker 19.
Ball 15 has a continuous length of stitching 63 as is typical in the case of a baseball. It is readily seen that ball 15 may be rotated about the linear axis of the bore 59 to change the relative position of the stitching 63 with respect to the lengths of elastic cord 13 which lie adjacent to the surface of ball 15 between aperture 59 and clamp 61. The tension in the section of elastic cord between aperture 59 and clamp 61 enables the position of ball 15, and therefore stitching 63 to remain relatively constant with respect to clamp 61 unless deliberately changed. This is particularly relevant since the configuration herein is such that ball 15 approaches batting marker 19 with elastic cord 13 trailing behind. Therefore, the position of the stitching 63 lying opposite the hemisphere of ball 15 adjacent clamp 61, is the position which will be seen by an observer at batting marker 19.
Referring to FIG. 10, an alternate embodiment of the present invention is illustrated. Davit-shaped support 11 is illustrated generally as before, including davit-shaped upper portion 31, tapering portion 47, ring 49, elastic cord 13, and ball 15. However, the vertically oriented base portion 33 of FIGS. 2-4 is replaced by a base portion 65 attached to a generally hollow, rectangular solid shaped base 67. Base 67 is fitted with a filler cap 69 and a securing pin 71 within a securing aperture 73. Base portion 65 is attached near a corner of base 67 in order to provide maximum rotational and non-tilting stability to davit-shaped support 11 when ball 15 is stretchably extended for release. This is particularly important to prevent a discontinuous or jerky flight of the ball which would occur if the davit-shaped support 11 were unstable.
Base 67 is designed to be filled, upon removal of filler cap 69 with sand, water, or any other dense material to lend base 67 sufficient weight for operation. Base 67 and base position 65 also enables the pitching apparatus of the present invention to be used indoors, in garages, gymnasiums and warehouses. This is particularly useful for winter practice where the weather in inclement and outside practice is not practicable.
The operation of the pitching apparatus and method as previously described is as follows. Vertical spike 39 and teeth 37 and 51 of vertical base portion 33 are thrust into the ground. Plate 41 on hilt portion 35 is for facilitating displacement into the ground, such as by pounding with a mallet, to lend the additional force which may be needed to properly implant base portion 33. Davit-shaped upper member 31, and in particular swaged section 43 is fitted within the open end 45 of the upper portion of base portion 33. Davit-shaped upper portion 31 has elastic cord 13 and ball 15 attached at the upper end. Batting marker 19 is placed a distance 23 from davit-shaped support 11 by measuring with measuring cord 25, as is pitching marker 17 and its associated distance 21. The markers or bars 27 and 29 on measuring cord 25 are used to help gauge the relative distance from support 11 from which ball 15 is to be released and from which ball 15 is to be struck. Generally, the distance between support 11 and batting marker 19 will be less than the distance between support 11 and pitching marker 17.
To operate the pitching apparatus, a pitcher grasps ball 15 and walks towards pitching marker 17. As the pitcher approaches pitching marker 17, the cord 13 begins to stretch which, in turn, begins to exert a force on ball 15 in the direction of davit-shaped support Il, which is, of course, opposed by the pitcher. This action also places significant bending moment and axial torque forces upon davit-shaped support 11, which due to the firm anchoring support and close fitting nature of swaged section 43, does not bend or twist. As a batter prepares to strike the ball, he stands near batting marker 19.
The pitcher can position the ball 15 to a point of release farther toward the ground, or away from the ground, to the left or right, in a direction transverse to the force exerted by elastic cord 15, and also may position the ball closer to or farther from davit-shaped support 11. The pitching marker 17 facilitates finer adjustments on the position of ball 15 by providing a background reference by which to judge the relative position of the pitcher, and the point from which the pitcher releases the ball 15. As the pitcher releases ball 15 from a point adjacent pitching marker 17, ball 15 accelerates due to the tension forces developed in elastic cord 13 due to its stretchable extension to pitching marker 17. Due to the stability of davit-shaped support 11, a smooth acceleration is had, allowing a consistently accurate flight of ball 15. Ball 15 accelerates, then passes davit shaped support 11, with elastic cord 13 trailing behind, and proceeds toward the batting marker 19. When batting marker 19 is positioned closely enough to davit-shaped support 11, the ball 15 will be near maximum velocity by the time it crosses batting marker 19, and, which may reach speeds in excess of 67 miles per hour. A batter standing near batting marker 19 then strikes the ball, whose flight is limited by virtue of ball 15's attachment to davit shaped support 11. Once the ball 15 comes to rest, the pitcher retrieves the ball 15, and the process is then repeated.
The velocity of ball 15 as it approaches batting marker 19 is dependent upon the tension forces developed in elastic cord 13 and therefore, the distance to which the pitcher 17 extends the ball before release. The level of ball 15 above the ground near pitching marker 17 will determine the trajectory of ball 15 and therefore the level of the point at which ball 15 crosses batting marker 19. If ball 15 is released from a low level, it will cross batting marker 19 at a high level. If ball 15 is released from a high level, it will cross batting marker 19 at a low level. If a pitcher releases the ball from a point to the right of the pitcher, the ball 15 will cross the batting marker to the right from the batter's perspective. Likewise, if a pitcher releases the ball from a point to the left of the pitcher, the ball 15 will cross the batting marker at a point to the left with respect to the batter's perspective.
In instances where the playing surface is hardened, as for example concrete and asphalt, the embodiment which was shown in FIG. 10 may be employed. Davit-shaped support 11 and base 67 can be set up before or after base 67 is filled with a suitable weighting material. Once filled, base 67 is designed to be employed within the perspective diagram of FIG. 1 with the greater length of base 67 from its point of attachment of base portion 65 extending generally from base portion 65 to pitching marker 17. Operation of the pitching device is in the same manner as previously described.
Although the dimensions of the pitching apparatus of the present invention may be varied, some dimensions, of course, were better than others. It has been found satisfactory to set the height of tapered portion 47 of davit-shaped support 11 approximately five feet above the ground. An elastic cord having an unstretched length of about eight feet and a diameter of approximately 3/16 of an inch has been found to work satisfactorily. The location of the pitching marker 17 at a distance of 18 ft. from vertically oriented base portion 33, and the location of the batting marker at a distance of about 13 ft. from vertically oriented base portion 33 has been found to be satisfactory. It has been found that when the ball is pulled to the pitching marker, stretching the elastic cord 13 to about 90% of its length caused the ball to reach the batting marker with high consistency and with the cord trailing behind the ball. As has been previously stated, since the elastic cord 13 trails ball 15, the adjustment of ball 15 and the stitching 63, with respect to clamp 61 will alter the stitching profile of ball 15 as it approaches the batting marker. It has been previously shown that such an alteration can cause a different path of flight, as between a straight flight and curved flight.
Thus, the invention provides an apparatus and method for the pitching of a baseball so that it arrives at a batting marker in a manner simulating an actually pitched ball, such as a baseball. The ball 15 of the present invention can therefore be pitched consistently by a relatively unskilled person. Optionally, pitching marker 17 and batting marker 19 may be attached to vertically oriented base portion 33 of davit-shaped support 11. The attachment of the pitching marker 17 and batting marker 19 to the vertically oriented base portions 65 or 33 would eliminate the necessity for measuring and remeasuring their distances from base portions 65 and 33 each time the pitching apparatus of the present invention is relocated.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the physical dimensioning, materials employed, and configuration of the pitching apparatus and method of the present invention may be made without departing from the spirit and scope of the invention, and it is intended that the claims herein be interpreted to cover such modifications and equivalents.
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The invention relates to tethered ball pitching device wherein a planar base member is provided with a plurality of ground penetrating planar teeth members and a central aperture. A vertically extending support member having a pointed end extending through the aperture and penetrating the ground. A davit shaped member having a vertical seating extending into the vertical support member and a horizontal portion having an aperture through its outer end. A ring extends through the aperture and an elastic cord has one of its ends attached to the ring. The other end of the elastic cord is attached to a ball.
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CROSS-REFERENCE TO RELATED APPLICATIONS
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
BACKGROUND OF THE INVENTION
The present invention relates to industrial controllers and in particular to an industrial controller system having a secondary controller providing back-up control capability.
Industrial controllers are special purpose computers used for controlling factory automation and the like. Under the direction of stored programs, a processor of the industrial controller examines a series of inputs reflecting the status of a controlled process and changes outputs affecting control of the controlled process. The stored control programs may be is continuously executed in a series of execution cycles, executed periodically, or executed based on events.
The inputs received by the industrial controller from the controlled process and the outputs transmitted by the industrial controller to the controlled process are normally passed through one or more input/output (I/O) modules) which serve as an electrical interface between the controller and the controlled process. The inputs and outputs are recorded in an I/O data table in processor memory. Input values may be asynchronously read from the controlled process by specialized circuitry. Output values are written directly to the I/O data table by the processor, then communicated to the controlled process by the specialized communications circuitry.
Industrial controllers must often provide uninterrupted and reliable operation for long periods of time. One method of ensuring such operation is by using redundant, secondary controller components (including processors) that may be switched in to replace primary controller components while the industrial controller is running. In the event of a failure of a primary component, or the need for maintenance of the components, for example, the secondary components may be activated to take over control functions. Maintenance or testing of the control program may be performed with the primary processor reserving the possibility of switching to the secondary processor (and a previous version or state of the control program) if problems develop.
Ideally, the switch-over between controllers or their components should occur without undue disruption of the controlled process. For this to be possible, the secondary processor must be running or waiting to run the same program (and maintaining its current state) and must be working with the same data in its I/O data table as is the primary processor.
The same control program may be simply pre-stored in each of the primary and secondary processors. The data of the I/O data table, however, cannot be pre-stored but changes continuously during the controlled process. Further, because control processes are I/O intensive, there is typically a large amount of data in the I/O data table. For this reason, transmitting the data to the secondary processor is difficult.
In order to effectively update the secondary processor with large amounts of I/O data, prior art controllers have continuously and asynchronously transmitted I/O data from the primary processor to the secondary processor during execution of the control program. Allowing the control program to continue to run, prevents the control process from being interrupted by the data transfer. Nevertheless, there are problems with this approach.
Asynchronous transfer means that at the time of switch-over to the secondary processor, the I/O data table of the secondary controller may have only been partially updated. Further, even the updated part of the I/O data table may be stale because the control program has continued to execute and change that data after its transmission. This I/O data will be termed "time fragmented" because it is not simply a uniformly delayed version of the I/O data table of the primary processor, but a version with different data delayed by sharply different amounts. Time fragmented data represents a control state that never existed because it includes I/O data taken from two or more different execution cycles of the control program.
A second problem that may occur at the time of switch-over is a so-called "data bump" where an output is changed back to an old state by a secondary controller only to be quickly restored to its original value as the secondary controller continues the control process. Data bumps can cause a momentary reversal of the control process with serious consequences to the controlled equipment. Unfortunately, even trivially stale data can cause data bumps.
BRIEF SUMMARY OF THE INVENTION
The present invention allows synchronization of the transmission of the I/O data with the execution of the control program eliminating time fragmentation of the data. The I/O data is transmitted to the secondary controller at predetermined times in the execution of the control program, and other control program operation is suspended during that transmission.
This synchronous transmission of I/O data, without undue disruption of the control process, is made possible by transmitting only the I/O data that has been changed since the last program execution cycle. Typically this is a small subset of the I/O data.
Tracking changed I/O data may be performed completely in hardware by detecting output writes to the I/O data table. The time consuming process of collecting this data for transmission may be performed by the control program itself at the conclusion of the execution cycle.
Specifically, the present invention provides a primary industrial controller communicating with a secondary industrial controller over a link. The primary industrial controller includes a memory holding a user program describing control of an industrial process or the like, and an I/O data table holding values of output signals exchanged with a controlled process. The memory also includes a flag table indicating changes to the I/O data table. A processor of the primary industrial controller communicates with the memory and operates to execute the user program to write to the I/O data table according to the user program. The processor also operates to flag changes in the I/O data by setting flags in the flag table. At a predetermined time, the processor communicates to the secondary processor only the values of the I/O data table that have changed as indicated by the flag table to the I/O data table.
Thus it is one object of the invention to provide a high speed data updating of a secondary processor that may be performed synchronously with program execution in the primary processor. By increasing the speed with which data may be transferred, the processor program may be stopped during the data transfer operation. Most simply, the data transfer may be initiated by the ending of an execution cycle of the control program or any one of the multiple control programs in a multi-tasking industrial controller. By concentrating and synchronizing the transfer of data at the end of a program, the secondary processor is assured of having an unfragmented control state when it begins I/O data table controlling.
The I/O data table may be divided into addresses and the flag table may include flags each indicating a change in at least one address in a defined range of addresses. The communication of changed values of the I/O data table will, in this case, communicate values from all addresses within ranges defined by set flags of the flag table. The range of addresses may be programmable as defined by a programmable register of the processor.
Thus it is another object of the invention to efficiently transfer I/O data by permitting the granularity of data transfer between the primary industrial controller and secondary industrial controller to be flexibly adjusted according to the amount of I/O and frequency of change in I/O data. Generally, larger I/O data table sizes may be accommodated with greater address ranges being assigned to each flag.
The primary industrial controller may at a second pre-determined time after communicating the changes in the output values of the I/O data table, transmit to the secondary industrial controller an unwind signal indicating completion of the transfer.
Thus it is another object of the invention to permit the secondary industrial controller to determine whether only a partial transfer of I/O data has occurred when the transmission is interrupted part way through its transfer.
The processor may be a multi-tasking processor executing multiple tasks, including at least one user program, with tasks preempting other tasks according to priority rules. The primary industrial controller's communication to the secondary processor of the changed values of the I/O data table may be initiated by instructions within a program of a low priority task. That user program may be preempted by a program in a higher priority task. In the event of such preemption, the primary industrial controller suppresses completion of the communication of the I/O data table when the program of the low priority task resumes execution.
Thus it is another object of the invention to provide a method of updating data of an I/O data table in a multi-tasking environment. The flag table is shared by all tasks to ensure that a preempting task transfers the I/O data of the preempted task and prevents retransmission of that data later.
The foregoing and other objects and advantages of the invention will appear from the following description. In this description reference is made to the accompanying drawings which form a part hereof and in which there is shown by way of illustration a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention, however, and reference must be made therefore to the claims for interpreting the scope of the invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a simplified perspective view of an industrial controller employing a primary and secondary controller communicating on a common link with a remote I/O rack and a separate communication bus for I/O data table transfer;
FIG. 2 is a schematic representation of prior art asynchronous transfer of data between I/O data tables of a primary and secondary industrial controller;
FIG. 3 is a table holding sequential output values of a prior art controller such as produces a rapid switching of an output to a previous state and then back again, such as is termed a data bump;
FIG. 4 is a block diagram of principal components of the controller of the present invention usable either as a primary or secondary controller;
FIG. 5 is a simplified diagram of two controllers of FIG. 4 used as primary and secondary controllers showing a sequence of data flow used in the present invention;
FIG. 6 is a table similar to that of FIG. 3 showing avoidance of the data bump problem with the sequence of data flow of FIG. 1;
FIG. 7 is a graphical representation of the execution of multiple programs on the controller of FIG. 4 showing synchronization points and unwind points for I/O data transfer;
FIG. 8 is a figure similar to that of FIG. 7 showing execution of multiple programs having different priorities and the operation of the data table transfer when a low priority program is pre-empted; and
FIG. 9 is a figure similar to that of FIG. 8 showing a preemption occurring during the period of the I/O data transfer.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, an industrial control system of the present invention includes primary controller 12(a) and secondary controller 12(b) housed in separate racks 14. Each rack 14 holds processor modules 16(a) and 16(b), respectively, to be described in detail below.
Within the racks 14 of primary controller 12a are I/O modules 18 having I/O lines 20 communicating with a controlled process (not shown) for transferring input and output signals between the controllers 12(a) and the controlled process. In addition, both the racks 14 include communication modules 22 connecting the controllers 12(a) and 12(b) to a common general purpose link 24 and communication modules 26 connecting controllers 12(a) and 12(b) to a special dedicated communication link 28. The general purpose communication link 24 may connect to an I/O rack 30 having additional I/O modules 18 and I/O lines 20.
The dedicated communication link is used for the communication of I/O data between the processor modules 16(a) and 16(b) and the communication of information coordinating a switch-over between the operation of the primary and secondary controllers 12(a) and 12(b).
Referring now to FIGS. 1 and 2 in a prior art system, a primary controller 12(a)' and secondary controller 12(b)' both include copies of a user program 32 comprised of a sequence of instructions 34. During operation of the primary controller 12(a)', instructions 34 are executed in repeated execution cycles 38 at a scan point 36 scanning through the user program 32 writing data 37 to an I/O data table 40.
At the same time, I/O data table 40 is asynchronously updated over link 24 with current input values 42 from I/O modules 18 as indicated by arrow 44. Input values 42 are also received via link 24 at I/O data table 40' in the secondary controller 12(b)'. Output values in the I/O data table 40 may be transmitted (not shown) to the I/O 18 asynchronously or synchronously to the execution cycles 38 of the user program.
In the prior art, the data of the I/O data table 40 is asynchronously transferred as indicated by arrow 46 to the I/O data table 40' in secondary controller 12(b)'. This transfer of data provides the secondary controller 12(b)' with an updated I/O data table 40' in the event of a switch-over of control from the primary controller 12(a)' and proceeds through the data tables 40 and 40' in a scanning process 48.
Generally the scanning 48 of the I/O data transfer is asynchronous to the execution cycle 38 of the user program 32. Accordingly, at the completion of an execution cycle 38 of the user program 32, the I/O data table 40' will still contain some data as changed in a previous execution cycle 38 of the user program and some data reflecting the most recent execution cycle 38 of the user program 32. Further, because the user program is executed during the data transfer, some of the data in the I/O data table 40' reflecting the most recent execution cycle of the user program will no longer be current.
When control is switched to the secondary controller 12(b)', the user program 32' of secondary controller 12(b)' will begin an execution cycle of the user program 32' operating on a set of data in I/O data table 40' different from any set of data seen by the user program 32 of the primary controller 12(a)' at the beginning of its execution cycle 38. This time fragmentation of the data of the I/O data table 40' can produce anomalous behavior of the controlled process.
Further, referring now to FIGS. 2 and 3, a second problem may arise from the lack of coordination between the transfer of data from the I/O data table 40 to the I/O modules 18, and the transfer of data from I/O data table 40 to the I/O data table 40'. This is illustrated in the table of FIG. 3, where the first column represents a single binary output value to the controlled process, the second column represents the output value contained in I/O data table 40 and the third column represents the output data contained in I/O data table 40'.
At a first interval in time shown in the first row of this table, the output value is `0` and a `0` is stored in the primary and secondary I/O data tables 40 and 40'. At a second later interval of time shown in the second column of the table in FIG. 3, the user program 32 may write a value of `1` to the I/O data table 40 and this value may be transmitted to the output. At a third later time interval in time shown by the third column of FIG. 3, the primary controller may switch-over control to the secondary controller 12(b)' prior to the scanning 48 of the I/O data table 40 updating the I/O data table 40' as would have occurred otherwise shown as a dotted arrow.
Immediately after the switch-over, shown in the fourth row of the table, a scanning of I/O data table 40' reads the old value of `0` from the secondary I/O data table 40' and writes it to the output returning the output value to ' 0'. Finally at the last column of FIG. 3, the user program of the secondary controller 12(b)' corrects the data value of the secondary I/O data table 40' as a result of the natural execution of the user program 32 and this value is written to the output value to restore it to `1`. This transition in the last three rows of the table of FIG. 3 of the output from `1` to `0` to `1` again is a data bump and is disruptive to a controlled process both because of the retrogressive state change from the new value of `1` to the old value of `0` (which would not have normally occurred) and because of the rapid toggling of the output value between `1`, `0`, and `1`, which may adversely affect physical equipment with limited speed and response rates.
Referring now to FIG. 4, the present invention provides for a processor module 16 in an industrial controller 12 allowing the controller to be used either as a secondary or primary controller and which has special features to avoid time fragmented data in the data table and the data bumps described above.
Generally, the processor module 16 includes a processor 50, which may execute relay ladder logic frequently used in the industrial control environment as well as general purpose arithmetic and logical instructions.
The processor 50 communicates with a memory 52 by means of an internal bus 54. Memory 52 may include volatile and non-volatile memory types well known in the art. The internal bus 54 also connects the processor 50 to input and output link buffers 56 handling communication of data on a backplane to other modules of the controller 12, including the I/O modules 18 and the communication modules 22 and 26.
The processor module 16 also includes write-detect circuitry 57 detecting writes of the processor 50 to certain addresses of the memory 52 as will be described.
Memory 52 includes an I/O data table 40 as described above and an I/O quarantine table 58 similar in size to the I/O data table. User programs 32 are also stored in memory 52 as well as a flag table 60 and a configuration register 62 as will be described.
Referring now to FIG. 5, the steps of synchronous data transfer between I/O data tables 40a and 40b of a primary processor 16(a) and secondary processor 16(b) begins when the primary processor 16(a) is ready to run a program 32. This program 32 may be one of several programs in the primary processor 16(a) distributed among several tasks of different priorities. The multi-tasking aspects of the present invention will be described below.
At the time primary processor 16(a) is ready to run a program 32, a message is transmitted to the secondary processor as indicated by the arrow labeled with a circled sequence number 1 indicating the order of the step in which the data transfer occurs. The message indicated by sequence number 1 includes a program instance number which identifies the program 32 from among many programs 32 which may be contained in the memory 52 of the processor 16(a) and many instances of program 32 which may occur in object oriented programming systems.
Processor 16(a) then receives back from processor 16(b) an acknowledgment signal indicated by sequence number 2 indicating that processor 16(b) has queued itself at the start of program 32 matching the program instance number previously provided.
In the event of a switch-over of control to the secondary processor 16(b), the secondary processor 16(b) will begin execution of program 32 at its start. It should be noted that at the time of switch-over, the primary processor 16(a) will typically be executing instructions somewhere in the body of program 32 rather than at the start. Accordingly, at the time of switch-over, there will be some rollback by the secondary processor 16(b) in the point of program execution. Nevertheless, it can be assured that the correct program 32 will be executing and that the I/O data is consistent with that of the primary processor 16(a) when it was at the beginning of its program as will be seen. Significantly, in multi-program systems, the partitioning of each of the programs with their own separate data transmissions ensures that the rollback experienced during a switch-over will be minimized to no more than the length of one program within any one task.
As indicated by sequence arrow 3, processor 16(a) then begins execution of the user program exchanging data with the I/O quarantine table 58 as indicated by sequence arrow 4. Such data exchange includes writing output values to I/O data table 40a and reading input values from I/O data table 40a.
The input values of the I/O data table 40a may be asynchronously updated with new input values from the controlled process, however, no output values are transmitted to I/O data table 40a at this time.
At the time of each writing to I/O data table 40a as indicated by sequence number 4, if the writing is to an output value or to an internal variable to processor 16(a), a flag is set in flag table 60a as indicated by sequence arrow 5. This setting of the flag in the preferred embodiment is accomplished by specialized circuitry of the processor 16(a). Specifically, the write lines to the I/O data table 40a are monitored and the range of addresses reserved for the I/O data table 40a detected. The I/O data table 40a is divided into subranges according to a range value held in the configuration register 62 (shown in FIG. 4). When a write to the quarantine table is detected, the particular subrange is then determined and any change within a given sub-range results in the setting of a flag in the flag table 60 unique to that sub-range. Thus, each set flag indicates that there has been a writing of an output value to the I/O data table 40a within a range defined by a start and ending value programmed into the configuration register 62. Hence at the conclusion of the execution of program 32, flags set in flag table 60a identify all changed output and internal variable values in the I/O data table 40a.
Because this flag setting process may be accomplished by circuitry, detecting writes and ranges, it does not slow down the execution of the program 32 by processor 16(a).
Referring still to FIGS. 4 and 5, ultimately, in the execution of any program 32 indicated by sequence number 3, a portion of program 32 termed the synchronization point (indicated by arrow 64) is reached. The synchronization point begins a packet collection portion 70 of the program 32 that reviews the flags of flag table 60a (as are readable by processor 16(a)) and for each flag that is set takes data out of I/O data table 40a and forms a transmission packet that is loaded into the link buffer 56. The packet collection portion 70 merely needs to search through the flag table 60a and collect the necessary data, but need not attend the low level data transmission problems which are tended to by the link buffer 56. The link buffer communicates the transmission packet on the link 28 to processor 16(b) via module 26 and to a second quarantine table 58b as indicated by an arrow marked by sequence number 6. As the data is collected for transmission, the associated flags are reset.
At processor 16(b), the data of the transmission packets are received by the quarantine table 58b . This process of writing also serves to set flags in a second flag register 60b operating similarly to flag register 16(a) as has been previously described.
Processor 16(a) after it has finished collecting and sending transmission packets sends to processor 16(b), an `unwind` signal (also indicated by sequence arrow 6) indicating a completion of the transmission and including an indication of the last packet sent. This unwind signal is necessary because the transmission of I/O data is not constant in length but depends on how much I/O data has changed. It will be understood that by transmitting only changed I/O data, however, the time required for transmission is much reduced. The data packets sent may contain an instance number indicating which portion of the program has been executed by the primary processor so that the secondary processor can take all program portions, for data packets that it has received since the last unwind signal, off its run list when the unwind command is received.
The secondary processor 16(b) after receiving the unwind signal sends back an acknowledgment signal indicated by sequence arrow 7 indicating that all the data has been received based upon the `last packet` number of the unwind command. At this time, back up processor 16(b) begins to transfer the data from quarantine register 58b to I/O data table 40b and output transmit buffers 59b associated with processor 16(b) as indicated by sequence number 8. This latter transfer transfers only changed data as indicated by flag register 60b and is extremely rapid as it is being accomplished internally to the processor 16(b). Accordingly in the event of a switch-over, the data in I/O data table 40b can be assured of reflecting a single scanning of program 32 and thus of not being time fragmented. If for some reason, the transmission process from processor 16(a) to processor 16(b) is interrupted, an unwind signal will not be received and no updating of 40b or 59b will occur.
When the primary processor 16(a) receives the acknowledgment signal 7, the primary processor 16(a) begins a transfer of output data for I/O data table 40a to the output transmit buffer 59a as indicated by sequence arrow 9. This transfer may begin at the same time as the transfer of sequence arrow 8 from quarantine register 58b to I/O data tables 40b and 59b.
Only after the output transfer buffer 59a is updated is the output data transferred to the controlled process as indicated by sequence arrow 10.
As indicated by sequence arrow 11, a switch-over message may be received by secondary processor 16(b) at which time it undertakes to execute program 32' starting at its top indicated by program counter 36 using the data of data table 40b. This switch-over may occur at any time.
Referring now to FIG. 6, it can be seen that the sequence of FIG. 5 eliminates data bumps by assuring that the secondary processor 16(b) has a complete copy of all output values before those output values are reflected to the actual outputs of the controlled process. In FIG. 6 as with FIG. 3, the first column indicates the state of an output to the controlled process, the second column indicates a data value of I/O data table 40a and the third column indicates a data value of I/O data table 40b. In a first interval in time, all values may be zero reflecting a previous updating of I/O data tables and outputs. At a second interval in time, represented by the second row of the table of FIG. 6, the user program 32 may write an output value of `1` to a primary I/O data table (in this case I/O data table 40a ) which is then transmitted to the secondary I/O data table (in this case quarantine output data table 58b ).
A switch-over at this interval does not cause a data bump because the value of `1` has not yet been transmitted to the controlled process. As mentioned above, the data transmitted to the secondary I/O table is quarantined until an unwind signal is received, so even an interruption during the transmission of data does not cause a problem.
At a third time interval represented by the third row of the table, a switch-over occurs. Still there is no data bump because the output value has not been sent to the controlled process. Only at the fourth interval in time represented by the fourth row of the table is the new output value transmitted from the secondary I/O data table to the output.
The present invention is intended to be used in a multi-tasking system in which tasks include multiple programs and where different tasks of different priorities may interrupt or pre-empt each other. Referring now to FIG. 7 in the execution of a single task with multiple programs, each program has its own synchronization point. The synchronization point is followed by packet collection portion 70 undertaking the transfer data from the I/O data table 40a to the data quarantine table 58b as has been previously described. The packet collection portion 70 concludes with the generation of an unwind signal 72.
Referring now to FIG. 8 in a multi-tasking system, a first program in a low priority task 74 may be preempted by a second and third program in a high priority task 76. In one case, the program `1` is pre-empted prior to reaching its synchronization point 64 by a program `2`. When program `2` reaches its synchronization point 64, it reviews the flag table 60a and transfers all the data indicated as having been changed including that data changed during the execution of program `1`. Program 2 sends an unwind signal causing the data of program `1` and `2` to be accepted by the secondary processor. Program `3` is then executed and at its synchronization point 64 accomplishes a similar transfer and then returns control upon completion of that transfer to program 1.
After the unwind signal of program `3`, the flag register 60a has no set flags as all the data that has changed was transmitted. Accordingly program 1 continues to execute and when it reaches its synchronization point 64 transmits only the data changed in program `1` after the return of control to program `1`. Because in this case, a low priority task was interrupted by a high priority task, program `2` essentially preempts the changes of program `1` as would be desired. That is, changes by higher priority programs preempt changes by lower priority programs.
Referring now to FIG. 9 in a more complex circumstance, program `1` of a low priority task 74 is preempted by program `2` of a high priority task 76 after the synchronization point 64 of program `1` has been reached but prior to completion of the packet collection portion 70 of program `1`. In this case, untransmitted data of program `1` is again transmitted by program `2` which can distinguish between transmitted and untransmitted packets by the resetting of the flags of the flag table 60a as packets are collected.
A program `3` is then executed and its changes are sent during packet collection portion 70 of program `3` and control is returned to low priority task 74. At this time, the remainder of packet collection portion 70 of program 1 including the unwind signal would normally be executed. However, the packet collection routine of the operating program recognizes this occurrence via link buffer semaphores and suppresses the remainder of packet collection portion 70 so that program `4` may execute immediately without further data transfer by packet collection portion 70 of program `1`.
The above description has been that of a preferred embodiment of the present invention. It will occur to those that practice the art that many modifications may be made without departing from the spirit and scope of the invention. In order to apprise the public of the various embodiments that may fall within the scope of the invention, the following claims are made.
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An industrial control system employs a primary and secondary controller each having a processor and an I/O data table. Updating of the secondary processor's I/O data table is accomplished synchronously with execution of the program in the primary processor at a particular point in the program. A tracking of changes in the I/O data table of the primary processor is used to transmit only changes in the I/O table to the secondary processor thereby avoiding undue interruption of the executing program while preserving synchronicity.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of International Patent Application No. PCT/EP99/02041, filed Mar. 22, 1999. This application also claims priority from U.S. Provisional Patent Application No. 60/192,882, filed on Mar. 29, 2000. The disclosures of the above-referenced applications are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method for determining the position and rotational position of an object in three-dimensional space.
The objects suitable for the invention are varied and are very different in their function and application. Examples of such objects are surgical microscopes and surgical tools in the medical sector, levelling staffs in geodetic surveying, gun barrels in the military sector or aerials, in particular directional aerials and radar aerials. In the case of such objects, their position in space plays an important role. This is determined in a specified coordinate system completely by six real position parameters which are composed of three parameters for the position (translation group) and three parameters for the rotational position (rotation group). The position of the object is given by the 3-dimensional coordinates of a point selected on the object. The rotational position of the object is generally described by the direction vector of a defined object axis and the angle of rotation of the object about the object axis. The direction vector of the object axis is a unit vector having the length 1 , i.e. the sum of the squares of its components is 1.
2. Description of the Background Art
WO 95/27918 describes an arrangement for determining the spatial position of a surgical microscope with the aid of coded light signals which are emitted by light emitting diodes, preferably in the infrared range, and received by light receivers. A surgical microscope is generally mounted on an arm by means of a cardan joint and can be moved translationally in three directions in space and rotated about three directions in space so that its position in space can be adjusted as desired. On the surgical microscope, the light emitting diodes or optical fibres which are fed with light from the light emitting diodes are mounted at specific points. Alternatively, reflectors may also be mounted on the surgical microscope. The light receivers are arranged at various points in space and receive the light signals specific to each of them. From this, the spatial position of the surgical microscope is determined. If the spatial position of the patient is simultaneously known, the coordinates of the operating site viewed through the surgical microscope are thus known, which is indispensable for microsurgery.
In geodetic surveying, levelling staffs are used for determining vertical points of reference and for topographical surveying. They are also used in construction surveying and in the construction of traffic routes. A levelling staff is sighted with the telescope optical system of the levelling instrument in order to measure the difference in height between levelling instrument and levelling staff. It is assumed that the levelling staff is aligned perpendicular to the optical axis of the telescope. Since the optical axis of the telescope is usually adjusted so that it is in a horizontal plane, an operator must keep the levelling staff aligned as far as possible perpendicular with the aid of the water levels mounted thereon. Tilting of the levelling staff results in an error in the height measurement.
With the advent of automated digital levelling instruments according to DE 34 24 806 C2, electronic reading of the staff became possible for the first time. For this purpose, the levelling staff has a code pattern comprising black and white elements, a part of which is produced as an image on a position-resolving detector with the aid of the telescope optical system of the electronic levelling instrument. Here, the code pattern information present in the field of view of the telescope is used to obtain the desired height measurement by comparison with the code pattern of the levelling staff, which pattern is stored as a reference code pattern in the levelling instrument. Although the measured code pattern is identified in this measurement and evaluation method, tilting of the levelling staff and the resulting contribution to the inaccuracy of measurement are not taken into account.
A specific code pattern is disclosed in DE 195 30 788 C1. A levelling staff having a rotationally symmetrical cross-section has, on its lateral surface, code elements which form lines closed rotationally symmetrically with respect to the longitudinal axis of the levelling staff. Consequently, the code pattern is visible from all sides.
DE 44 38 759 C1 describes a method for determining the tilt angle of coded levelling staffs in the measuring direction by means of an electronic levelling instrument. The tilt of the levelling staff is taken into account exclusively in the measuring direction, i.e. in the observation direction. The resulting recording of the code pattern on the detector is evaluated and the tilt angle is determined. Lateral tilting of the levelling staff, which thus takes place transversely to the observation direction of the levelling instrument, is however not taken into account. A one-dimensional diode array is therefore adequate as a detector.
Owing to a lateral tilt of the levelling staff, an error also occurs in the height and distance measurement. The point of intersection of the optical axis of the levelling instrument with a tilted levelling staff is further away from the bottom of the levelling staff than in the case of exactly perpendicular alignment of the levelling staff. An insufficiently perpendicular alignment due to inaccurate reading of the water level by the operator therefore leads to erroneous measurements. There is subsequently no possibility for correcting errors. Moreover, often only a single operator is used today, said operator operating the levelling instrument for surveying. The levelling staff standing alone is exposed to the wind, which leads to corresponding deviations in the surveying.
In the case of a gun barrel—and the following statement also applies analogously in the case of directional aerials and radar aerials—the primary concern is to determine its orientation in space or to rotate the gun barrel into a specific predetermined direction and to measure said rotation. The horizontal and vertical angular position (azimuth and elevation) of the gun barrel is controlled with the aid of encoders which are mechanically connected to the gun barrel. The encoders contain in general coded rotary discs which execute a rotational movement by means of a gear during rotation of the gun barrel and thus deliver electrical signals corresponding to the angles of rotation. The mechanical play is disadvantageous in the case of such controls. Moreover, the large thermal loads and shocks lead to inaccuracies and to increased wear.
SUMMARY OF THE INVENTION
It is the object of the invention to provide a method by means of which the position and the rotational position of an object in three-dimensional space can be determined quickly and without contact.
The object is achieved, according to the invention, by use of an optical measuring head including an imaging optical system and a detector which is position-resolving in two dimensions and is arranged in the focal plane of the imaging optical system. The object with its object structures is focused onto the detector by the imaging optical system. The object structures are known from the outset as a priori information. The object structures may contain the geometric shape of the object and its dimensions or may be marks at specific points on the object or they may be a code pattern which is applied to the object. The image of the object or of the object structures which is present in two-dimensional form on the detector is evaluated in an evaluation unit connected to the detector.
There are various possibilities for evaluating the two-dimensional image information. For example, the image of the object can be compared with calculated images. From the known geometry of the object or from existing marks on the object or from an existing code pattern on the object or from all these object structures together, the expected detector image can be calculated using the known properties of the imaging optical system (and optionally the resolution of the position-resolving detector) for any reasonable values of the six position parameters stated at the outset. Optimization methods are used for determining those values of the position parameters which give the best or at least a sufficiently good agreement between the calculated image and the image actually recorded. Such optimization methods are, for example, quasi-Newton methods (determination of the least squares or of the maximum likelihood, etc.), which are known from K. Levenberg: “A Method for the Solution of Certain non-linear Problems in Least Squares”, Quart. Apl. Math. 2 (1944), pp. 164-168, or from D. W. Marquardt: “An Algorithm for Least-squares Estimation of Nonlinear Parameters”, SIAM J. Appl. Math. 11 (1963), pp. 431-441, or from J. J. Moré: “The Levenberg-Marquardt Algorithm: Implementation and Theory”, Numerical Analysis, ed. G. A. Watson, Lecture Notes in Mathematics 630, Springer Verlag (1978), pp. 105-116.
Another possibility for evaluation is to analyze the object structures focused on the detector with respect to their geometrical parameters and to determine the position parameters of the object therefrom. Thus, the planar position and the rotational position of the focused geometrical shapes (e.g. edge contours) or of the code pattern on the detector and the variation in the image scale changing as a function of the detector coordinates are first measured and determined. If a code pattern is present, all code elements of the code pattern focused on the detector are preferably completely used since high accuracy and especially high ruggedness and stability of the evaluation result can thus be achieved. For other requirements, such as, for example, for particularly rapid availability of the results of the measurement, however, the evaluation of only three decoded code elements of the code pattern is sufficient. The accuracy of the measurement is somewhat limited. Alternatively, it is also possible to evaluate only the focused edge contours of the object.
From the determined geometrical parameters of the detected object structures, the position parameters of the object are determined with the aid of the optical imaging equation and geometrical relationships (vector algebra). By means of the position parameters, which as mentioned at the outset include the position vector, the direction vector of the object axis and the angle of rotation of the object about the object axis, the spatial position of the object, i.e. the position and rotational position, is reconstructed.
Of course, said possibilities for evaluation can also be combined with one another. For example, a rough determination of the position parameters can be effected by a rough evaluation of the edge contours or of only a few code elements and an accurate evaluation including the total recorded object geometry or all recorded code elements can follow. For the accurate evaluation, in particular the optimization method cited above can also be used and the position parameters determined from the rough evaluation can be employed as starting parameters for the optimization.
Expediently, a three-dimensional Cartesian coordinate system is chosen for determining the spatial position of the object. The coordinates of the measuring head and hence of the detector are known in this coordinate system. The coordinate system may also be chosen from the outset so that it agrees with the detector coordinates. Of course, the position parameters of the object can be converted into any desired expedient coordinate system. In particular, the rotational position of the object may also be specified by two polar angles or by azimuth, elevation and in each case the angle of rotation of the object about the axis of rotation or by three Eulerian angles.
An optoelectronic detector capable of position resolution in two dimensions is required for the invention. Said detector may be, for example, a video camera or two-dimensional CCD array. However, it is also possible to use a plurality of one-dimensional CCD arrays arranged side by side. The object is mapped with such a detector and by means of the imaging optical system. The object structures present in the field of view of the imaging optical system are focused and detected. The detector is adjusted with its light-sensitive detector surface generally perpendicular to the optical axis of the imaging optical system. The point of intersection of the optical axis with the light-sensitive detector surface may define the zero point of the coordinate system of the detector.
When a CCD detector having discrete light-sensitive pixel structures is used, the positional resolution of the CCD detector can be further considerably increased by means of suitable optic structures, in particular by means of suitable structures of a code pattern. More than 10 times the pixel resolution of the detector is thus achievable. The particular measurement sensitivity is obtained if the fundamental spatial frequency or one of the higher harmonic spatial frequencies of the intensity distribution caused by the code pattern on the detector forms a low-frequency superposition pattern together with the fundamental spatial frequency of the radiation-sensitive structures of the detector. The low-frequency superposition pattern acts in the same way as a moirépattern. Moiré patterns are known to be very sensitive to a shift in the structures which produce them. Here, this means that, even in the case of a very small change in the intensity distribution on the detector compared with its pixel structure, the low-frequency superposition pattern changes considerably in its spatial frequency. Thus, the position of the focused code pattern on the detector can be measured very precisely. Since a change in the superposition pattern is caused by a change in the position and rotational position of the object, the position parameters of the object in space can therefore be measured in a very sensitive and hence highly precise manner.
If the object is a levelling staff, the direction vector of its axis is also important in addition to its position, since said vector describes the tilt of the levelling staff from the perpendicular. In addition to the known conventional levelling staffs where a code pattern is applied to a flat surface, it is also possible to use a levelling staff which is rotationally symmetrical with respect to its longitudinal axis and has a rotationally symmetrical bar code. In this case, the imaging optical system can pick up the same code pattern even continuously from all sides of the levelling staff. By determining the direction vector of the levelling staff axis from the focused code pattern or the detected contours of the levelling staff, both the inclination of the levelling staff in the direction of view of the imaging optical system and the lateral inclination of the levelling staff transverse to the direction of view of the imaging optical system are determined. Thus, the deviation of the levelling staff from the ideal perpendicular is determined and is taken into account in a corresponding correction for the surveying. This correction is made automatically in every survey. Consequently, it is even possible to dispense with prior alignment of the levelling staff. As a result, fast and precise surveying with only a single operator and also independently of the wind conditions is possible. If moreover, in the given case, the angle of rotation of the levelling staff about its axis is also determined—assuming a suitable code pattern or specific marks—this automatically also gives the sighting direction of a movable measuring head.
If the object is a gun barrel, this can be equipped with various code patterns, analogously to the case of the levelling staff. If only elevation and azimuth of the gun barrel are to be determined, a code pattern rotationally symmetrical with respect to the longitudinal axis of the gun barrel or only the edge contour of the gun barrel is sufficient. If a code pattern comprising code lines aligned parallel to the longitudinal axis is additionally applied to the gun barrel, its angle of rotation about its axis can additionally be determined. The code lines may also be stochastically oriented. Combinations of these code patterns in which, for example, segments having rotationally symmetrical code rings and segments having parallel or stochastic code lines alternate can also be used. A code pattern which is wound in a spiral manner around the gun barrel and with which about the same sensitivity for the direction vector of the gun barrel axis and the angle of rotation of the gun barrel about its axis can be achieved is also advantageous. However, it is also possible to use a code pattern having a completely irregular structure, as possessed, for example, by military camouflage patterns. What is decisive for all code patterns is that they are either known per se or are determined by surveying. Advantageously, such code patterns can be readily used for the correlation procedures.
By means of the imaging optical system, the contours of the gun barrel and/or of the code pattern are recorded and the rotational position of the gun barrel is determined without contact. Optionally, the gun barrel can be actively illuminated, for example with infrared light. The gun barrel or the applied code pattern may also be luminescent. Generally firm locking of imaging optical system and detector relative to the gun barrel and the optical surveying result in the great advantage that absolutely no mechanically moving components are required for determining azimuth, elevation and angle of rotation of the gun barrel. This contactless measurement takes place rapidly and gives precise results.
If the object is an aid used in the medical environment, in particular in automated microsurgery, such as, for example, a surgical microscope, a surgical tool (scalpel, drill, endoscopic aid, etc.) or a radiation source for tumour treatment, good visibility of the object structures of the aid must be ensured for the measuring head. During handling of the aid, the latter may be temporarily concealed by persons or instruments and the direction of view of the measuring head interrupted. However, if it is intended constantly to measure the spatial position of the aid under these conditions, it is useful if the object structures to be detected by the measuring head are located in an exposed area of the aid so that they are as far as possible in the unobstructed direction of view of the measuring head. When a code pattern is used, it may also be applied to a plurality of points on the aid or it may even cover the entire surface of the aid. The measuring head may be movable in space for an optimal recording, or preferably a plurality of measuring heads distributed in space are used simultaneously. The redundancy of the results delivered by a plurality of measuring heads moreover meets the requirement set in the medical sector for particular equipment safety.
Otherwise, the object may also be the patient itself, i.e. more precisely a frame which is firmly connected to the patient and defines the coordinate system of the patient. Precisely in operations on tumours in the brain, such a frame is fixed to the patient's head, the spatial position of the tumour relative to the frame being determined, for example, by computed tomography images. If the geometric structures of the frame or the code patterns applied to the frame are recorded by the measuring heads and the spatial position of the frame is determined, the coordinates of the tumour are also known in the coordinate system of the measuring heads. Since moreover the spatial position of the surgical microscope and of the surgical tool is determined with the aid of the measuring heads, endoscopic navigation through the brain to the tumour can be performed fully automatically.
In all stated application examples of the invention, it is possible that it may be difficult to provide an object with a code pattern to be used or that the object is already present as a complete component. In such cases, it is possible to mount a separate body provided with a code pattern eccentrically on the object (“booster principle”). The body may have a cylindrical shape. It is of course also possible to mount a plurality of such bodies on one object. If the object moves in space, the separately mounted body, too, performs clearly coupled movements, in particular rotational movements so that the position and rotational position of the object can always be computed.
In addition, an object can also be recorded stereoscopically. For this purpose, either two measuring heads can form a stereo base or the stereo base is produced by a measuring head together with a focusing mirror or a plurality of focusing mirrors, so that the measuring head can record stereoscopic images of the object. By means of this additional image information, the accuracy of the position determination of the object can be further increased—analogously to seeing with two eyes.
Finally, a distance measuring instrument can also be connected to the measuring head or integrated therein. With such additional information about the distance of the object, it is also possible to increase the accuracy of measurement. Moreover, the additional information can ensure that the measured result regarding the position of the object is available more quickly.
BRIEF DESCRIPTION OF THE DRAWINGS
The embodiments of the invention are explained in more detail below with reference to the drawing.
FIG. 1 shows a schematic representation of the rotational position of an object provided with a code pattern and the recording of the object structures by a measuring head comprising an optical imaging system and a position-resolving detector,
FIG. 2 shows a schematic representation of detector recordings of the object for different rotational positions,
FIG. 3 shows a representation of geometrical relationships for determining the rotational position and the position vector of the object,
FIGS. 4 a, b show distortion of a code pattern at different elevation angles,
FIG. 5 shows a schematic representation of an object in the form of a medical aid and its recording by a plurality of measuring heads,
FIGS. 6 a, b shows separate bodies which are provided with a code pattern and are mounted on the object to be surveyed,
FIGS. 7 a, b, c show a schematic representation for the stereo recording of the object,
FIGS. 8 a, b show a schematic representation of the measuring head with a distance measuring instrument, and
FIGS. 9 a, b, c show embodiments of the invention providing both large and small field of view.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 schematically shows an object 1 in a Cartesian coordinate system x, y, z. The object 1 has a foot 3 and an object axis 4 and can be provided with a code pattern 2 b . The object contours 2 a and/or the code pattern 2 b are either known from the outset or they are surveyed so that the size, shape and the spacing of the details of the object contours 2 a and of the individual code elements of the code pattern 2 b relative to the foot 3 of the object 1 are obtained. In the simplest case, the object contours 2 a are straight lines. The object contours 2 a shown in FIG. 1 are additionally rotationally symmetrical with respect to the object axis 4 , and, in the special case, the angle of rotation κ of the object 1 about the axis 4 cannot be determined from the object contours 2 a alone.
With the aid of an imaging optical system 5 present in a measuring head 9 , that part of the object structures 2 a , 2 b present in the field of view of said optical system is focused onto a two-dimensional position-resolving optoelectronic detector 7 . The electrical signals of the detector 7 are evaluated in an evaluation unit 8 . According to the diagram in FIG. 1, the evaluation unit 8 is likewise integrated in the measuring head 9 . In principle, the evaluation unit 8 can of course also be present outside the measuring head 9 , for example in a separate electronics arrangement or in a computer (PC).
A coordinate system x Det , y Det is defined in the light-sensitive detector plane of the detector 7 , the origin of said coordinate system being chosen at the point of intersection of the optical axis 6 of the imaging optical system 5 with the detector plane. The optical axis 6 arranged perpendicularly to the detector plane is lying parallel to the z axis of the coordinate system x, y, z. In the case of a horizontal imaging optical system 5 , the y axis is simultaneously normal to the Earth's surface. Of course, other coordinate systems can also be used.
The position of the object 1 in space is uniquely determined by six position parameters. They arise from the components of the position vector {overscore (r)} 0 , the components of the direction vector {overscore (ν)}, which contains only two independent parameters owing to its unit vector property, and the angle of rotation κ of the object 1 about its axis 4 . The position vector {overscore (r)} 0 points from the imaging optical system 5 to the foot 3 of the object 1 . The direction vector {overscore (ν)} points in the direction of the object axis 4 and thus indicates its position in space. Instead of the direction vector {overscore (ν)}, the position of the object axis 4 can also be described by the angle δ measured from the vertical y axis and the horizontal angle φ measured from the y-z plane. In the case of unique object contours 2 a or a unique code pattern 2 b , the angle of rotation κ about the object axis 4 can be determined. The angle of rotation κ can be measured, for example, from the plane defined by the position vector {overscore (r)} 0 and by the direction vector {overscore (ν)}. Thus, the complete rotational position of the object 1 is determined.
According to the invention, the position parameters of the object 1 are determined from the planar position and the local mapping of the object structures 2 a , 2 b focused on the detector 7 . Depending on the magnitude of the polar angles (φ, δ) and of the position vector {overscore (r)} 0 , the position shown schematically in FIG. 1 and the mapping of the object structures 2 a , 2 b on the detector 7 change.
In this context, images of the object 1 at various polar angles (φ, δ) on the detector 7 are shown schematically in FIG. 2 . Each of the lines shown on the detector coordinate system X Det , Y Det corresponds symbolically to the image of the same section of object 1 which is detected by the imaging optical system 5 , in each case for a different pair of polar angles (φ, δ). The individual code elements of any code pattern 2 b present are not shown here.
FIG. 2 reveals three groups of lines G 1 , G 2 , G 3 , which represent three different vertical angles δ. A small vertical angle δ can be assigned to group G 1 in the upper region of FIG. 2, whereas a large angle δ gives rise to group G 3 . Within each group G 1 , G 2 , G 3 , the horizontal angle φ varies, correspondingly large negative or positive angles φ being assigned to the lines at positive and negative coordinate values, respectively, of X Det .
The different lengths of the lines depending on φ and δ indicate different imaging scales according to the rotational position of the object 1 . The imaging scale of the object structures 2 a , 2 b varies along each line since the object structures 2 a , 2 b are different distances away from the imaging optical system 5 owing to the rotational position of the object 1 . The imaging scale is obtained from the quotient of the known sizes of the object structures 2 a , 2 b on the object 1 and the measured size of the object structures 2 a , 2 b on the detector 7 . With the aid of the focal distance f of the imaging optical system 5 , the distance between the imaging optical system 5 and the object structures 2 a , 2 b on the object 1 is calculated therefrom according to the laws of geometrical optics.
The geometrical situation in this context is shown in FIG. 3 . To present the principle more clearly, the thickness of the object 1 is neglected. The sighting point can then coincide with the foot 3 and both are given by the position vector {overscore (r)} 0 . The object structures 2 a , 2 b should in this case be a code pattern 2 b . The i th code element of the code pattern 2 b is located at a fixed, known distance |{overscore (L)} i | from the foot 3 of the object 1 . It is assumed here that the number i of the code element is known; this can be obtained either by counting if the total code pattern 2 b is focused on the detector 7 or by decoding a sufficiently long focused section of the code pattern 2 b . The i th code element is focused on the detector 7 at a distance |{overscore (ρ)} i | from the optical axis 6 by the imaging optical system 5 having the focal distance f. The vectors {overscore (ρ)} i and {overscore (L)} i are three-dimensional, where {overscore (ρ)} i lies in the plane of the detector 7 . In general, the vectors {overscore (ρ)} i and {overscore (L)}i are not located in the plane of the drawing in FIG. 3 . Below, a distinction is made between two cases.
In a first case, the position vector {overscore (r)} 0 from the imaging optical system 5 to the foot 3 of the object 1 should be predetermined. The predetermined position vector {overscore (r)} 0 means that the imaging optical system 5 and the foot 3 of the object 1 are invariable relative to one another. The position vector {overscore (r)} 0 can be determined by a simple mechanical measurement or, in the case of higher requirements, also by laser surveying or by a calibration measurement in which the object 1 is present in a previously known spatial position. Such mutual fixing of measuring head 9 and object 1 may be the case, for example, when object 1 is a gun barrel. With the known position vector {overscore (r)} 0 , the polar angles (φ, δ) of the gun barrel are determined, with the result that the latter can be brought or adjusted to a predetermined rotational position. Within the range of rotation of the gun barrel, code pattern 2 must be capable of being at least partly detected by the imaging optical system 5 .
The distance |λ i a i | from the imaging optical system 5 to the i th code element of the code pattern 2 is determined in the following equations, where
{overscore (a)}
i
=∫·{overscore (e)}
z−ρ
i
and {overscore (e)} z is the unit vector in the positive z direction. The vector {overscore (a)} i is thus known, while λ i is the multiplication factor to be determined. The following vector equation is applicable
{overscore (L)} i =λ i ·{overscore (a)} i −{overscore (r)} 0 .
By calculating the square of the absolute value, the following quadratic equation for λ i is obtained:
| á i | 2 ·λ i 2 −2·({overscore (r)} 0 ·á i )·λ i +|{overscore (r)} 0 | 2 −|{overscore (L)} i | 2 =0.
There are thus two solutions for λ i , which is shown in FIG. 3 schematically by the two points of intersection of the dashed arc with the direction of observation {overscore (a)} i to the i th code element. The uniqueness of the solution is established by mapping the i th code element on the detector 7 . The mapping describes the deviation of the shape of the focused code element (or generally of object 1 ) from its shape which it has at the “zero point” (polar angles φ=0 and δ=0) of the object 1 .
The three-dimensional coordinates of the vector {overscore (L)} i are obtained on the basis of the distance |λ i {overscore (a)} i | to the i th code element, determined from the above equations, and of the vector {overscore (a)} i determined from the detected vector {overscore (ρ)} i . This immediately gives the direction vector v _ = L _ i L _ i ,
from which the polar angles (φ, δ) can easily be calculated by means of trigonometrical functions. Thus, when position vector {overscore (r)} 0 is known, the measurement of a single code element is sufficient for calculating the polar angles (φ, δ). The accuracy of the polar angle calculation can of course be substantially increased by including more code elements of the code pattern 2 b . If in addition a code pattern 2 b unique with respect to the angle of rotation κ is applied to the object 1 , the angle of rotation κ of the object 1 about its axis 4 can also be determined from the focused code pattern 2 b . Thus, the total rotational position of the object 1 is determined rapidly, precisely and without contact.
In a more extensive second case, the measuring head 9 and the object 1 are to be spatially variable relative to one another. In this case, the position vector {overscore (r)} 0 is also unknown in addition to the rotational position. The additional determination of the position vector {overscore (r)} 0 is essential particularly when the object 1 is a levelling staff, a surgical microscope or a surgical tool (and can of course also be performed in the case of the above-mentioned gun barrel) In the case of surveys, the position vector {overscore (r)} 0 —in particular the distance Z 0 and the height H of the imaging optical system 5 from the foot 3 of the levelling staff—is even the measured quantity of actual interest. If at the same time the direction vector {overscore (ν)} of the levelling staff always deviating slightly from the exact perpendicular is determined, this has the advantageous effects, mentioned further above, on the accuracy of the surveying and the handling during the levelling process. It is even possible deliberately to dispense with a perpendicular orientation of the levelling staff and to omit the application of a water level on the levelling staff. Finally, in the case of said medical aids for diagnosis, therapy or surgery, a knowledge of the position vector {overscore (r)} 0 , of the direction vector {overscore (ν)} and of the angle of rotation κ is also important.
For simultaneous determination of {overscore (r)} 0 and {overscore (ν)}, it is sufficient in principle to select only three code elements from the code pattern 2 b focused on the detector 7 , to determine their code numbers i and to apply the vector mathematics described by the above equations to these code elements.
It is of course advantageous for the accuracy and reliability of the result to use additional or all detected code elements for the evaluation and to apply the vector mathematics described. Moreover, generally known estimation and fit procedures from mathematics can be used. Moreover, the above vector equations can be solved with the aid of iteration procedures and similar mathematical methods.
Instead of the code elements of code pattern 2 b , details of object contours 2 a or marks on the object 1 can also be evaluated in an analogous manner.
Advantageously, the position parameters of the object 1 which have been determined in this manner can be used in subsequent optimization procedures and thus determined even more accurately. The position parameters are varied until the detector image of the object structures 2 a , 2 b which are calculated from the position parameters agree optimally with the image information actually detected. In principle, however, the optimization procedures can also be performed independently of preceding calculations.
FIGS. 4 a, b are simulated views of an object 1 at different elevation angles ψ showing distortion of a code pattern 2 b.
FIG. 5 schematically shows, as object 1 , an aid for the medical sector whose spatial position and rotational position relative to a patient are of decisive importance. Thus, the object 1 may be a surgical microscope, a surgical tool, such as, for example, a scalpel, a drill, an endoscope, etc., or a frame firmly connected to the patient or a radiation source for tumour treatment. As shown schematically in FIG. 5, the object 1 may be provided with a code pattern 2 b in a plurality of areas on its surface. The spatial position of the object 1 is changed, for example, with the aid of a swivel arm 10 . Moreover, the object 1 is mounted on the swivel arm 10 so as to be rotatable at a pivot point 3 through the three angles φ, δ, κ, so that its rotational position, too, can be adjusted as desired. Thus, the object 1 —for example in the case of a brain operation—can be brought into any desired required spatial position on the patient's head.
The object 1 can be picked up by a plurality of measuring heads 9 a , 9 b , 9 c and the object structures 2 a , 2 b can be evaluated according to the above equations or with the aid of the optimization methods. For reasons of redundancy and because of the possible concealment of the object structures 2 a , 2 b by persons or instruments, a plurality of measuring heads 9 a , 9 b , 9 c are arranged in space. The spatial coordinates of the pivot point 3 (position vector {overscore (r)} 0 ) and the rotational position φ, δ, κ of the object 1 can be determined relative to each measuring head 9 a , 9 b , 9 c . Since the spatial positions of the measuring heads 9 a , 9 b , 9 c relative to one another are known, the positional parameters of the object 1 can be transformed to a superior coordinate system, for example into the coordinate system of the patient. Thus, the exact spatial position of the surgical microscope or of the surgical instruments relative to the operating site can be displayed for the surgeon. In addition, the surgical instrument can be guided fully automatically.
FIG. 6 a schematically shows an object 1 on which a separate body la has been mounted. By means of the novel surveying and evaluation of the object structures 2 a , 2 b of the body 1 a , the (6-dimensional) spatial position of the body 1 a and hence also that of the object 1 are determined. Advantageously, an object 1 which has insufficient structures for an intended use can be subsequently equipped with a suitable body 1 a . Optionally, the body 1 a can also be readily removed again. Of course, a plurality of such bodies 1 a can also be fastened to an object 1 (FIG. 6 b ).
FIG. 7 a shows a stereoscopic arrangement of two measuring heads 9 a , 9 b , which permit a high accuracy of the determination of the object position on the basis of the additional image information. The measuring heads 9 a and 9 b can on the one hand be firmly connected to one another so that the mutual position of their optical axes 6 a , 6 b is fixed. The axes 6 a , 6 b may make an angle with one another. Because little mounting work is required, they are preferably aligned parallel to one another. On the other hand, it may be advantageous to keep the two measuring heads 9 a , 9 b variable relative to one another and to make a suitable adjustment only when they are set up for surveying the object 1 . If the object 1 is brought into an initial, previously known position, the mutual position of the optical axes 6 a , 6 b of the measuring heads 9 a , 9 b can be automatically set by self-calibration. Of course, the measuring heads 9 a , 9 b can if required be housed in a single housing.
A variant of the stereoscopic arrangement is shown in FIG. 7 b . Only one measuring head 9 is used, which picks up one partial stereo image directly and the other partial stereo image via a laterally arranged mirror 15 . The coupling of the light picked up via this mirror 15 into the beam path of the measuring head 9 is effected either via a pivotable coupling mirror 16 which, depending on its position, lets through only one or only the other partial stereo image for image mapping with the detector 7 of the measuring head 9 , or the coupling mirror 16 is controllable in its reflection and transmission properties, for example according to the function of an LCD shutter, in such a way that the two partial stereo images reach the detector 7 alternately at high transmission and at high reflection of the coupling mirror 16 . On the other hand, it is possible to use a half-silvered coupling mirror 16 which transmits the two partial stereo images simultaneously to different detector regions of the detector 7 or to two separate detectors 7 . This is possible with suitable tilting of the half-silvered mirror 16 and of an imaging optical system 5 tailored thereto.
Of course, a stereo basis can also be generated by two mirrors 15 a , 15 b according to FIG. 7 c , and the associated partial stereo images can be received alternately by the detector 7 via a rotatable mirror 17 . The rotatable mirror 17 may also be replaced by a rotatable or fixed prism. In the case of the fixed prism or with a suitable mirror arrangement, simultaneous focusing of both partial stereo images onto different regions of the detector 7 can be effected.
Instead of the stereo imaging or in addition thereto, the distance to the object 1 can furthermore be determined using a distance measuring instrument 18 , 18 a and can be used as further measuring information in the evaluation. The measured distance value improves the accuracy and/or the rapidity of the evaluation for determining the position parameters for the object 1 .
Electrooptical distance measuring instruments 18 , 18 a are preferred. They are connected as an independent device to the measuring head 9 , for example according to FIG. 8 a , or integrated in the measuring head 9 , according to FIG. 8 b . FIG. 8 a furthermore schematically shows a cooperative target mark 19 (reflective foil, reflector, retroreflector, etc.) to which the distance is measured. Of course, the distance measurement is also possible without reflective aids and merely to the given surface of the object 1 as an uncooperative target.
That version of an integrated distance measuring instrument 18 a which is shown in FIG. 8 b has the advantage that the imaging optical system 5 of the measuring head 9 can also be used and the distance along the optical axis 6 of the measuring head 9 can be determined. Coupling of the emitted light of the distance measuring instrument 18 a into the optical beam path of the measuring head 9 or coupling out of the received light for detection in the distance measuring instrument 18 a are effected, for example, via a half-silvered or wavelength-selective mirror 20 .
The electrooptical distance measuring instrument 18 , 18 a is usually operated in the visible or infrared wavelength range. Wavelengths which are outside the sensitivity of the detector 7 of the measuring head 9 are preferred, or corresponding filters for the detector 7 and/or for the distance measuring instrument 18 , 18 a are used. With the use of a wavelength-selective mirror 20 , the latter may optionally reflect the infrared light of the distance measuring instrument 18 a particularly well and at the same time transmit the visible light to the detector 7 of the measuring head 9 particularly well. Otherwise, all types of electrooptical distance measuring instruments 18 , 18 a can be used, including those which have, for example, a biaxial design with separate transmitted and received beam path or which are of monoaxial design and simultaneously make use of the same optical setup for the transmitted and received radiation.
A problem encountered with target pointing, acquisition and tracking (PAT) is that the target 1 may move in a large angular range Ω as shown in FIGS. 9 a, b, c . To cover the angular range Ω one would need a wide angle optical system, i.e. an imaging optical system with a large field of view (FOV) commensurate with the angular range of movement Ω. FIG. 9 a shows how an object 1 under test can rotate azimuthally around 360°. If the distance between the object 1 and the position measuring device or head 9 has to be kept short by specifications, a large field of view Ω of the optics is needed to detect where the object is located (acquisition mode).
On the other hand, when the target is finally caught by the detector and the tracking mode is activated, an imaging optical system with a small field of view ω is advantageous. Then the target appears large on the detector, which increases the accuracy for determining the target position and in our case additionally, the target orientation. In other words, a small field of view ω is required to image the detected object with sufficient resolution on the detector of the position measuring device (detecting mode).
The above problems can be overcome in accordance with additional aspects of the present invention.
In FIG. 9 a , a measuring head 9 is shown which is essentially the same as the measuring head previously described but with an imaging optical system 5 ′ modified to include a zoom which allows variation of the angular magnification to obtain both a narrow and a large angular range (i.e., small and large FOV).
According to another embodiment shown in FIG. 9 b , a measuring head 9 of the type described herein is configured as a tracking instrument (tracker), e.g., like a modern theodolite or goniometer. Although measuring head 9 has an imaging optical system 5 with a small field of view ω, in this embodiment the head mechanically scans a large field of view Ω. While overcoming the aforementioned problems, the tracking mechanics of such a system is presently slow and expensive.
Another embodiment of a measuring head 9 according to the present invention, shown in FIG. 9 c , includes an optical system 5 with a small field of view ω and a pupil multiplexer made of several deflecting elements 22 (e.g., small prisms) placed side-by-side in the pupil of the optical system. Each deflecting element functions as a subpupil which images an angular segment ω on the detector to cover completely a large angular range Ω. This task is similar to prior German patent document No. DE 195 04 039 C1 disclosing a fixfocus level, where small prisms were placed side-by-side in the pupil. Each of the prisms deflects different depth-of-focus regions simultaneously on the detector 7 . Some of the advantages of this system are that it requires no moving parts and offers immediate response. In the case where the object moves around a fixed pivot point, it is possible to determine the position of the object by making the prisms in such a way that the segments ω assigned to each prism slightly overlap one another. Then in any situation we have two target images with different orientation on the detector, from which the actual segment position can be uniquely deduced.
In the case of a free moving and free orienting target the situation is more complicated, but again can be solved. One possibility is to make the angular overlaps between two pupils variable. Then from the distance and the mutual orientation of both images on the sensor we can determine where the target actually is.
While the preferred embodiments of the invention have been disclosed in detail above, the invention is not intended to be limited to the embodiments as disclosed. Those skilled in the art may make numerous uses and modifications of and departures from the specific embodiments described herein without departing from the inventive concepts.
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The invention relates to a method for determining the spatial and rotational positions of an object. With the assistance of an imaging optical system, the object is mapped and detected on a high-sensitivity resolution optoelectronic detector. The location parameter of the object, such as the position vector ({overscore (r)} 0 ), the direction vector ({overscore (ν)}) of the object axis, and the angle (κ) of rotation of the object around the object axis is determined from the planar position of the mapped object structures in the coordinate system (X Det , Y Det ) of the detector by means of geometric optical relationships and mathematical evaluation methods. With this, the spatial position of the object is determined in a quick and contactless manner.
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FIELD OF INVENTION
[0001] This invention concerns sharpness enhancement of images and video sequences.
BACKGROUND OF THE INVENTION
[0002] This invention concerns the enhancement of the perceived sharpness of sampled images and video sequences. The invention is particularly suitable for images that have been upconverted from lower resolutions, for images that are defocused and for moving video sequences that are blurred by camera integration.
[0003] Images and video sequences are today being captured on devices with a very wide range of resolutions, from a few hundred pixels wide in the case of inexpensive mobile phones, to professional cameras whose resolution in some cases approaches 10,000 pixels wide. Likewise, the resolution of display devices covers a similar range. There is therefore an increasing need to convert between different resolutions, a process that is often referred to as “resizing” in image processing software. Resizing may be classified into two types: downconversion, where the sampling resolution of the output is lower than that of the input, and upconversion, where the sampling resolution of the output is higher than that of the input. Downconversion can usually be accomplished at high quality with a linear filtering operation that ensures that the picture signal meets the Nyquist limit of the new sampling frequency, so that aliasing is avoided. With upconversion, there are two broad approaches. One is to upconvert by repeating input pixels over rectangular blocks of output pictures. This gives a perception of sharpness, but a generally unacceptable overall degradation due to the visibility of the block structure. The other approach is to apply a linear interpolation filter which suppresses frequencies beyond the bandwidth of the input sampling structure. This gives a subjectively smooth and artefact-free output picture, but the problem, especially when comparing with pictures that were created at a higher resolution, is the subjective impression of “softness”. There has for a long time been an interest in enhancing upconverted images to increase their subjective sharpness without introducing the artefacts that arise from sample-repeat upconversion.
[0004] Other applications for image enhancement to increase sharpness are defocused pictures, and moving video sequences that are blurred by camera integration. In these cases, the sampling structure can support the portrayal of sharper edges, but the high-frequency signals responsible for subjective sharpness have been attenuated or suppressed. Again, there is interest in enhancing the subjective sharpness of such images.
[0005] One method of enhancement has been applied to analogue cathode-ray-tube video displays. For example, S. Yashuda et al in “25-v inch 114-degree Trinitron color picture tube and associated new developments”, IEEE BTR-20, Issue 3, August 1974, pp 193-200, describe a method of beam scan velocity modulation, in which horizontal transitions are sharpened by varying the scan velocity during the transition. Referring to FIG. 1 , a video signal ( 101 ) is differentiated to obtain a derivative signal ( 102 ) which is used to control the beam scan velocity, leading to a variation of the position ( 103 ) of the deflected scanning spot from its usual linear ramp characteristic. The effect of this variation on a white window pattern ( 104 ) is shown ( 105 ) as a narrowing of the pattern. This method underwent several improvements, including the development of versions suitable for digital processing. However, the method is only applicable to horizontal enhancement in beam-scanning displays, which are now largely obsolete.
[0006] Another, more generally applicable, method of enhancement involves linear filtering to amplify or “boost” high spatial frequencies. This can be performed as a separate operation or, in the case of upconversion, by modifying the upconversion filter so that the response at higher frequencies is increased. Linear filtering can be effective in the cases of defocusing or motion blur, where high frequencies may be present in the picture but have been attenuated by the defocused lens or by camera integration. The filter can reverse the effect of that attenuation and restore the lost sharpness of the picture. In the case of linear upconversion, there is no benefit in boosting the highest frequencies of the output picture because no signals are present at those frequencies. However, subjective sharpness can sometimes be increased by boosting the highest input frequencies either before or after upconversion.
[0007] Linear filtering has various disadvantages. One disadvantage is that noise on the input picture can be amplified. This is because noise generally makes a greater relative contribution to the higher frequency signals, and can therefore be disproportionately amplified. Another disadvantage is that high-pass filtering can increase the dynamic range of the signal, leading to the possibility of clipping and, ironically, consequential loss of detail. An example of this is given in FIG. 2 , in which a linear filter is applied to a rising and a falling edge in the input video ( 201 ) which has the effect of steepening the transition but which also leads to overshoots in the output signal ( 202 ).
SUMMARY OF THE INVENTION
[0008] The inventor has recognised that the principle of scan velocity modulation can be applied horizontally and vertically to sampled signals regardless of the technology of the display. The invention works by generating a mapping by which each input sample is projected onto output space. The use of a mapping approach maintains the dynamic range of the input signal, avoiding problems of overshoots and of noise amplification, while increasing the subjective sharpness of picture detail.
[0009] The invention consists in a method and apparatus for enhancing the perceived sharpness of an image by reducing the spatial extent of a portrayed image feature in which data describing a point in an input image is used to compute data describing a different point in an enhanced output image according to a digitally-implemented spatial interpolation process controlled in dependence on a rectified pixel-value spatial gradient measure.
[0010] Advantageously, a sample-spacing parameter that controls the said spatial interpolation process is derived from a high-pass filtered pixel value spatial gradient function of the said input image.
[0011] In a preferred embodiment, a sequence of values of the said pixel value spatial gradient function for a sequence of adjacent pixels of the said input image are accumulated, prior to high-pass filtering.
[0012] Suitably, the said pixel value spatial gradient function is a combination of a horizontal pixel value gradient and a low-pass filtered version of said horizontal pixel value gradient.
[0013] In some embodiments the said pixel-value spatial gradient function is a combination of a vertical pixel value gradient and a low-pass filtered version of said vertical pixel value gradient.
[0014] In certain embodiments pixels are positioned according to a map comprising a sequence of pixel position values where the distance between each pixel and its preceding adjacent pixel is the sum of a fixed pixel-pitch value and the value of a high-pass filtered pixel value spatial gradient function.
[0015] In a preferred embodiment a map representing the positions of input image samples in an output image is inverted to form a map that represents the positions of output image samples in an input image before being used to control the spatial interpolation process.
[0016] Preferably, the map is corrected to ensure that it increases monotonically.
[0017] Suitably, maximum and minimum filters are applied to the map and the outputs of said filters are combined such that the resulting output is monotonically increasing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] An example of the invention will now be described with reference to the drawings in which:
[0019] FIG. 1 illustrates the principle of scan velocity modulation in sharpening horizontal transitions according to prior art;
[0020] FIG. 2 is a graph illustrating the behaviour of a prior art linear enhancement filter;
[0021] FIG. 3 is a top-level block diagram of a sharpness enhancement system according to the invention;
[0022] FIG. 4 is a detailed block diagram of a video rendering circuit according to prior art;
[0023] FIG. 5 is a detailed block diagram of the horizontal component of a sharpness enhancement system according to the invention;
[0024] FIG. 6 is a graph illustrating the operation of a scan correction algorithm according to the invention;
[0025] FIG. 7 illustrates the behaviour of the invention on a test pattern.
DETAILED DESCRIPTION OF THE INVENTION
[0026] A first image sharpness enhancement system according to the invention will now be described. All signals referred to in the following description are in normal raster scanning order, so that there is a direct correspondence between time and pixel position. Horizontal position increases by one pixel-pitch unit for every sample clock period; and, vertical position increased by one scan-line-pitch unit for every L sample clock periods, where L is the number of samples per scan line.
[0027] Referring to FIG. 3 , an input video luminance signal ( 301 ) comprising a sequence of luminance values for the pixels of an input image is applied to a horizontal map circuit ( 302 ) to produce a horizontal map signal ( 303 ), and to a vertical map circuit ( 304 ) to produce a vertical map signal ( 305 ). These map signals represent respective sequences of pixel position values for horizontally and vertically adjacent pixels. The operation of these map circuits ( 302 ) and ( 304 ) will be described later with reference to FIG. 5 . The input luminance signal ( 301 ), the accompanying input colour difference pixel values ( 306 ), and the horizontal and vertical map signals ( 303 , 305 ) are applied to a known rendering engine ( 307 ) to produce enhanced output luminance and colour difference signals ( 308 , 309 ). The pixel position values of the horizontal and vertical map signals ( 303 , 305 ) provide sub-pixel-resolution horizontal and vertical spatial addresses, which are used by the rendering engine ( 307 ) to spatially interpolate the input signals ( 301 , 306 ).
[0028] The operation of a suitable prior art rendering engine ( 307 ) will now be described in detail with reference to FIG. 4 , in which, for convenience, only one component (luminance or one of the colour difference components) is shown. An input video signal ( 401 ) is written into a frame store ( 402 ). Incoming horizontal ( 403 ) and vertical ( 404 ) map signals are applied to circuits ( 405 , 406 ) which calculate their integer parts ( 407 , 408 ) and, by means of subtractors ( 410 , 411 ), their fractional parts ( 412 , 413 ) denoted α and β. The values of pixels denoted A, B, C and D ( 409 ) are read from the frame store ( 402 ) from locations given by the integer map values ( 407 , 408 ). Sample A is addressed directly by those map values; associated samples B, C and D are in adjacent locations, as shown in the accompanying diagram ( 416 ).
[0029] The four samples, together with the fractional map values α and β ( 412 , 413 ) are then applied to a bilinear interpolation circuit ( 414 ) which calculates an interpolated sample value P ( 415 ) according to the following well-known formula:
[0000] P= (1−α)(1−β) A+ α(1−β) B+ (1−α) βC+αβD
[0030] This interpolation is a “read-side” rendering process because it reads input image samples from frame store locations determined by the map signals, which define output pixel positions that typically do not correspond to input pixel locations.
[0031] The operation of the inventive horizontal map circuit ( 302 ) will now be described in detail. The vertical map circuit ( 304 ) operates in a corresponding manner and follows the description of the horizontal map circuit ( 302 ) but with references to “horizontal” replaced by “vertical”, single-sample delays replaced by line delays, and lines of pixels replaced by columns of pixels.
[0032] With reference to FIG. 5 , an input luminance signal comprising a sequence of pixel luminance values is applied to a single-sample delay ( 502 ) to produce a delayed luminance signal ( 503 ), which is subtracted ( 504 ) from the input luminance ( 501 ) to produce a horizontal gradient signal ( 505 ). The sign of the subtractor's output is ignored to obtain the absolute value of the gradient, so that the gradient signal ( 505 ) is a rectified gradient. This gradient signal is applied to a low-pass filter ( 506 ) whose output ( 507 ) is applied, along with the unfiltered gradient signal ( 505 ), to a pixel value spatial gradient function ( 508 ), whose output ( 509 ) will be used to produce a sample-spacing signal that controls the interpolation of output pixels.
[0033] A suitable low-pass filter ( 506 ) is a symmetric running-average filter of length (2n+1) samples, where n is approximately equal to the degree of sharpening required. That is to say horizontal transitions are narrowed by a factor of n.
[0034] The operation of the pixel value spatial gradient function ( 508 ) will now be described. A suitable function is
[0000]
max
{
0
,
1
+
α
(
1
-
g
max
{
g
min
,
(
g
)
]
)
}
[0000] where g is the (absolute) gradient ( 505 ), g min is a constant noise floor, g is the output ( 507 ) of the low-pass filter ( 506 ), and α is a constant gain factor. Suitable values of the constants are α=1 and g min =4 (in 8-bit luminance units).
[0035] The principle of the function is to replace the original input image sample pitch, which is represented by a value of 1, with a desired spacing which decreases as the local gradient (relative to nearby picture information) increases. The process operates at the input pixel rate and outputs a value for every input pixel that represents the desired distance of that pixel from its preceding pixel. In regions of high pixel-value gradient these distances will be less than the input pixel pitch, that is to say numeric values less than unity.
[0036] The output ( 509 ) from the pixel value spatial gradient function ( 508 ) is accumulated, at the input pixel rate, along each line of the picture. The accumulator consists of an adder ( 510 ) whose output ( 514 ) is delayed in a single-sample delay ( 513 ), and added to its current input.
[0037] The sequence of accumulated values at the adder output ( 514 ) is potentially a map defining the required horizontal position of each input pixel in the enhanced output image.
[0038] However, at this stage it is not suitable for direct application as a mapping function, for two reasons:
its value at the end of a line may not be close to the number of pixels per line, so that, when used to control a spatial interpolation process, it would bring about a net shrinkage or expansion of the line; and, it may contain significant low-frequency components, which would lead to undesirable large-scale horizontal shifts of picture information.
[0041] These problems are overcome by the action of subsequent processing as follows. First, the accumulated sample-spacing signal ( 514 ) is applied to a high-pass filter ( 515 ) to produce a sample-shift signal ( 516 ). A suitable filter is a high-pass filter ‘complementary’ to the low-pass filter ( 506 ); that is to say it has the response that would be obtained by subtracting the response of the filter ( 506 ) from unity.
[0042] The sample-shift signal ( 516 ) is added ( 517 ) to a horizontal position signal ( 525 ) to produce a map signal ( 518 ). The horizontal position signal ( 525 ) starts at zero on the first pixel of each input image line and increments by unity every pixel until it reaches the number of pixels per line L at the end of each input image line.
[0043] One potential problem remains with the map signal ( 518 ). It should be monotonically increasing, otherwise some picture information will end up being left-right reversed. The accumulation of the values of the pixel value spatial gradient function ( 509 ) prior to the high-pass filter ( 515 ) reduces the likelihood of negative-going transitions appearing at the filter output that would cause this problem. However, the actions of all the previous processing elements may occasionally lead to violation of the monotonicity constraint. The invention therefore contains a monotonicity correction process ( 530 ) whose operation will be described later with reference to FIG. 6 .
[0044] The map signal ( 526 ), corrected by the monotonicity correction process ( 530 ) is a “write-side” map because it defines a, typically non-integer, output horizontal position for every input pixel. However, the known rendering circuit ( 307 ) in FIG. 3 requires a “read-side” map comprising a, typically non-integer, input position for every output pixel. The final action of the horizontal map generator ( 302 ) is therefore to apply the monotonicity-corrected, write-side map ( 526 ) to an inversion circuit ( 527 ) to produce a read-side map ( 528 ). Such inversion is well-known in the art and may, for example, be performed using an algorithm which identifies input pixels located adjacent to the required output pixel position and uses their values in a linear, or higher order, interpolation process to find the value of the output pixel.
[0045] The monotonicity correction process ( 530 ) operates as follows. The map signal ( 518 ) is applied to a minimum filter ( 519 ) whose output ( 520 ) is the minimum of the past (n+1) samples. It is also applied via an n-sample delay ( 521 ) to a maximum filter ( 522 ) whose output ( 523 ) is the maximum of its past (n+1) input samples. The outputs ( 520 , 523 ) of the minimum and maximum filters ( 519 , 522 ) are applied to a modified-average circuit ( 524 ) which computes the average of those two signals, modified by adding a very small fraction of the horizontal position ( 525 ). A suitable small fraction is 1/(100 N) where N is the picture width in samples. The modification ensures that the output is strictly increasing, which avoids problems of division by zero in subsequent processing stages.
[0046] Further explanation of the correction circuit ( 530 ) will now be given by way of an example, in which n=5, illustrated in the graphs of FIG. 6 . The x-axis ( 601 ) represents input pixel locations or addresses, and the y-axis ( 602 ) represents write-side map address values. Four curves ( 603 to 606 ) are shown, which all coincide in the straight sections at input addresses 0 to 6 and 14 to 20. The long-dashed curve ( 603 ) shows the uncorrected map signal, corresponding to the input ( 518 ) to the correction process ( 530 ). To aid explanation, the other curves are all drawn with suitable delays so that the addresses they represent are co-timed and therefore co-located; they thus do not have the actual timing relationships that would occur in the system of FIG. 5 .
[0047] The curves are drawn for a portion of a line containing a range ( 610 ) of input pixel values where the uncorrected address ( 603 ) is decreasing as the input address increases; this illustrates the problem that the correction circuit needs to solve.
[0048] The output ( 520 ) of the minimum filter applied to the uncorrected signal is shown as a dot-dashed line ( 604 ). The propagation delay of the process ( 530 ) is five samples and so the minimum filter effectively looks ahead by n=5 samples, thereby picking up the local minimum ( 607 ) at input address 12. Likewise, the output ( 523 ) of the maximum filter is shown as a dotted line ( 605 ). The input to the maximum filter ( 522 ) is delayed by five samples in the delay ( 521 ), therefore it looks back by n=5 samples, thereby picking up the local maximum ( 608 ) at input address 8. The modified average ( 526 ) of the minimum and maximum filter outputs is shown as the full line ( 606 ). Note that the addition of the fraction of the horizontal position value ( 525 ) ensures that the curve continues to rise slightly even though it is derived from the constant minimum value ( 607 ) and the constant maximum value ( 608 ). This modified output curve ( 606 ) is (qualitatively) as close as possible to the input curve ( 603 ), while meeting the monotonicity constraint.
[0049] Other correction methods to ensure monotonicity may be employed. One other method is to apply local scaling to the sample-shift signal ( 516 ) to ensure that it is always greater than −1 (so that it is monotonic after the horizontal position has been added).
[0050] Another method is to sort the map values ( 518 ) into ascending order. Finally, with careful choice of the parameters of the sample-spacing function ( 508 ), it may be possible to ensure that the monotonicity constraint is never violated in the first place, avoiding the need for a correction circuit. However, in the inventor's experience, the method given in the description above gives the best results.
[0051] An example of the overall performance of the invention will now be given. Referring to FIG. 7 , an input picture ( 700 ) is shown with increasing contrast from top to bottom and with decreasing sharpness from left to right. An output image ( 710 ) from processing according to an embodiment of the invention is shown, illustrating the substantial increase in sharpness of most of the picture, even ( 701 ) where the input picture is very blurred. The reasonable limitations of the algorithm are shown in regions of extreme blur ( 702 ) where some blur is still visible on the output, and in regions of very low contrast ( 703 ) where the noise floor g min comes into play.
[0052] The skilled person will recognise that variations to the design of the components of the invention are possible without departing from the scope of the invention. In the system of FIG. 3 , the vertical map signal ( 303 ) and the horizontal map signal ( 305 ) would typically be derived from the luminance values of the pixels of the input image according to the processes illustrated in FIG. 5 . Although two-dimensional enhancement of both luminance and colour difference signals is shown, other variations are possible. For example only luminance could be enhanced, or colour difference pixel value gradients could be used to determine mapping for colour difference pixels. Only horizontal enhancement, or only vertical enhancement could be applied. Luminance values could be used to derive map functions to be applied to RGB values.
[0053] The gradient may be measured by means other than a simple sample difference. Low-pass and high-pass filters need not be based on a simple running average. Other sample-spacing functions may be used. And, the map inversion function may involve interpolation techniques other than simple linear interpolation.
[0054] The above described steps of
high-pass filtering a rectified pixel-value gradient measure; combining a directional (horizontal or vertical) pixel value gradient and a low-pass filtered version of the directional pixel value gradient; accumulating a sequence of values of the pixel value spatial gradient function for a sequence of adjacent pixels of the input image;
are important steps which can be taken alone or in any combination to improve functionality. They are not however essential to the claimed invention.
[0058] The step of correcting a map to ensure that it increases monotonically may in some arrangements be unnecessary and—where it is necessary—techniques other than those specifically disclosed above may be used. Similarly, the step of inverting the map may not be required in all architectures.
[0059] The above description has been given in terms of streaming processes operating on samples in raster-scan order. However the processes of the invention can be carried out in other ways, including the processing of stored pixel values from files at speeds unrelated to the spatial or temporal sampling of an image or image sequence.
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A method of enhancing the perceived sharpness of an image by controlling a spatial interpolation process. A pixel value spatial gradient measure is formed and used to generate a map of modified pixel positions. In this map, the pixel spacing is reduced when the gradient measure is high. By using this map of modified pixel positions to control an otherwise conventional interpolation process, an output image is formed having a perceived sharpness which is greater than that of the unmodified output of the interpolation process.
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[0001] The present invention relates to a method for manufacturing a metal coated steel strip product in a roll-to-roll process and in particular to a coated metallic substrate material suitable for manufacturing high strength stainless steel products. This is achieved by coating a metallic strip with an electrically conductive layer, in accordance with claim 1 .
BACKGROUND OF THE INVENTION
[0002] In many electronic devices such as telephones, remote controls, computers, etc., springs and other formed metallic parts are used for different functions. Hence, for electromagnetic shielding (EMS) purposes, springs are used in so called “finger stocks” as gaskets in removable sections in shielded boxes. In most such products, several different requirements on the material are at hand. For springs, the requirements are in general related to the mechanical behavior such as force, relaxation resistance, and fatigue resistance. However, as forming is generally involved, the material must be able to be formed to requested shapes without any cracking. Further, the ongoing miniaturization within this field also puts increasing demands on tight geometrical tolerances of components and parts in electronic devices. In addition to the above, it is sometimes crucial to have well defined electrical characteristics of such parts and components. This may involve specific properties regarding electrical conductivity or contact resistivity at interfaces within devices. Generally, when such requirements are present, the solution is to choose a conductive material such as copper or copper alloys, or alternatively to coat a steel with a conductive layer. Copper and copper alloys are often characterized by good electrical conductivity and good formability but most of them are suffering from low mechanical strength, which means that they are not suitable for applications that are highly stressed, as for instance springs. Alloys of copper and beryllium may be hardened to a tensile strength up to approximately 1400 MPa but also this tensile strength level limits the spring force, fatigue and relaxation resistance that can be achieved for spring applications. Further, beryllium is a toxic metal, which may put restrictions during manufacturing and use due to health considerations. Finally, copper-beryllium alloys are costly and, therefore, less expensive products are requested in many applications.
[0003] Coating may be carried out by various methods that can be divided into mechanical and chemical methods. These may also be sub-divided into high and low temperature methods. Mechanical methods may be exemplified by cladding, thermal by spraying or painting. In this context, cladding is represented by roll bonding, i.e., to bind two (or more) different materials by a rolling process that is relatively simple and may be carried out with different combinations of substrates and coatings. However, cladding suffers from some technical disadvantages, which are related to thickness tolerances and poor adhesion of the coated layer. This often requires a post-bonding heat treatment in order to obtain a diffusion zone between layers. If one (or several) of the layers is/are stainless steel, then a good adhesion is even more difficult to obtain due to the passive film at the stainless surface. Further, roll bonding is a low speed process and is limited in the possible combinations of base materials and coatings.
[0004] There also exist numerous different deposition techniques based on spraying methods with different names such as Thermal Spray, High Velocity Oxide Fuel (HVOF), Plasma Spray, Combustion Chemical Vapor Deposition (CCVD); however, the underlying method is the same. The coating is sprayed onto a substrate and the material is fed into the nozzle or “flame” from either a rod, wire, stock, powdered material, liquid or gas. Spray techniques are most often used to coat details and are not suitable for roll-to-roll coatings, with high requirements on close tolerances and high productivity.
[0005] Another method to coat a substrate is by hot dipping of the product into a molten metal. Hot dipping is generally carried out with coatings that have a low melting point, e.g., zinc, etc. For coatings with higher melting points, such as nickel and copper, the temperature of the molten metal is so high that it will often affect the substrate material in a negative way. Further, to have an accurate process control of such molten bath allowing close tolerances on layer thickness, is difficult.
[0006] Electroplating is an electrochemical process in which the coating is achieved by passing an electrical current through a solution containing dissolved metal ions and the metal object to be plated. The metal substrate serves as the cathode in an electrochemical cell, attracting metal ions from the solution. Ferrous and non-ferrous metal substrates are plated with a variety of metals, including aluminum, brass, bronze, cadmium, copper, chromium, iron, lead, nickel, tin, and zinc, as well as precious metals, such as gold, platinum, and silver.
[0007] As the substrate acts as a cathode in the process and thereby attracts the ions in the solution, it is difficult for flat products to obtain an even layer distribution. Local variations in current density will create an inhomogeneous deposition rate. A well-known problem is the “dog bone” effect that means that the thickness of the coating is often higher towards the edges of a coated strip. Further, the method is characterized by not being environmentally friendly as it involves electrolytes and costly wastewater treatment. Electrochemical methods and dipping methods also have the disadvantage that if a single sided coating is requested, the surface that shall remain uncoated has to be masked in some way prior to the coating. The masking then has to be removed subsequent to the coating operation.
[0008] There are also some vapor deposition methods that can be used for depositing metals. Most methods are batch-like processes, but there are also some continuous processes. One example of a roll-to-roll method making use of electron-beam deposition is disclosed in WO 98/08986, which describes a method of manufacturing ferritic stainless FeCrAl-steel strips, by bringing about an aluminum coating of a substrate material in a roll-to-roll process. However, the method described in this patent application is optimized for a product suitable for use in a high temperature corrosive environment, thus requiring a material with a good high-temperature strength and also a good high-temperature corrosion resistance, i.e., oxidation resistance. Moreover, this patent application suggests that a homogenization annealing at a temperature of 950-1150° C. is made in connection to the coating, in order to have the aluminum evenly distributed in the ferrite. This means that the final product in this case is not a coated product with an aluminum layer on the surface. Hence, it is rather a FeCrAl strip product with a uniform distribution of the alloying elements, including also aluminum. Further, this means that there are no special requirements on an oxide free interface and on a good adhesion of the layer.
[0009] Thus, all these conventional methods are suffering from different disadvantages, which means that there is a need for a development of a new product combining good mechanical properties with excellent electrical characteristics and narrow geometrical tolerances.
[0010] All processes based on batch-type production will always increase the cost and it is therefore essential that the production will be by a roll-to-roll process to decrease the cost.
[0011] Therefore, it is a primary object of the present invention to provide a flexible metallic product with tailor-made physical and mechanical characteristics suitable for further processing that may be exemplified by, but not limited to, blanking, bending, drilling, heat treatment etc.
[0012] Yet another object of the present invention is to provide a flexible strip product, for springs and other products, that requires a good electrical conductivity, made from a single- or multilayered metallic strip that is inexpensive and which may be produced in a continuous roll-to-roll process.
[0013] These and other objects have been attained in a surprising manner by creating a coated steel product with the features according to the characterizing clause of claim 1 . Further preferred embodiments are defined in the dependent claims.
BRIEF DESCRIPTION OF THE INVENTION
[0014] Thus, the above objects and further advantages are achieved by applying one or more thin continuous, uniform, electrically conductive layer(s) of a metal, such as nickel, silver, tin, molybdenum, copper, tungsten gold or cobalt, on the top of a metal stainless strip serving as substrate. The coating may be done on one or both sides of the substrate strip. The metal layer should be smooth and dense and have a good adhesion in order to allow for further processing without the risk of flaking or peeling. The final product, in form of a high strength strip steel with one or two electrically conductive surfaces, is suitable for use in electrical devices, in gaskets for electromagnetic shielding or for any other purpose, where a high strength material with a low contact resistance in the interface between the product according to the invention and its contact point is requested.
[0015] The coated layer is deposited by means of the previously known method electron beam evaporation (EB), in a roll-to-roll process, to an evenly distributed layer with a thickness of preferably less than 15 μm. The substrate material should be a stainless steel with a Cr content above 10% (by weight) and with a strip thickness of usually less than 3 mm. The substrate material should have a tensile strength of at least 1000 MPa, which can be achieved by cold deformation or by thermal treatment such as hardening from high temperature or by precipitation hardening at lower temperatures. As a first step, the roll-to-roll process may also include an etch chamber, in order to remove the oxide layer that otherwise normally is present on a stainless steel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 shows a schematic cross-section of a first embodiment of the present invention, i.e., a substrate strip 2 with a coating of an electrically conductive layer 1 , 3 on one or both surfaces. If the substrate is coated on both surfaces, then the coatings may be of the same composition, or if so desired, of different compositions. Also the thickness of the coating may be the same or different for the two surfaces.
[0017] FIG. 2 shows a schematic cross-section of a second embodiment of the present invention, i.e., a substrate strip 2 with coatings of multiple layers ( 1 , 3 , 4 and 5 , 6 , respectively) on one or both surfaces.
[0018] FIG. 3 shows schematically a production line for the manufacturing of a coated metal strip material according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The final product, in the form of a metal coated strip material, is suitable for the use as load carrying parts that also are characterized by providing a low contact resistance at the interface. Examples of such applications are connectors and switches. By applying a given force on the spring, it will contact a surface and thus close an electrical circuit. At the point of contact, where the current is transferred, it is important that the contact resistance is low. Stainless steel is an increasingly used material for spring applications. This is due to the attractive combination of high mechanical strength and good formability, allowing forming also rather complex spring geometries. High strength stainless spring steels have in general superior mechanical properties compared to non-ferrous materials. In the context of spring properties, especially the fatigue and relaxation resistance of high strength stainless steel are crucial for a long lasting spring with a constant force throughout its service life. However, stainless steel is characterized by a passive film on the surface. This film consists of chromium oxide and has a significantly lower electrical conductivity than the steel itself. As a reference value, a stainless steel has an electrical resistivity of 80-90×10 −8 Ωm, depending on the tensile strength. However, at the surface, the oxide (Cr 2 O 3 ), has a resistivity of approximately 1.3×10 11 Ωm. If an oxide film is present at the interface between two conductive surfaces, a drop in conductivity will occur. This will decrease the efficiency in current circulation in the circuit and thus decrease the performance.
[0020] To eliminate the problem of low conductivity in high strength stainless steel, at least one of the strip surfaces is coated with a metal layer that is less prone to form an oxide film at the surface. The coated layer will thus allow for an oxide free surface at the contact point, whereby the drop in electrical conductivity at the interface is avoided. Depending on the requirements, the coating may be of different metals. Silver, copper, nickel, cobalt, gold, tungsten, tin and molybdenum are all metals with a good electrical conductivity that may be deposited on the surface by the method according to the invention. It is also of vital importance that the coating is homogeneously distributed on the surface and is not too thick compared to the substrate thickness. A thick or an uneven layer will affect the spring properties, as the bending force is proportional to the thickness of a rectangular section raised to the third power. The thickness of the layer is therefore preferably max 10% of the substrate thickness. Moreover, the thickness of each coating layer is preferably maximally 15 μm, typically 0.05-15 μm, preferably 0.05-10 μm and even more preferably 0.05-5 μm. If multiple layers are to be deposited, then the total summarized thickness of the coatings should not exceed 20% of the total thickness of the coated strip. The thickness tolerance of the coated layer according to the invention is very good. The variation in thickness of and within each layer should not exceed +/−20% of the nominal thickness of said layer. More preferably, the thickness variation should be maximum +/−10% of the nominal thickness within each layer.
[0021] The coating should show a good adhesion to the substrate and thus make subsequent manufacturing possible. The product according to the invention shows an excellent adhesion between the coating and the substrate. This is achieved by a pre-treatment operation of the stainless strip by means of an ion etching in vacuum prior to the deposition of the coating on the substrate. This allows for a metal-metal contact with an oxide free interface that will give a product that may be bent, blanked, slit or deep-drawn, the only limit being set by the ductility of the substrate material.
[0000] The Substrate Strip to be Coated
[0022] The material that shall be coated should have a good general corrosion resistance. This means that the material must have a chromium content of at least 10% by weight, preferably minimum 12% or more preferably minimum 13% or most preferably minimum 15% chromium. Further, the material must be alloyed in a way that allows for a high tensile strength of at least 1000 MPa, more preferably a minimum of 1300 MPa or even more preferably minimum 1500 MPa, or most preferably a minimum of 1700 MPa. The mechanical strength may be achieved by cold deformation such as for steels of the ASTM 200 and 300 series, or by thermal hardening as for hardenable martensitic chromium steels. Other suitable substrate materials are precipitation hardenable (PH) steels of type 13-8PH, 15-5PH, 17-4PH or 17-7PH. Yet another group of suitable substrate materials are stainless maraging steels that are characterized by a low carbon and nitrogen containing martensitic matrix that is hardened by the precipitation of substitutional atoms such as copper, aluminum, titanium, nickel etc.
[0000] The Conductive Layer(s)
[0023] The material to be coated in the form of a thin layer film on the substrate surface should be characterized by a good electrical conductivity at room temperature, a thermodynamic stability against oxide formation and a suitable modulus of elasticity. The characteristics of the suitable elements are listed below.
[0024] Silver has a very low electrical resistivity, approximately 1.47×10 −8 Ωm, at room temperature. The free energy for oxide formation for Ag 2 O at room temperature is approximately ΔG=−10.7 kJ which makes silver significantly more stable against oxidation compared with the formation of Cr 2 O 3 , as in stainless steel. As a reference value, Cr 2 O 3 has a free energy at room temperature of approximately ΔG=−1050 kJ. Silver has a modulus of elasticity of approximately 79000 MPa that can be compared to the 180,000-220,000 MPa for different steel types. Silver is however relatively expensive and sometimes cheaper alternatives are required.
[0025] Copper has a low electrical resistivity of approximately 1.58×10 −8 Ωm, a modulus of elasticity of approximately 210,000 MPa and a free energy of ΔG=−145 kJ and ΔG=−127 kJ for the formation of Cu 2 O and CuO respectively. This combination of properties makes also copper a suitable coating in the product according to the invention.
[0026] Nickel has a low electrical resistivity of approximately 6.2×10 −8 Ωm, a modulus of elasticity of 200,000 MPa and a free energy of approximately ΔG=−213 kJ for the formation of NiO.
[0027] Gold has an electrical resistivity of approximately 2×10 −8 Ωm, a modulus of elasticity of 80,000 MPa. Gold is also extremely stable against oxidation. This makes gold in many applications most suitable as an element for conductive coatings. However, gold is expensive and alternatives are always looked for due to the high alloy cost as well as re-cycling costs.
[0028] Molybdenum has a low electrical resistivity of approximately 5.3×10 −8 Ωm, a modulus of elasticity of 329,000 MPa and a free energy of approximately ΔG=−668 kJ for the formation of MoO 3 and ΔG=−533 kJ for the formation of MoO 2 .
[0029] Cobalt has a low electrical resistivity of approximately 6.24× 10 −8 Ωm, a modulus of elasticity of 209,000 MPa and a free energy of approximately ΔG=−241 kJ for the formation of CoO.
[0030] Tungsten has a low electrical resistivity of approximately 5.3×10 −8 Ωm, a modulus of elasticity of 360,000 MPa and free energies of approximately ΔG=−534 kJ and ΔG=−764 for the formation of WO 2 and WO 3 , respectively.
[0031] Tin has an electrical resistivity of approximately 10×10 −8 Ωm and a modulus of elasticity of 50,000 MPa. The free energy to form SnO is approximately ΔG=−534 kJ at room temperature. Tin is also a relatively soft metal and is easily deformed at the point of contact and may by this generate a larger contact area at the interface. This may be utilized, e.g., in gasket springs for electromagnetic shielding.
[0000] Description of Coating Method
[0032] Advantageously, the coating method is integrated in a roll-to-roll strip production line. In this roll-to-roll production line, the first production step is an ion-assisted etching of the metallic strip surface, in order to achieve good adhesion of the first layer. The conductive layer is deposited by means of electron beam evaporation (EB) in a roll-to-roll process. The formation of multi-layers can be achieved by integrating several EB deposition chambers in-line (see FIG. 3 ).
PREFERRED EMBODIMENT OF THE INVENTION
[0033] Two examples of embodiments of the invention will now be described in more detail. One example is based on a silver coating on a ASTM 301-type of steel with a chemical composition of max 0.12% C, max 1.5% Si, max 2% Mn, 16-18% Cr and 6-8% Ni with balance Fe and residual elements that are present according to the metallurgical method used. The second example is a nickel coating on a modified ASTM 301-type of steel with a chemical composition of max 0.12% C, max 1.5% Si, max 2% Mn, 16-18% Cr and 6-8% Ni, 0.5-1.0% Mo with balance Fe and residual elements that are present according to the metallurgical method used.
[0034] Firstly, the substrate materials are produced by ordinary metallurgical steel-making to a chemical composition as exemplified above. They are then hot rolled down to an intermediate size, and thereafter cold-rolled in several steps with a number of recrystallization steps between said rolling steps, until a final thickness of about 0.02-1 mm and a width of maximum 1000 mm are attained. The surface of the substrate material is then cleaned in a proper way to remove all oil residuals from the rolling.
[0035] Thereafter, the coating process takes place in a continuous process line, starting with decoiling equipment. The first step in the roll-to-roll process line can be a vacuum chamber or an entrance vacuum lock followed by an etch chamber, in which ion-assisted etching takes place in order to remove the thin oxide layer on the surface of the stainless substrate material. The strip then enters into the E-beam evaporation chamber(s) in which the deposition of the desired layer takes place. A metal layer of normally 0.05 up to 15 μm is deposited, the preferred thickness depending on the application. In the two examples described here, a thickness of 0.2-1.5 μm is deposited by using one E-beam evaporation chamber.
[0036] After the EB evaporation, the coated strip material passes through the exit vacuum chamber or exit vacuum lock before it is coiled on to a coiler. The coated strip material can now, if needed, be further processed by, for example, rolling or slitting, to obtain the preferred final dimension for the manufacturing of components.
[0037] The final product as described in the two examples, i.e., a 0.05 mm thick strip of ASTM 301 with a single sided 1.5 μm Ag-coating and a 0.07 mm thick strip of ASTM 301, modified with a single sided 0.2 μm Ni-coating, have a very good adhesion of the coated layer and are thus suitable to be used in subsequent manufacturing of components for high strength applications, e.g., for springs. The good adhesion of the layers is tested according to standard tensile testing. From a substrate material of a stainless steel strip that has been coated with a thin covering layer so as to produce a coated strip product in accordance with the present invention, tensile test specimens are produced according to standard. Tensile testing of 4 specimens, for example according to EN 10002-1, is thereafter carried out until fracture. After testing, the fractured part of the specimen is investigated in an optical microscope with a magnification of 50 times. Beside the actual fracture from testing, no signs of flaking, peeling or any other damage of the coated layer has been observed in any tested specimen. The results from this test are presented in Table 1.
TABLE 1 Mechanical properties and adhesion of layer. Proof Proof Tensile Visual Thick- strength strength stregth examination ness, Rp 0.05%, Rp 0.2%, Rm, at 50 times Sample Mm MPa MPa MPa magnification 301 + Ni 0.07 1659 2108 2120 No peeling or flaking, 301Mod + 0.05 1445 1920 1945 No peeling or Ag flaking
[0038] The roll-to-roll electron beam evaporation process referred to above is illustrated in FIG. 3 . The first part of such a production line is the uncoiler 13 within a vacuum chamber 14 , then the in-line ion assisted etching chamber 15 , followed by a series of EB evaporation chambers 16 , the number of EB evaporation chambers needed can vary from 1 up to 10 chambers, this to achieve a multi-layered structure, if so desired. All the EB evaporation chambers 16 are equipped with EB guns 17 and suitable crucibles 18 for the evaporation. After these chambers, comes the exit vacuum chamber 19 and the recoiler 20 for the coated strip material, the recoiler being located within vacuum chamber 19 . The vacuum chambers 14 and 19 may also be replaced by an entrance vacuum lock system and an exit vacuum lock system, respectively. In the latter case, the uncoiler 13 and the coiler 20 are placed in the open air.
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A coated high strength stainless steel strip product with a dense and evenly distributed metallic layer on one side or both sides of said strip is provided. Said layer consists of essentially pure gold, copper, nickel, cobalt, molybdenum, silver, tin or tungsten or alloys of at least 2 of these metals, the thickness of said layer is preferably maximally 15 μm, the tolerance of said layer is maximally +/−30% of the layer thickness, the Cr content of the steel strip substrate is at least 10%, and that the layer has such a good adhesion so that the coated steel strip can be uniaxially stretched to fracture by tensile testing without showing any tendency to peeling, flaking or the like. The metal-coated strip product is suitable for use in applications that are load carrying and is able to transfer electrical currents to a contacting surface without an electrical conductivity drop at the interface between the surfaces.
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FIELD
[0001] This invention relates to medicine, cancer, chemotherapy, materials science and medical devices. In particular it relates to a method of treating solid tumors, especially hepatocellular carcinomas using an improved TACE procedure.
BACKGROUND
[0002] Cancer is currently the second greatest cause of death in the United States behind coronary heart disease. Even though there is trend toward lower death rates from cancer in the U.S., it has been estimated that the annual personal and financial cost of cancer will be $1.62 trillion dollars by 2017. Further, according to the World Health Organization cancer is set to become the leading cause of death world-wide by 2010.
[0003] A particularly nefarious cancer is hepatocellular carcinoma (HCC). This is a primary liver cancer as opposed to a secondary or metastatic liver cancer that begins in another organ and migrates to the liver. HCC accounts for 80 to 90% of liver cancers and occurs in men more than women and is usually seen in patients between about 50 and 60 years old. It is more prevalent in Africa and Asia than the Americas and Europe. Its reputation is due not so much to any particular virulence compared to other solid tumor cancers but rather to the fact that it is rarely diagnosed at an early stage of development and when it is discovered, most chemotherapies and radiation treatment are usually ineffective. Surgery is the only recourse but even then it is very difficult to completely remove the entire tumor; the 5-year survival rate for patients with resectable HCCs is 60 %, which is low by current standards. For unresectable tumors the prognosis is extremely poor: the disease is usually deadly within 3-6 months of diagnosis.
[0004] The currently preferred treatment for unresectable HCC, which is thought to extend the lifespan of a patient to 1-2 years, is transcatheter arterial chemoemolization (TACE). TACE is implemented in two ways. In the first, a drug is administered in a sterile drip into a selected artery servicing the tumor. After the drug has been administered over a period of time, usually about 30 minutes, microparticles such as gelfoam are infused into the artery to cut off the flow of blood to the tumor. In the second procedure, the chemotherapeutic agent itself is loaded onto microbeads which then are infused into the artery where they serve both to block blood flow and to deliver the drug.
[0005] The problem is that by either of the above methods the drug concentration reaches a maximum in serum, i.e., blood in the vicinity of the tumor, within about 5 minutes of administration. It then drops to a baseline level within about 24 hours. Because of the variation in the drug concentration, TACE must presently be repeated every 4 to 12 weeks.
[0006] What is needed is a method for applying TACE in a manner such that a single application of the procedure lasts for a prolonged period, preferably at least 6 months or more. The current invention provides such a method.
SUMMARY
[0007] Thus, in one aspect the current invention relates to a method, comprising; identifying a malignant solid tumor in a patient; providing a plurality of first biodegradable microparticles comprising a chemotherapeutic agent, wherein the first plurality of microparticles have a mean diameter of about 10 to 300 μm; delivering the first plurality of microparticles through an artery to a first location at or near the tumor; providing a second plurality of biodegradable microparticles, wherein the second plurality of microparticles have a mean diameter of about 900 to about 1200 μm; and delivering the second plurality of microparticles through the artery to a second location proximal to the location at which the first plurality of particles was delivered, wherein a therapeutically effective amount of the chemotherapeutic agent is released as the first plurality of microparticles degrades over a period of at least 6 months while the second plurality of microparticles substantially completely cuts off the flow of blood to the tumor upon initial delivery to its location and as it degrades over the same time-span as the first plurality of microparticles, blood flow is restored.
[0008] In an aspect of this invention, the first and second plurality of microparticles independently comprise a polymer that undergoes about 50% to about 100% mass loss in vivo at about 6 months after delivery at or near the tumor.
[0009] In an aspect of this invention, the first and second plurality of microparticles independent comprise a polymer that undergoes about 70% to about 80% mass loss in vivo at about 6 months after delivery of the microparticles at or near the tumor.
[0010] In an aspect of this invention, the first plurality of microparticles comprise liposomes.
[0011] In an aspect of this invention, the first plurality of microparticles comprise polymersomes.
[0012] In an aspect of this invention, the first plurality of microparticles comprise solid polymeric particles.
[0013] In an aspect of this invention, the first and second plurality of microparticles independently comprise a polymer selected from the group consisting of poly(D,L-lactide), poly(D,L-lactide-co-glycolide), poly(L-lactide-co-glycolide), poly(L-lactide-co-glycolide-co-ε-caprolactone) and poly(D,L-lactide-co-ethylene glycol), poly(L-lactide-co-ethylene glycol), poly(D, L-lactide-bl-glycolide), poly(L-lactide-bl-glycolide), poly(D,L-lactide-bl-ethylene glycol), poly(L-lactide-bl-glycolide), poly(D,L-lactide-bl-glycolide-bl-caprolactone), poly(L-lactide-bl-glycolide-bl-ethylene glycol, a poly(ester amide) and any combination thereof.
[0014] In an aspect of this invention, the first plurality of microparticles comprises poly(L-lactide-co-glycolide).
[0015] In an aspect of this invention, the molar ratio of L-lactide to glycolide is about 3:2 to about 9:1.
[0016] In an aspect of this invention, the number average molecular weight of the poly(L-lactide-co-glycolide) is about 100 kDa to about 150 kDA.
[0017] In an aspect of this invention, the first plurality of microparticles comprises a polymer comprising poly(ethylene glycol).
[0018] In an aspect of this invention, the number average molecular weight of poly(ethylene glycol) in any of the poly(ethylene glycol)-containing polymers is about 500 kDa to about 10,000 kDa.
[0019] In an aspect of this invention, the chemotherapeutic drug to polymer weight ratio is about 1:1 to about 1:5.
[0020] In an aspect of this invention, two or more chemotherapeutic agents are loaded into or onto the same first microparticles.
[0021] In an aspect of this invention, two or more chemotherapeutic agents are loaded into or onto different first microparticles, the different first microparticles being mixed together prior to delivery at or near the tumor.
[0022] In an aspect of this invention, the malignant solid tumor is a hepatocellular carcinoma.
[0023] In an aspect of this invention, the chemotherapeutic agent is doxorubicin.
[0024] In an aspect of this invention, the chemotherapeutic agent further comprises an agent selected from the group consisting of cisplatin and mitomycin C.
[0025] In an aspect of this invention, the second plurality of microparticles comprise solid polymeric particles.
[0026] In an aspect of this invention, the first plurality of microparticles is delivered at or near the tumor prior to delivery of the second plurality of microparticles, or the second plurality of microparticles is delivered at or near the tumor after which the first plurality of microparticles is injected into the artery between the tumor and where the second plurality of microparticles have lodged in the artery.
DETAILED DESCRIPTION
[0027] It is understood that use of the singular throughout this application including the claims includes the plural and vice versa unless expressly stated otherwise. That is, “a” and “the” are to be construed as referring to one or more of whatever the word modifies. Non-limiting examples are: “a therapeutic agent,” which is understood to include one such agent, two such agents or, under the right circumstances, as determined by those skilled in the treatment of diseased tissues, even more such agents unless it is expressly stated or is unambiguously obvious from the context that such is not intended. Likewise, “a biodegradable polymer” refers to a single polymer or a mixture of two or more polymers unless, again, it is expressly stated or absolutely obvious from the context that such is not intended.
[0028] As used herein, unless specified otherwise, any words of approximation such as without limitation, “about,” “essentially,” “substantially” and the like mean that the element so modified need not be exactly what is described but can vary from exact compliance with the written description by as much as ±15% without exceeding the scope of this invention. Thus, for example without limitation, to stop the flow of blood through an artery “substantially completely” means to cut off at least 85% of the flow of blood.
[0029] The target tissue of this invention is a malignant solid tumor. A solid tumor refers to an abnormal mass of tissue that usually does not contain cysts or liquid areas. A tumor that is not cancerous is described as “benign” while a cancerous tumor, the targets of this invention, are termed “malignant.” Different types of solid tumors are named for the particular cells that form them, for example, sarcomas formed from connective tissue cells (bone cartilage, fat, etc.), carcinomas formed from epithelial tissue cells (breast, colon, pancreas, etc.) and lymphomas formed from lymphatic tissue cells (lymph nodes, spleen, thymus, etc.). Treatment of all types of solid tumors is within the scope of this invention. In particular the target tumor is an HCC.
[0030] As used herein, “identifying” a malignant solid tumor simply refers to detecting its presence and its type by any means currently known in the art or as may become known in the future.
[0031] As used herein, “chemotherapeutic agent” refers to any substance that, when administered in a therapeutically effective amount to a patient suffering from a solid tumor cancer, has a therapeutic beneficial effect on the health and well-being of the patient. A therapeutic beneficial effect on the health and well-being of a patient includes, but it not limited to: (1) curing the cancer; (2) slowing the progress of the cancer; (3) causing the tumor to retrogress; or (4) alleviating one or more symptoms of the cancer. As used herein, a chemotherapeutic agent also includes any substance that, when administered in a prophylactic amount to a patient afflicted with a solid tumor cancer or who has been rendered substantially free of cancer as the result of one or more therapeutic treatment regimes, has a beneficial effect on the health and well-being of the patient. A prophylactic beneficial effect on the health and well-being of a patient includes, but is not limited to: (1) maintaining the cancer at a retrogressed level once such level has been achieved by a therapeutically effective amount of a substance, which may be the same as or different from the substance used in a prophylactic effective amount; or, (2) preventing or delaying recurrence of the cancer after a course of treatment with a therapeutically effective amount of a substance, which may be the same as or different from the substance used in a prophylactic effective amount, has concluded. It is presently preferred that, when the solid tumor is an HCC, the chemotherapeutic agent comprises at least doxorubicin. Any other chemotherapeutic that has a beneficial effect on the HCC may be combined with the doxorubicin but at present cisplatin and mitomycin C are preferred co-therapeutic agents to be administered with doxorubicin.
[0032] A “therapeutically effective amount” refers to that amount of a chemotherapeutic agent that will have a beneficial effect, which may be curative or palliative, on the health and well-being of the patient so afflicted. A therapeutically effective amount may be administered as a single bolus, as intermittent bolus charges, as short, medium or long term sustained release formulations or as any combination of these. As used herein, short-term sustained release refers to the administration of a therapeutically effective amount of a therapeutic agent over a period of about an hour to about 3 days. Medium-term sustained release refers to administration of a therapeutically effective amount of a therapeutic agent over a period of about 3 days to about 4 weeks and long-term refers to the delivery of a therapeutically effective amount over any period in excess of about 4 weeks. Presently, it is preferred that a therapeutically effective amount of the chemotherapeutic agent be delivered over a period of at least 6 months.
[0033] As used herein, the use of “preferred,” “preferably,” or “more preferred,” and the like refer to modify an aspect of the invention refers to preferences as they existed at the time of filing of the patent application.
[0034] Structural vehicles or “particles” that may be used with the method of this invention include, without limitation, liposomes, biodegradable polymersomes and biodegradable microparticles of a mean size such that at least 80% of them will not be able to pass through the vasculature servicing the target tumor, in particular an HCC. For the purposes of this invention, two different mean particle sizes are employed. One plurality of particles will have a mean size of about 10 nanometers (nm) to about 300 micrometers (μm), these being the drug-delivery particles. The other plurality of particles will have a mean size of about 900 μm to about 1200 μm and will be used to embolize an artery in the vicinity of a tumor being treated. The two pluralities of particles may comprise the same structural vehicle or they may be fabricated of different such vehicles. For example without limitation, the drug-carrying plurality of particles may be liposomes while the embolizing plurality of particles may be polymersomes or solid microparticles.
[0035] As used herein, “embolization,” embolizing” and any other variations on the term refers to the procedure of introducing an artificial material at a site in a blood vessel such that the material lodges there and blocks the flow of blood. Materials that can be used to embolize a vessel include, without limitation, coils or hydrocoils, particles, foams and plugs but for the purpose of this invention, the structural vehicles mentioned above are preferred.
[0036] As used herein, a “liposome” refers to a core-shell structure in which the shell comprises phospholipids or sphingolipids that surround a usually liquid, and in most cases aqueous, core.
[0037] Phospholipids are molecules that have two primary regions, a hydrophilic head region comprised of a phosphate of an organic molecule and one or more hydrophobic fatty acid tails. In particular, naturally-occurring phospholipids have a hydrophilic region comprised of choline, glycerol and a phosphate and two hydrophobic regions comprised of fatty acid. When phospholipids are placed in an aqueous environment, the hydrophilic heads come together in a linear configuration with their hydrophobic tails aligned essentially parallel to one another. A second line of molecules then aligns tail-to-tail with the first line as the hydrophobic tails attempt to avoid the aqueous environment. To achieve maximum avoidance of contact with the aqueous environment, i.e., at the edges of the bilayers, while at the same time minimizing the surface area to volume ratio and thereby achieve a minimal energy conformation, the two lines of phospholipids, know as a phospholipid bilayer or a lamella, converge into a sphere and in doing so entrap some of the aqueous medium, and whatever may be dissolved or suspended in it, in the core of the sphere. Examples of phospholipids that may be used to create liposomes are, without limitation, 1,2-dimyristroyl-sn-glycero-3-phosphocholine, 1,2-dilauroyl-sn-glycero-3-phosphocholine, 1,2-distearoyl-sn-glycero-3-phosphocholine, 1,2-dimyristoyl-sn-glycero-3-phosphoethanolamine, 1,2-dipalmitoyl-sn-glycero-3-phosphoethanolamine, 1,2-dioleoyl-sn-glycero-3-phosphate monosodium salt, 1,2-dipalmitoyl-sn-glycero-3-[phosphor-rac-(1-glycerol)]sodium salt, 1,2-dimyristoyl-sn-glycero-3-[phospho-L-serine]sodium salt, 1,2-dioleoyl-sn-glycero-3-phosphoethanolamine-N-glutaryl sodium salt and 1,1′,2,2′-tetramyristoyl cardiolipin ammonium salt.
[0038] Liposomes may be unilamellar, composed of a single bilayer, or they may be multilamellar, composed of two or more concentric bilayers. Liposomes range from about 20-100 nm diameter for small unilamellar vesicles (SUVs), about 100-5000 nm for large multilamellar vesicles and ultimately to about 100 microns for giant multilamellar vesicles (GMVs). LMVs form spontaneously upon hydration with agitation of dry lipid films/cakes which are generally formed by dissolving a lipid in an organic solvent, coating a vessel wall with the solution and evaporating the solvent. Energy is then applied to convert the LMVs to SUVs, LUVs, etc. The energy can be in the form of, without limitation, sonication, high pressure, elevated temperatures and extrusion to provide smaller single and multi-lamellar vesicles. During this process some of the aqueous medium is entrapped in the vesicle. Generally, however, the fraction of total solute and therefore the amount of therapeutic agent entrapped tends to be rather low, typically in the range of a few percent. Recently, however, liposome preparation by emulsion templating (Pautot, et al., Langmuir, 2003, 19:2870) has been shown to result in the entrapment of virtually 100% of aqueous solute. Emulsion templating comprises, in brief, the preparation of a water-in-oil emulsion stabilized by a lipid, layering of the emulsion onto an aqueous phase, centrifugation of the water/oil droplets into the water phase and removal of the oil phase to give a dispersion of unilamellar liposomes. This method can be used to make asymmetric liposomes in which the inner and outer monolayers of the single bilayer contain different lipids. Any of the preceding techniques as well as any others known in the art or as may become known in the future may be used as compositions of therapeutic agents in or on a delivery interface of this invention. Liposomes comprising phospho- and/or sphingolipids may be used to deliver hydrophilic (water-soluble) or precipitated therapeutic compounds encapsulated within the inner liposomal volume and/or to deliver hydrophobic therapeutic agents dispersed within the hydrophobic core of the bilayer membrane.
[0039] As used herein, a “microparticle” refers to a solid having as its smallest cross-sectional, i.e., through the solid as opposed to along its surface, dimension about one micron. Presently preferred are microparticles having a mean size of about 10 nm to about 300 μm if intended as the drug-carrying particles or about 900 to about 1200 μm if intended to be the embolizing particles. The solid can have any desired shape such as without limitation spherical, ellipsoid, rod-like, entirely random shaped, etc., although substantially spherical microparticles are well-known in the art, are readily prepared and are presently preferred. The microparticle may be constructed of one or more biocompatible substances and may be porous so as to permit elution of the therapeutic substance embedded in it or may be biodegradable such that as the particle degrades the therapeutic substance is released into the environment.
[0040] Particle size distributions may be represented in a number of ways, one of the most common of which is “mean particle size.” A “mean” size may refer to a value based on particle length, width and/or diameter, on area or on volume. As used herein, “mean size” is determined by measuring the longest through-particle distance of each microparticle and then dividing by the total number of microparticles. Of course, this requires sophisticated equipment when dealing with the large numbers of microparticles contemplated by this invention but such equipment is well-known and readily available to those skilled in the art and such determination of mean size is commonplace in the art. To assure efficient capture of the microparticles of this invention, not only should the microparticles have the stated mean size, the distribution of particle size should be a narrow as possible, that is as close to monodisperse as can be achieved. No specific size dispersion is presently preferred because the narrower the better and, while several techniques are discussed below for achieving relatively narrow size distributions, as the state of the art advances, equipment and procedures for reaching even narrower size distributions will surely become available and all such equipment, procedures and size distributions will clearly be within the scope of this invention.
[0041] A particular method of determining mean particle size is dynamic light scattering (“DLS”), which is also called photon correlation spectroscopy, and which determines the hydrodynamic or Stokes diameter based on diffusion measurements. The hydrodynamic diameter includes solvent associated with the particle. This mean hydrodynamic diameter obtained from DLS is close to the volume-average diameter. One method is outlined in the International Standards Organization (“ISO”) 13321. There are many other means of determining mean particle size known to those skilled in the art. Also known to those skilled artisans is the fact that the various means tend to give different results but the correlation of the results of one method to each other method is also well known. Thus, any method of particle size determination may be used but the result should be correlated with that obtained by DLS to assure a mean particle size that will be entrapped at the correct point in the circulatory system, i.e., the capillaries.
[0042] With regard to mean size and size distribution, as noted above, it is presently preferred that at least 80% of the particles, be they liposomes, polymersomes or solid microparticles, administered into an artery serving a particular tissue are entrapped at the selected location in the vasculature servicing the target tumor. More preferably, at least 90% of the microparticles will be so entrapped and most preferably at present, at least 99% of the microparticles will be entrapped.
[0043] The plurality of particles herein can comprise several different designs. In the simplest, the therapeutic agent is simply encapsulated in the carrier at a single concentration so that all particles are substantially the same with regard to drug load. In another design, the therapeutic agent can be encapsulated in the carrier, or if desired in several different carriers, at different concentrations in separate preparations and the particles formed in those separate preparations can be combined for administration to a patient. In yet another design, different therapeutic agents can be separately encapsulated in a carrier, or, again, in different carriers, at various concentrations, the particles being combined for administration or, if desired, administered sequentially. Two or more therapeutic agents can, of course, be encapsulated in the same particulate carrier such that the resulting particles each contain more than one therapeutic agent. Those skilled in the art will, based on the disclosure herein, be able to devise additional combinations of carrier and therapeutic agent(s); all such combinations are within the scope of this invention.
[0044] The selection of the presently preferred range of particle sizes is based on the average diameter of various portions of the vasculature. A basic premise of this invention is that microparticles containing an appropriate therapeutic agent or combination of agents can be administered into an artery that directly services a tissue of interest. By “directly services” is meant that blood flowing through the artery proceeds in one direction only through the labyrinthine maze comprising artery→arterioles→metarterioles→capillaries→postcapillary venules→venules—vein. It is noted that the kidneys have a rather unique circulatory system: arteries afferent arterioles glomerular capillaries efferent arterioles but the methods of this invention are eminently suitable for use with the kidneys as well as other organs. Thus, particles injected into blood in the artery have nowhere to go but into the diseased tissue where, depending on their size, they lodge in whichever of the preceding substructures has a diameter that is smaller than the selected particle mean size. Arterioles are generally regarded as having inside diameters in the range of about 10 to 50 microns, metarterioles about 10 to 20 microns and capillaries approximately 4 to 15 (average about 8) microns in diameter. Thus, microparticles having a mean size of about 10 μm, the smallest size for drug-carrying particles of this invention, should be efficiently trapped at the capillary level. For example, it has been reported that in one experiment 97% of 15 micrometer radiolabeled microspheres injected in an artery servicing the eye were entrapped at the first pass. At the other end of the spectrum for drug-carrying particles, those with a mean size of about 300 μm, these will be entrapped in the main artery in the vicinity of where it necks down to arteriole size.
[0045] Entrapping the drug-carrying particles at the capillary level is presently preferred in that it offers the broadest specific application of chemotherapeutic agent to the target tumor assuming the tumor has developed a mature capillary system. This is due to the physiology of the capillary system. That is, the capillary system comprises a vast network of minute (averaging approximately one millimeter in length and 8-10 microns in diameter) vessels that permeates virtually every tissue in the mammalian body. As testament to the ubiquity of capillaries, it has been estimated that their number is approximately 19,000,000,000 and that most living tissue cells lie within 1-3 cell lengths of a capillary. Thus, to achieve maximum dispersion of a therapeutic agent in a target tissue, it makes sense that the vehicle carrying the therapeutic agent be capable of maneuvering through the circulatory system to the capillary level.
[0046] On the other hand, if the target tumor has not developed a sophisticated capillary system, it might be preferable to use larger size delivery vehicles/particles that will lodge in larger diameter vessels servicing the capillaries. Such determination is left to the attending physician and should be based on whatever diagnostic evidence is evinced during the course of treatment of the patient.
[0047] Whatever the selected mean particle size of the drug delivery vehicles, the mean size of the embolizing particles must be larger so as to substantially or, if desired, completely cut off the flow of blood to the region where the drug-delivery vehicle has lodged. In this manner, drug can be released from the delivery vehicle and have time to enter into the surrounding tissue without the risk of being carried away by the blood.
[0048] It may, on the other hand, be desirable to select the embolizing particle size based on the dimensions of the largest artery servicing the tumor that services only or predominantly the tumor. In this manner, stress can be placed on the entire tumor while at the same time embolization of healthy tissues is held to a minimum.
[0049] In addition to solid microparticles and liposomes, a particle of this invention may be a polymersome, which is akin to a liposome wherein the shell is made up of synthetic amphiphilic polymers rather than phospholipids and sphigolipids. Examples of polymers that can be used to prepare polymersomes include, without limitation, poly(ethylene glycol)-b-poly(ε-caprolactone), poly(ethylene glycol)-b-polyesters, poly(ethylene glycol)-b-poly(L-aminoacids), poly(N-vinylpyrrolidone)-bl-poly(orthoesters), poly(N-vinylpyrrolidone)-b-polyanhydrides and poly(N-vinylpyrrolidone)-b-poly(alkyl acrylates). Depending on the length and chemical nature of the polymers in the diblock copolymer, polymersomes can be substantially more robust that liposomes. In addition, the ability to control completely the chemical nature of each block of the diblock copolymer permits tuning of the polymersome's composition to fit the desired application. For example, membrane thickness can be controlled by varying the degree of polymerization of the individual blocks. Adjusting the glass transition temperatures of the blocks will affect the fluidity and therefore the permeability of the membrane. Even the mechanism of release can be modified by altering the nature of the polymers.
[0050] Polymersomes can be prepared in the same manner as liposomes. That is, a film of the diblock copolymer can be formed by dissolving the copolymer in an organic solvent, applying a film of the copolymer-containing solvent to a vessel surface, removing the solvent to leave a film of the copolymer and then hydrating the film. Polymersomes can also be prepared by dissolving the diblock copolymer in a solvent and then adding a poor solvent for one of the blocks, which will result in the spontaneous formation of polymersomes.
[0051] As with liposomes, polymersomes can be used to encapsulate therapeutic agents by including the therapeutic agent in the water used to rehydrate the copolymer film. Polymersomes can also be force-loaded by osmotically driving the therapeutic agent into the core of the vesicle. Also as with liposomes, the loading efficiency is generally low. Recently, however, a technique has been reported that provides polymersomes of relative monodispersity and high loading efficiency; generation of polymersomes from double emulsions. Lorenceau, et al., Langmuir, 2005, 21:9183-86. The technique involves the use of microfluidic technology to generate double emulsions consisting of water droplets surrounded by a layer of organic solvent. These droplet-in-a-drop structures are then dispersed in a continuous water phase. The diblock copolymer is dissolved in the organic solvent and self-assembles into proto-polymersomes on the concentric interfaces of the double emulsion. The actual polymersomes are formed by completely evaporating the organic solvent from the shell. By this procedure the size of the polymersomes can be finely controlled and, in addition, the ability to maintain complete separation of the internal fluids from the external fluid throughout the process allows extremely efficient encapsulation. This technique along with any other technique know in the art or as may become known in the future can be used to prepare a composition of therapeutic agents for use in or on a delivery interface of this invention.
[0052] As used herein, “delivering” microparticles “at or near” a tumor refers to deposition of the particles in an artery sufficiently close to the target tumor to assure to the extent possible that the first instance of encountering a vessel of sufficiently small internal diameter to prevent passage of the particles will be the capillary system of the tumor itself. Such delivery can be accomplished by a number of means including, without limitation, the use of catheters and direct injection. Both of these methods of delivering microparticles to a specific locale in a patient's body are well-known to those skilled in the art and require no further explication here.
[0053] As use herein, “proximal to the location of the first plurality of microparticles” refers to a point in the target artery that is between where the first plurality of microparticles has lodges and the heart so as to substantially cut off the flow of blood past the region with the first plurality of microparticles has lodged.
[0054] As mentioned previously, presently preferred delivery vehicles of this invention are microparticles, liposomes and polymersomes having a mean particle size such that the majority of the particles are entrapped in the vascular system at the chosen locale upon the first pass of the plurality of particles through the patient's circulatory system.
[0055] As used herein, “first pass” refers to the first time a particle encounters a vessel of the correct inside diameter be it a capillary, an arteriole, etc. With regard, without limitation, to a capillary target, first pass refers to the first time the drug delivery vehicle encounters the capillary bed at the terminus of a selected artery serving a tumor. Microparticles that, for one reason or another, pass through the bed and find their way to venules and thence to veins will continue to circulate in the circulatory system until they once again encounter a capillary bed (although it may not be the capillary bed of the target tissue, which is why it is preferred that as high a percentage as possible are entrapped in the capillary bed of the target diseased tissue after having been administered into an artery serving that tissue). Again, for the purpose of this invention, it is preferred that at least 80% of the microparticles are entrapped at the first pass, more preferably 90% and presently most preferably, 99%.
[0056] With regard to embolizing particles, they will clearly be trapped on the first pass since their size renders them incapable of passing through the capillary system to the veins. The critical aspect of these particles is that they interrupt blood flow upstream from where the drug-carrying particles are trapped.
[0057] As mentioned above, in order to achieve the preceding degrees of entrapment it is necessary to produce microparticles having a size distribution a narrow as possible around the target mean size wherein the target mean size is determined by the vessel size in the tissue being treated. That is, again with reference to capillary bed entrapment, the mean particle size must be small enough to pass through an arteriole (afferent arteriole in the case of the kidneys) but large enough to be trapped by a capillary. While there may be other means to accomplish this and any such means is within the scope of this invention, presently preferred means include emulsification followed by supercritical fluid solvent extraction, ultrasonic atomization or droplet formation, electrohydrodynamic atomization and membrane emulsification.
[0058] Emulsification followed by supercritical fluid solvent extraction to form microparticles having a very narrow size range is a well-known technique in the art and therefore need not be extensively discussed herein, In brief, the technique involves the formation of an emulsion by dissolving a polymer and a therapeutic agent in a solvent for both, adding the solution under high shear to water containing emulsifying agent, sonicating to achieve a narrow droplet size range, passing the droplets through a porous membrane of well-defined pore size and then extracting the solvent from the microparticles using a supercritical fluid to give a hardened particle. A supercritical fluid, that is a fluid above its critical temperature and pressure, is used because of the physical properties of such fluids, which are intermediate between those of a gas those of a liquid. For example, supercritical carbon dioxide has a viscosity in the range of about 0.02 to about 0.1 centipoise (cP) whereas liquids have viscosities 0.5-1.0 cP and gasses have viscosities around 0.01 cP. Further, the diffusivities of solutes in supercritical carbon dioxide are up to a factor of 10 higher than in liquid solvents. This and the tunability of the solvating properties of supercritical fluids, which are a complex (but relatively well-understood) function of pressure and temperature, permit extremely selective extraction of one material, the solvent herein for instance, from others it may be combined with.
[0059] In any event, the hardened microparticles obtained after supercritical fluid solvent extraction may then be passed through yet another filter with well-defined pore size to still further control particle size distribution.
[0060] Atomization of a solution using an ultrasonic transducer can produce relatively monodisperse droplets. When captured in a appropriate bath and hardened, this can result in a narrow distribution of microspheres. The ultrasonic energy may be applied using a “horn” with the solution either flowing through it or being applied to its surface. The ultrasonic horn oscillates at a fixed frequency supplied by an ultrasonic transducer. Ultrasonic spray nozzles of this sort are readily available from Sono-Tek Corp, Milton, N.Y.
[0061] Another technique that produces relatively monodisperse particles involves the use of acoustic excitation of a liquid stream to break the stream up into monodisperse particles (Berkland, et al., J. Control. Rel., 2001, 73:59-74). The liquid stream is composed of a polymer and a therapeutic agent dissolved in one or more solvents. The droplets are carried by a carrier stream to a hardening bath where the solvent is removed. The frequencies needed to excite the liquid stream sufficiently to break it up into droplets are in the ultrasonic region of the spectrum.
[0062] Electrohydrodynamic atomization (EDHA) is another, relatively new but nevertheless well-characterized technique in the art for producing narrow size distribution, i.e. essentially monodisperse, microparticles. Again, without going into unnecessary detail since those skilled in the art will be very familiar with the technique, electrohydrodynamic atomization involves pumping a solution through a nozzle wherein a high voltage potential has been established between the tip of the nozzle and a counter-electrode. The high potential causes a build-up of electric charge in droplets at the nozzle tip and when the coulombic forces exceed the surface tension of the droplets, they separate, essentially explode, into smaller droplets. If parameters are optimized to achieve a stable spray, monodispersed droplets are obtained. Removal of solvent from the droplets yields monodisperse solid microparticles. Parameters that may be varied to achieve a particular average size droplet/particle include, without limitation, the applied voltage, the flow rate, density, conductivity and surface tension.
[0063] Normal emulsification techniques generally afford droplets of relative polydispersity, at least with regard to the narrow size distribution desired for use in the current invention. Thus, the requirement of one and perhaps two filtrations as set forth above with regard to emulsification/supercritical fluid solvent extraction. This is due primarily to the myriad parameters that come into play when preparing an emulsion such as, without limitation, the concentration of the agents, the nature of the drug/polymer/surfactant/solvent interaction, polymer molecular weight, sonication power, stir speed, fluid dynamics of the system and temperature. These shortcomings, at least with regard to the present invention, can be overcome by using the technique known as membrane emulsification.
[0064] Membrane emulsification is another relatively new technique for producing essentially monodisperse microparticles. As with standard emulsification followed by multiple filtrations and electrohydrodynamic atomization, membrane emulsification, while a relatively recent development, is well-known to those skilled in the art and need not be detailed herein. In brief, membrane emulsification involves the injection of an intended discontinuous phase through a porous membrane in which pore size is very carefully controlled into the intended continuous phase, which is moving past the porous membrane on the side opposite that from which the discontinuous phase is being injected. Droplets are sheared off the membrane by the moving continuous phase. Control of droplet size is quite exquisite compared to normal emulsification techniques because size is determined predominantly by easily varied parameters including the speed of the continuous phase, viscosity of the continuous phase, interfacial tension between the phases, the chemistry of the system—surfactant type and physical properties of all the constituents—and, of course, pore size. Newer techniques for creating porous membranes with a very precise pore size such as laser drilling and lithographic procedures have made membrane emulsification even more attractive as a technique for control of particle size distribution.
[0065] Any selected particle size can be prepared with relatively narrow mean size distribution using the above techniques, as well as others known in the art, by incorporating well-known mechanical and procedural changes in the methods described.
[0066] Polymeric microparticies presently preferred drug delivery vehicles of this invention. The polymer(s) must be biocompatible and can be either biostable or biodegradable. As used herein, biodegradable includes all means by which a polymer can be disposed of in a patient's body, which includes bioabsorption, resorption, etc. Biostable simply means that the polymer does not biodegrade or bioabsorb under physiological conditions over a relatively long period of time that may reach years.
[0067] As used herein, “biocompatible” refers to a polymer that both in its intact, that is, as synthesized, state and in its decomposed state, i.e., its degradation products, is not, or at least is minimally, toxic to living tissue; does not, or at least minimally and reparably, injure(s) living tissue; and/or does not, or at least minimally and/or controllably, cause(s) an immunological reaction in living tissue.
[0068] As used herein, “biodegradable” refers to any natural means by which a polymer can be disposed of in a patient's body. This includes such phenomena as, without limitation, biological decomposition, bioerosion, absorption, resorption, etc. Biodegradation of a polymer in vivo results from the action of one or more endogenous biological agents and/or conditions such as, without limitation, enzymes, microbes, cellular components, physiological pH and temperature and the like. Bioabsorbable or bioresorbable on the other hand generally refers to the situation wherein the polymer itself or its degradation products are removed from the body by cellular activity such as, without limitation, phagocytosis. Bioerodible refers to both physical processes such as, without limitation, dissolution and chemical processes such as, without limitation, backbone cleavage by hydrolysis of the bonds linking constitutional units of a polymer together. As used herein, biodegradable includes bioerodible, bioresobable and bioabsorbable.
[0069] The biodegradability of a polymer can be characterized by its “mass loss” in vivo over a period of time. By “mass loss” is meant loss in actual weight of a particle fabricated from the polymer a contrasted with “molecular weight loss,” which refers to the break-down of individual polymer chains to smaller fragments, a process that generally precedes mass loss when the smaller fragments break off of the polymeric particle.
[0070] Physiological conditions merely refers to the physical, chemical and biochemical milieu that constitutes the mammalian body and includes, without limitation, pH, temperature, enzymes and the presence of destructive cells such as phagocytes.
[0071] Among biocompatible, relatively biostable polymers useful as carriers for the preparation of microparticles of this invention are, without limitation, polyacrylates, polymethacryates, polyureas, polyurethanes, polyolefins, polyvinylhalides, polyvinylidenehalides, polyvinylethers, polyvinylaromatics, polyvinylesters, polyacrylonitriles, alkyd resins, polysiloxanes and epoxy resins.
[0072] Biocompatible, biodegradable polymers that can be used for the carrier/particle-forming of this invention include, again without limitation, naturally-occurring polymers such as, without limitation, collagen, chitosan, alginate, fibrin, fibrinogen, cellulosics, starches, dextran, dextrin, hyaluronic acid, heparin, glycosaminoglycans, polysaccharides and elastin.
[0073] Synthetic or semi-synthetic biocompatible, biodegradable polymers may also be used as carriers for the purpose of this invention. As used herein, a synthetic polymer refers to one that is created wholly in the laboratory while a semi-synthetic polymer refers to a naturally-occurring polymer than has been chemically modified in the laboratory. Examples of synthetic polymers include, without limitation, polyphosphazines, polyphosphoesters, polyphosphoester urethane, polyester urethanes, polyester urethane ureas, polyhydroxyacids, polyhydroxyalkanoates, polyanhydrides, polyesters, polyorthoesters, polyamino acids, polyoxymethylenes, poly(ester amides) and polyimides.
[0074] Further non-limiting examples of biocompatible biodegradable polymers that may be suitable as carriers herein include, without limitation, polycaprolactone, poly(L-lactide), poly(D,L-lactide), poly(D,L-lactide-co-PEG) block copolymers, poly(D,L-lactide-co-trimethylene carbonate), polyglycolide, poly(lactide-co-glycolide), polydioxanone (PDS), polyorthoester, polyanhydride, poly(glycolic acid-co-trimethylene carbonate), polyphosphoester, polyphosphoester urethane, poly(amino acids), polycyanoacrylates, poly(trimethylene carbonate), poly(iminocarbonate), polycarbonates, polyurethanes, copoly(ether-esters) (e.g. PEO/PLA), polyalkylene oxalates, polyphosphazenes, PHA-PEG, and combinations thereof. The PHA may include poly(α-hydroxyacids), poly(β-hydroxyacid) such as poly(3-hydroxybutyrate) (PHB), poly(3-hydroxybutyrate-co-valerate) (PHBV), poly(3-hydroxyproprionate) (PHP), poly(3-hydroxyhexanoate) (PHH), or poly(4-hydroxyacid) such as poly poly(4-hydroxybutyrate), poly(4-hydroxyvalerate), poly(4-hydroxyhexanoate), poly(hydroxyvalerate), poly(tyrosine carbonates), poly(tyrosine arylates), poly(ester amide), polyhydroxyalkanoates (PHA), poly(3-hydroxyalkanoates) such as poly(3-hydroxypropanoate), poly(3-hydroxybutyrate), poly(3-hydroxyvalerate), poly(3-hydroxyhexanoate), poly(3-hydroxyheptanoate) and poly(3-hydroxyoctanoate), poly(4-hydroxyalkanaote) such as poly(4-hydroxybutyrate), poly(4-hydroxyvalerate), poly(4-hydroxyhexanote), poly(4-hydroxyheptanoate), poly(4-hydroxyoctanoate) and copolymers including any of the 3-hydroxyalkanoate or 4-hydroxyalkanoate monomers described herein or blends thereof, polyglycolide, poly(D,L-lactide-co-glycolide), poly(L-lactide-co-glycolide), polycaprolactone, poly(lactide-co-caprolactone), poly(glycolide-co-caprolactone), poly(dioxanone), poly(ortho esters), poly(anhydrides), poly(tyrosine carbonates) and derivatives thereof, poly(tyrosine ester) and derivatives thereof, poly(imino carbonates), poly(glycolic acid-co-trimethylene carbonate), polyphosphoester, polyphosphoester urethane, poly(amino acids), polycyanoacrylates, poly(trimethylene carbonate), poly(iminocarbonate), polyphosphazenes, silicones, polyesters, polyolefins, polyisobutylene and ethylene-alphaolefin copolymers, acrylic polymers and copolymers, vinyl halide polymers and copolymers, such as polyvinyl chloride, polyvinyl ethers, such as polyvinyl methyl ether, polyvinylidene halides, such as polyvinylidene chloride, polyacrylonitrile, polyvinyl ketones, polyvinyl aromatics, such as polystyrene, polyvinyl esters, such as polyvinyl acetate, copolymers of vinyl monomers with each other and olefins, such as ethylene-methyl methacrylate copolymers, acrylonitrile-styrene copolymers, ABS resins, and ethylene-vinyl acetate copolymers, polyamides, such as Nylon 66 and polycaprolactam, alkyd resins, polycarbonates, polyoxymethylenes, polyimides, polyethers, poly(glyceryl sebacate), poly(propylene fumarate), poly(n-butyl methacrylate), poly(sec-butyl methacrylate), poly(isobutyl methacrylate), poly(tert-butyl methacrylate), poly(n-propyl methacrylate), poly(isopropyl methacrylate), poly(ethyl methacrylate), poly(methyl methacrylate), epoxy resins, polyurethanes, rayon, rayon-triacetate, cellulose acetate, cellulose butyrate, cellulose acetate butyrate, cellophane, cellulose nitrate, cellulose propionate, cellulose ethers, carboxymethyl cellulose, polyethers such as poly(ethylene glycol) (PEG), copoly(ether-esters) (e.g. poly(ethylene oxide-co-lactic acid) (PEO/PLA)), polyalkylene oxides such as poly(ethylene oxide), poly(propylene oxide), poly(ether ester), polyalkylene oxalates, phosphoryl choline containing polymer, choline, poly(aspirin), polymers and co-polymers of hydroxyl bearing monomers such as 2-hydroxyethyl methacrylate (HEMA), hydroxypropyl methacrylate (HPMA), hydroxypropylmethacrylamide, PEG acrylate (PEGA), PEG methacrylate, methacrylate polymers containing 2-methacryloyloxyethyl-phosphorylcholine (MPC) and n-vinyl pyrrolidone (VP), carboxylic acid bearing monomers such as methacrylic acid (MA), acrylic acid (AA), alkoxymethacrylate, alkoxyacrylate, and 3-trimethylsilylpropyl methacrylate (TMSPMA), poly(styrene-isoprene-styrene)-PEG (SIS-PEG), polystyrene-PEG, polyisobutylene-PEG, polycaprolactone-PEG (PCL-PEG), PLA-PEG, poly(methyl methacrylate)-PEG (PMMA-PEG), polydimethylsiloxane-co-PEG (PDMS-PEG), poly(vinylidene fluoride)-PEG (PVDF-PEG), PLURONIC™ surfactants (polypropylene oxide-co-polyethylene glycol), poly(tetramethylene glycol), hydroxy functional poly(vinyl pyrrolidone), biomolecules such as collagen, chitosan, alginate, fibrin, fibrinogen, cellulose, starch, dextran, dextrin, hyaluronic acid, fragments and derivatives of hyaluronic acid, heparin, fragments and derivatives of heparin, glycosamino glycan (GAG), GAG derivatives, polysaccharide, elastin, elastin protein mimetics, or combinations thereof.
[0075] Blends and copolymers of the above polymers may also be used and are within the scope of this invention. Based on the disclosures herein, those skilled in the art will recognize those implantable medical devices and those materials from which they may be fabricated that will be useful with the coatings of this invention.
[0076] Any reference to the molecular weight of a polymer of this invention is reported as the number average molecule weight, the nature and determination of which is well-known in the art and need not be explicated further here.
[0077] As used herein, The “weight ratio” of a chemotherapeutic drug to a polymer refers to quantity of the drug relative to the quantity of polymer that constitutes the microparticle carrying the drug in like units, e.g. without limitation, mg:mg so that, for instance, a drug to polymer weight ratio of 1:5 would mean that the amount of drug in or on a microparticle in which the polymer component weights 5 mg would be 1 mg.
[0078] As noted previously, a chemotherapeutic agent may be administered to a patient using the method of this invention in a bolus or sustained release format. The manner of fabrication of the carrier microparticle including the material of which it is made will determine how the chemotherapeutic agent is released after the particles have been delivered at or near the target tumor. Such fabrication techniques are well-documented in the patent and technical literature and need not be replicated here. Suffice it to say that any fabrication materials and procedures resulting in a desired release format are all within the scope of this invention.
[0079] As used herein, loading a chemotherapeutic drug “into or onto” a microparticle refers to (1) “into”—drug-carrying particles where the drug is encapsulated in the matrix of the particle, if it is solid, or at the core of the particle if it constitutes a core-shell structure—liposomes and polymersomes herein or (2) “onto”—drug-carrying particle where the drug is attached to the outer surface of the particle, which can be accomplished by any number of means well-known in the art.
[0080] The method of this invention can be used to treat any solid tumor cancer to which blood is supplied by a dedicated, relatively reachable artery such as the renal, hepatic, pulmonary and cardiac arteries. In particular at present it can be used to treat HCC tumors. As such, the chemotherapeutic agent(s) which may be used in the instant method include virtually all known chemotherapeutics as well as those that become available in the future.
[0081] As used herein, a “patient” refers to any species that might benefit from treatment using the method herein but at present is preferably a mammal and most preferably a human being.
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This invention is directed to methods of treating solid tumor cancers, particularly refractory cancers by administration of two pluralities of microparticles, one comprising drug-carrying microparticles sized to lodge at the tumor preferably in the capillary bed of the tumor and the other comprising non-drug-carrying microparticles sized to lodge in the arterial system servicing the tumor so as to embolize the tumor.
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BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
The invention concerns a configuration for detecting mail items and is to be used in franking machines and other devices for processing mail that involve the transport of mail items.
Modern franking machines, such as the thermal transfer franking machine described in U.S. Pat. No. 4,746,234, make use of fully electronic digital printing devices. This makes it possible in principle to print any required text and special characters, and any required advertising block or an advertising block allocated to a cost center, in the area stamped by the franking machine. For example, the company Francotyp-Postalia AG & Co. produces the franking machine model T1000 with a microprocessor, which is enclosed in a secure housing with an opening for feeding in a letter. If a letter is fed in, a mechanical letter sensor, in this case a microswitch, transmits a print instruction to the microprocessor. The franked (stamped-on) impression contains postal information which is needed for forwarding the letter and which was entered and stored beforehand. U.S. Pat. No. 5,949,444, which corresponds to German Patent No. DE 196 05 015 C1, discloses an embodiment of a printing device which is known under the trademark JetMail®. This printing device uses an ink jet printing head provided in a stationary position in a recess behind a guide plate and produces a franked imprint during a non-horizontal, almost vertical letter transport. A sensor for triggering the printing process is provided just upstream of a recess for the ink jet printing head, wherein the sensor for triggering the printing process functions in combination with an incremental sensor.
U.S. Pat. No. 5,495,103 corresponding to European Patent No. EP 673 001 B1 describes a triggering of the printing process through an optical mail item sensor. The optical mail item sensor is constructed as a reflection light barrier. The surface of the letter should therefore ideally be as even or as flat as possible, in particular at the leading edge of the letter, as otherwise a reflection light barrier is disadvantageous in the detection of the leading edge of thick mail items.
For this reason the printing process in the printing device known under the trademark JetMail® is preferably triggered by a transmitted-light barrier or through-beam light barrier of the franking machine (see also Published European Patent Application No. EP 901 108 A2). This allows to clearly detect the front edge even of thick mail items. In addition, the JetMail® printing device also makes use of optical sensors for detecting mail item jams. Providing the main printed circuit board at a distance behind the guide plate requires the use of screened copper cables. High costs are generated not only by the manufacture of both reflection sensors and transmitted-light sensors (through-beam light sensors), but also by their installation, which involves fixing them to the guide plate and providing plug-in connectors with cables to the main printed circuit board in the base.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a configuration for detecting mail items which overcomes the above-mentioned disadvantages of the heretofore-known configurations of this general type and which has a robust sensor technology for detecting letters at low manufacturing costs.
With the foregoing and other objects in view there is provided, in accordance with the invention, a configuration for detecting mail items, including:
a main printed circuit board having a controller, the main printed circuit board defining a monitoring location spaced at a given distance from the main printed circuit board;
a transmitter disposed on the main printed circuit board;
a receiver disposed on the main printed circuit board;
rigid optical waveguide elements provided between the monitoring location and a respective one of the transmitter and the receiver; and
the rigid optical waveguide elements being configured, at the monitoring location, in accordance with a transmitted-light principle, for detecting mail items.
A franking machine or other mail processing device involving the transport of mail items has a housing or case with an opening for feeding in the mail items and with an internally provided main printed circuit board for the control. Providing as many of the electronic components as possible on the main printed circuit board makes it unnecessary to have a costly installation of a transmitting device and a receiving device near the transport path in the opening for feeding in the mail items. The separation between the main printed circuit board and the monitoring location in the opening is bridged, according to the invention, through the use of rigid optical waveguide elements. The rigid optical waveguide elements and the transmitting device and the receiving device on the main printed circuit board serve to detect the item to be franked at the monitoring location according to the known transmitted-light principle (through-beam principle), whereby relative to the direction of flow of mail the monitoring location is provided upstream from a printing head located in a printing position.
In accordance with another feature of the invention, the rigid optical waveguide elements include a first rigid optical waveguide element provided between the monitoring location and the transmitter and a second rigid optical waveguide element provided between the monitoring location and the receiver.
In accordance with yet another feature of the invention, a housing having a slot-shaped opening is provided, the main printed circuit board, the transmitter, the receiver, and the rigid optical waveguide elements are disposed in the housing, the slot-shaped opening has two sides and defines a transport path, and the rigid optical waveguide elements are disposed, at the monitoring location and close to the transport path, at a respective one of the two sides of the slot-shaped opening.
In accordance with a further feature of the invention, the main printed circuit board, the transmitter, the receiver, and the rigid optical waveguide elements form a detection device, and the housing encloses the detection device except at the slot-shaped opening.
In accordance with another feature of the invention, the given distance is a first distance, the two sides of the slot-shaped opening are disposed opposite one another, a guide plate is formed at a first one of the two sides, the guide plate is configured such that a mail item rests against the guide plate and such that a transport force is exerted on the mail item in a direction of transport, and the main printed circuit board is provided at the first distance from the guide plate and at a second distance from a second one of the two sides wherein the first distance is greater than the second distance.
In accordance with yet another feature of the invention, one of the rigid optical waveguide elements is disposed at one of the transmitter and the receiver, and the one of the rigid optical waveguide elements is an I-shaped, rigid optical waveguide element.
In accordance with a further feature of the invention, one of the rigid optical waveguide elements is disposed at one of the transmitter and the receiver, and the one of the rigid optical waveguide elements is an I-shaped, rigid optical waveguide element and has a length substantially equal to the second distance.
In accordance with another feature of the invention, one of the rigid optical waveguide elements is a U-shaped, rigid optical waveguide element with a first leg and a second leg, the first leg has a first length such that the first leg substantially reaches one of the transmitter and the receiver, the second leg has a second length, the second length is shortened by a length substantially equal to the given distance, and the second leg is disposed closer to a transport path at the monitoring location than the first leg.
In accordance with yet another feature of the invention, the rigid optical waveguide elements are transparent plastic optical waveguides for localizing and concentrating a light beam.
In accordance with an additional feature of the invention, the transmitter is a clocked light-emitting diode for minimizing extraneous light and for increasing detection reliability.
In accordance with another feature of the invention, a printing head is located, when in a printing position, downstream of the monitoring location with respect to a transport direction.
With the objects of the invention in view there is also provided, a franking machine configuration, including:
a franking machine including a housing, the housing having a slot-shaped opening formed therein;
a main printed circuit board having a controller, the main printed circuit board defining a monitoring location spaced at a given distance from the main printed circuit board;
a transmitter disposed on the main printed circuit board;
a receiver disposed on the main printed circuit board;
rigid optical waveguide elements provided between the monitoring location and a respective one of the transmitter and the receiver;
the rigid optical waveguide elements being configured, at the monitoring location, in accordance with a transmitted-light principle, for detecting mail items;
the main printed circuit board, the transmitter, the receiver, and the rigid optical waveguide elements form a detection device; and
the housing encloses the detection device except at the slot-shaped opening.
The franking machine preferably has a printing head positioned, when in a printing position, such that the monitoring location is provided, relative to a flow direction of mail items, upstream from the printing head.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a configuration for detecting mail items, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE EMBODIMENTS
FIG. 1 is a diagrammatic, perspective view of a franking machine open at the top;
FIG. 2 is a diagrammatic front view of a franking machine transparent on top; and
FIG. 3 is a diagrammatic, sectional side view of a franking machine.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the figures of the drawings in detail and first, particularly, to FIG. 1 thereof, there is shown a perspective view of a franking machine 1 open at the top. The mail items are fed in through a slot-shaped opening 3 in the housing 4 , which in the closed state encloses the configuration for mail item detection except at the opening. The direction of transport of a fed-in mail item (not shown) is indicated by an arrow and runs from top left to bottom right. During transport the mail item comes to lie against a guide plate 2 . The housing 4 open at the top shows two printing heads 21 , 22 located in printing position.
FIG. 2 shows a front view of the franking machine 1 , which in this case—solely for purposes of clearer illustration—is fitted with a transparent top cover 14 . One side of the opening 3 is constructed as a guide plate 2 , against which the mail item 12 lies and starting from which a drive device 5 exerts a transporting force on the mail item 12 in the transport direction (arrow). The counter-pressure device 6 is provided on the opposite side of the opening 3 and sprung-mounted perpendicularly to the transport direction for a fed-in mail item 12 . The transport direction for a fed-in mail item 12 runs from left to right.
FIG. 3 shows a section through the franking machine in side view, whereby the section runs through the monitoring location. The franking machine 1 has a housing 4 , inside which is provided a main printed circuit board 11 with a transmitting device 7 and a receiving device 8 and the associated rigid optical waveguide elements 9 and 10 . A controller for controlling the franking machine is only schematically illustrated as a dashed box. Of course the controller may be provided as several components on the main circuit board.
The main printed circuit board 11 is provided at a distance A from the guide plate 2 on one side of the opening and at a distance B from the opposite side, whereby distance A>distance B. Rigid optical waveguide elements 9 , 10 are provided at the monitoring location on both sides of the opening near the transport path. One rigid optical waveguide element 9 provided at the transmitting device 7 is I-shaped and has a length approximately equal to the distance B. It is provided that a clocked light emitting diode (LED) is used as a transmitting device in a franking machine in order to minimize light from external sources and to increase the reliability of detection.
A further rigid optical waveguide element 10 is U-shaped, whereby one of the legs located near the transport path is shortened by a length approximately equal to the distance A.
The length of the other leg is formed such as to reach approximately to the receiving device 8 .
It is provided that the rigid optical waveguide elements 9 , 10 for fixing and concentrating the light (white arrow) are formed as transparent plastic optical waveguides. The plastic optical waveguides are preferably formed of polycarbonate or acryl.
A drive device 5 can, for example, be a drive roller and a counter-pressure device 6 can, for example, be a counter-pressure roller. However, the drive device 5 and the counter-pressure device 6 can also be constructed in any other way. The transmitting device 7 and receiving device 8 can be a laser diode, an LED and a photodiode, a phototransistor or a different suitable light source or optoelectric receiver. Preferably a transmitting diode 7 is used with a very narrow transmission angle and high pulse load capacity and reliability. An example of a suitable device is a GaAs infrared light-emitting diode of the type LD 274 available from the company Siemens. As an example for a phototransistor an NPN silicon phototransistor of the type SFH 300 from the company Siemens can be used. Needless to say, the assignment of the rigid optical waveguide elements 9 , 10 to the transmitting device 7 and the receiving device 8 can be reversed, i.e. a rigid optical waveguide element 9 assigned to the transmitting device 7 is U-shaped and a rigid optical waveguide element assigned to the receiving device 8 is I-shaped.
The invention is not limited to the above embodiments. Rather, a number of variants are possible within the definition of the claims. Thus it is clear that further embodiments of the invention can be developed and/or used which arise from the same basic ideas of the invention and are covered by the associated claims.
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A configuration for detecting mail items includes rigid optical waveguide elements between a monitoring location and transmitting and receiving devices on a main printed circuit board. The configuration makes use of a transmitted-light principle for detecting mail items to be franked.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to a one-step process for the emulsion polymerization of vinyl chloride.
2. DESCRIPTION OF THE Prior Art
The use of conventional straight chain surfactants, e.g., sodium lauryl sulfate, in the emulsion polymerization of vinyl chloride will generally result in the formation of very small polymer particles unless the quantity of surfactant is carefully controlled by an incremental feed technique. One common way in which larger particles of polyvinyl chloride can be obtained is by first forming a "seed" particle of the polymer in an initial polymerization procedure, followed by a second polymerization or "seed growth" step. Some recently issued U.S. patents which relate to this seed growth technique are U.S. Pat. No. 3,383,346 to E. S. Smith, U.S. Pat. No. 3,642,740 to J. K. Pierce, Jr. and U.S. Pat. No. 3,755,225 to J. K. Pierce, Jr. et al. The effect of a mixed emulsifier system of a conventional surfactant and an alcohol during only the second step of such a process has been studied in the scientific literature, J. Ugelstad et al. J. Polymer Sci., Symposium No. 42, 473-485 (1973).
In addition to the foregoing prior art, the presence of various alcohols, such as stearyl alcohol, as a component in a polymerization reaction medium has been studied by other investigators. For example, U.S. Pat. No. 3,324,097 to G. E. A. Pears and U.S. Pat. No. 3,654,248 to E. Iida et al., relate to a polymerization system wherein a homogenized vinyl chloride monomer is polymerized in the presence of an oil-soluble catalyst in a suspension polymerization procedure. When such a system is used a mixture of emulsion and suspension polymerized polyvinyl chloride particles are formed. The effect of a mixed emulsifier of surfactant and alcohol in a one-shot polymerization of styrene has also been studied: J. Ugelstad et al., Die Makromolekulare Chemie, Vol. 175, pp. 507-521 (1974); J. Ugelstad, J. Polymer Science, Polymer Letters, Vol. 11, pp. 503-513 (1973), and A. R. M. Azad et al., ACS Polymer Reprints, Vol. 16, No. 1, pp. 131-142 (April 1975).
Alkyl phosphate surfactants have been proposed as primary emulsifiers in the emulsion polymerization of vinyl chloride in a seed technique, British Pat. No. 1,142,425 to Stauffer Chemical Company. They have also been proposed as emulsifiers in emulsion polymerization procedures in conjunction with monomer-soluble initiators in order to obtain a product having a highly porous configuration in the form of aggregates, U.S. Pat. No. 2,843,576 to J. H. Dunn et al.
It has not, however, been appreciated hitherto that a one-step polymerization procedure for vinyl chloride monomer can be achieved using a water-soluble initiator and an aqueous mixed emulsifier system containing a straight chain alkyl or alkenyl phosphate surfactant.
SUMMARY OF THE PRESENT INVENTION
The present invention is a one-step emulsion polymerization process which comprises the use of an aqueous mixed emulsifier of (1) a C 12 -C 18 straight chain alkyl or alkenyl phosphate surfactant, such as sodium lauryl phosphate, and (2) a C 12 -C 20 straight chain alkyl or alkenyl alcohol, such as cetyl alcohol, oleyl alcohol, stearyl alcohol and eicosanol and/or a straight chain saturated hydrocarbon having a carbon content of greater than 18. The products are useful as plastisol or organosol resins.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The polymerization medium contains effective amounts for the desired polymerization of vinyl chloride monomer (and, optionally, comonomers), a water-soluble initiator, a mixed emulsifier and, if desired, a buffer.
Vinyl chloride monomer comprises at least 50%, preferably at least 85%, by weight of the entire monomeric component. Preferably, it is the sole monomer that is present. However, copolymers may be advantageously prepared in accordance with this invention. For example, copolymerizable mixtures, containing vinyl chloride and up to 49 percent vinyl acetate, but preferably in the range of 5 to 10 percent vinyl acetate, may be employed. Other monomers copolymerizable with vinyl chloride, which may be used in accordance with this invention, include: vinyl esters of other alkanoic acids, such as vinyl propionate, vinyl butyrate, and the like; the vinylidene halides, such as vinylidene chloride; vinyl esters of aromatic acids, e.g., vinyl benzoate; esters of alkenoic acids, for example, those of unsaturated mono-carboxylic acids such as methyl, acrylate, 2-ethyl hexyl acrylate, and the corresponding esters of methacrylic acid; and esters of alpha, beta-ethylenically unsaturated dicarboxylic acids, for example, the methyl, ethyl, propyl, butyl, amyl, hexyl heptyl, octyl, allyl methallyl and phenyl esters of maleic, itaconic, fumaric acids, and the like. Amides such as acrylamide and methacrylamide, and nitriles, such as acrylonitrile, may also be suitably employed. Vinyl phosphonates, such as bis(beta chloroethyl)vinylphosphonate may also be employed. The water to monomer ratio in the reaction medium can be varied widely with values of from about 1.5 to about 2.5:1, preferably from about 1.7 to about 2.0:1, being representative.
The initiator or catalyst which is used in the present invention can be any of the well-known water-soluble initiators which are used in the emulsion polymerization of vinyl chloride monomer. Oil soluble catalysts are not recommended for they yield a mixture of suspension and emulsion particles rather than the desired product which either exhibits a binodal or polydisperse particle size distribution depending on whether the mixed emulsifier is non-prehomogenized prior to use or is used as a prehomogenized addition to the reaction. Such free radical, water soluble initiators as the peroxygen type compounds ammonium persulfate, sodium perborate potassium persulfate, sodium persulfate and potassium percarbonate are illustrative of initiators that may be employed. If desired, a redox system can be used. Representative of such a system is a hydrogen peroxide initiator/ascorbic acid activator combination of a potassium persulfate/ascorbic acid combination. Combinations of persulfates and bisulfites, as for example, potassium persulfate and sodium metabisulfite can also be used. The amount of said initiator which is used should be an amount which is effective to polymerize the monomers which are present in the reaction medium. Generally, from about 0.05% to about 1%, preferably about 0.075% to about 0.10%, based on the weight of monomers, of initiators or redox system is needed.
The mixed emulsifier system of the present invention contains: (1) a C 12 -C 18 straight chain alkyl or alkenyl phosphate surfactant and (2) a C 12 -C 20 straight chain alkyl or alkenyl alcohol and/or saturated hydrocarbon of greater than 18 carbon atom chain length.
The C 12 -C 18 straight chain phosphate surfactant which is useful in practicing the present invention has the formula ##STR1## wherein R is a straight chain alkyl or alkenyl group containing from about 12 to 18 carbon atoms inclusive, M is an ammonium or alkali metal ion and X is either 1 and/or 2. Representative R groups include lauryl, tridecyl and octadecyl. Some suitable M groups include ammonium, lithium, sodium and potassium. One preferred surfactant from this class of compounds which may be used is sodium lauryl phosphate.
The C 12 -C 20 straight chain alkyl or alkenyl alcohols which are to be used in the mixed emulsifier system of the present invention include such alcohols as cetyl alcohol, oleyl alcohol, stearyl alcohol and eicosanol. A representative saturated hydrocarbon having a chain length of greater than 18 carbon atoms is eicosane. Compatible mixtures of any of the forgoing second components of the mixed emulsifier can be used.
The amount of such mixed emulsifier system which is used must be sufficient to maintain a stable emulsion in the reaction environment. Use of smaller amounts than described herein will result in coagulation of the latex, whereas use of larger amounts will result in undesirable contamination of the product without providing any other significant benefit. The weight ratio of surfactant to alcohol in the mixture can range anywhere from about 0.8:1 to about 1:4, preferably from about 0.8:1 to about 1:2 in order to produce the desired product of the present invention having the desirable physical properties associated with the present invention. The amount of mixed emulsifier to vinyl chloride monomer (optionally in the presence of the copolymerizable monomers) is from about 0.7 to about 3%, preferably 0.8% to about 2%, by weight of all such copolymerizable monomers.
The presence of a suitable buffer, e.g., borax, in order to maintain the reaction medium at a pH of from about 5 to about 8, preferably from about 6 to about 7.5, is highly desirable since it will insure production of a polydisperse distribution of resin particles generally larger than obtainable with a straight surfactant system.
If desired, the mixture of phosphate surfactant and alcohol and/or hydrocarbon can be prehomogenized prior to use in the polymerization reaction in order to achieve a more reproducible product having a more uniform particle size distribution for the particles which result. In such a technique the two components of the mixed emulsifier are first prehomogenized by subjecting them to agitation in water when they are both in the liquid state in any suitable agitation apparatus until a visually homogeneous mixture is formed. The mixture of the two components may have to be heated if one or both of the selected components is a solid at ambient temperature to above the melting point of each component or components. The monomeric reactants and initiator can then be added for the polymerization reaction.
The polymerization process of the present invention is conducted by heating the reaction mixture to a temperature of from about 45° to about 70° C. for about 3 hrs. to about 5 hrs.
The foregoing invention is illustrated by the Examples which follow:
EXAMPLE 1
This Example illustrates preparation of the mixed emulsifier which was used in the polymerization process of this invention.
Lauryl acid phosphate (3 gm. of this phosphate required 4.5 gm. of 10% NaOH for adjustment to a pH of 8.0) was used in order to prepare the sodium lauryl phosphate salt by mixing the following ingredients and heating them to 70° C.:
______________________________________Ingredient Amount (in gm.)______________________________________Deionized water 2520Sodium hydroxide (97%) 23.3Lauryl acid phosphate 150.0 g.______________________________________
From this resulting solution a series of stearyl alcohol/sodium lauryl phosphate mixed emulsifiers were prepared for use in later Examples.
EXAMPLE 2
This Example illustrates the use of a sodium lauryl phosphate/stearyl alcohol mixed emulsifier (abbreviated "SLP/SA" hereinafter) in the one-shot polymerization of vinyl chloride monomer. The reaction was run in bottles at a temperature of 54° C. for 4 hours. The Table given below sets forth the reactants that were used and the results that were obtained.
__________________________________________________________________________ RUN NUMBERIngredient 1 2 3 4 5 6 7 8 9 10 11 12__________________________________________________________________________Vinyl chloride monomer 150 150 150 150 150 150 150 150 150 150 150 150SLP/SA (1:0.5)* 100 125 150 -- -- -- -- -- -- -- -- --SLP/SA (1:1)* -- -- -- 100 125 150 -- -- -- -- -- --SLP/SA (1:2)* -- -- -- -- -- -- 100 125 150 -- -- --SLP alone -- -- -- -- -- -- -- -- -- 15 15 15Sodium bicarbonate (1%,by weight, aq. soln.) 20 20 20 20 20 20 20 20 20 20 20 20Sodium persulfate (1%,by weight, soln.) 54 54 54 54 54 54 54 54 54 54 54 54Deionized Water 50 25 -- 50 25 -- 50 25 -- 136 136 136Coagulum (wt. in gm).sup.1 7.3 10.4 12.4 8.4 9.0 10.9 10.7 13.6 15.4 5.2 9.2 8.Mechan. Stability (in sec.).sup.2 65 90 108 32 74 85 25 4 66 8.5 -- --pH of latex 7.8 7.85 8.0 7.7 7.85 7.15 -- -- -- -- -- --Particle Size Range -- -- 0.08 -- -- 0.01- -- -- 0.12- -- -- --(microns) 0.05 0.87 0.34__________________________________________________________________________ Footnotes: *The figures in parentheses indicate the weight ratio of sodium lauryl phosphate to stearyl alcohol. .sup.1 The amount of dry coagulum is based on the weight of the monomer charge. Lower amounts of coagulum are desirable since coagulum adversely affects commercial operations. .sup.2 The mechanical stability is measured by agitating the product late in a Hamilton Beach laboratory mixer set at low speed. The time required to coagulate the product in the mixer is determined by visual inspection. This test gives a measure of the time required for a latex to coagulate o setup. Higher times are more desirable. Coagulation adversely affects the case with which latex can be pumped in commercial production environments
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A one-step process for the emulsion polymerization of vinyl chloride using a water-soluble initiator and an aqueous emulsifier system of (1) a C 12 -C 18 straight chain alkyl or alkenyl phosphate surfactant and (2) a C 12 -C 20 straight chain alkyl or alkenyl alcohol and/or a straight chain saturated hydrocarbon having a carbon content of greater than 18 is disclosed. One suitable example of a straight chain phosphate surfactant is sodium lauryl phosphate. Suitable alcohols include stearyl alcohol, cetyl alcohol and eicosanol. A suitable hydrocarbon is eicosane. The resulting homo- and copolymer latices can be used in plastisols and organosols.
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TECHNICAL FIELD
Chemical vapor deposition (CVD) systems can be used to deposit thin films on substrates by decomposing vapor precursors within low-pressure reactors. The vaporization of the precursors takes place prior to entry of the precursors into the reactors.
BACKGROUND
Purified forms of metals, metal compounds, and other materials can be deposited in uniformly thin layers onto substrates by decomposing vaporized precursors of the materials. The depositions take place inside reactors with evacuatable environments and temperature controls. Many of the precursors take liquid form at ambient temperatures and are vaporized at higher temperatures just prior to entry into the reactors.
High deposition rates for such chemical vapor deposition (CVD) processes require correspondingly high delivery rates of vaporized precursors into the reactors. Vaporization of liquid precursors can be carried out by mixing the liquid precursor with a carrier gas or by atomizing the liquid precursor in a suspended gas. Liquid flow rates into vaporizers are limited by conversion capabilities of the vaporizers to vaporize the liquid precursors. Incomplete vaporization can result in the passage of large droplets of the liquid precursor into the reactors. The entry of liquid precursor into reactors, which is referred to as “flooding”, contaminates the reactors and diminishes pumping performance. Flooding increases deposition processing time by requiring more time to evacuate the reactors.
SUMMARY OF INVENTION
Our invention provides opportunities for vaporizing liquid precursors at high rates and for delivering the vaporized precursors to low-pressure reactors for processing, while preventing the delivery of any remaining liquid precursor to the reactors. Droplets of liquid precursor remaining after a first stage of vaporization are trapped and subject to a second stage of vaporization. More efficient vaporization enables the higher rates of vaporization to be achieved. Throughput processing rates can also be improved by avoiding passage of liquid precursor droplets into the reactors.
One example of a precursor vaporizer for a chemical vapor deposition system has an inlet arrangement for admitting a liquid precursor and a carrier gas into the vaporizer. A first vaporizing stage vaporizes a portion of the liquid precursor into the carrier gas. A second vaporizing stage located gravitationally below the first vaporizing stage vaporizes another portion of the liquid precursor into the carrier gas. A vaporization chamber interconnects the first and second vaporizing stages. An outlet conveys the vaporized precursor from both vaporizing stages to a reactor of the chemical vapor deposition system. The outlet is connected to the vaporizing chamber out of liquid communication with the first vaporizing stage and extending gravitationally above the second vaporizing stage to prevent the remaining liquid precursor from reaching the reactor.
The inlet arrangement preferably includes separate conduits that support flows of carrier gas through both vaporizing stages towards the vaporizing chamber. The flows of carrier gas supported by the inlet arrangement can include (a) a first flow of the carrier gas through the first vaporizing stage in a direction corresponding to a gravitationally directed seepage of the liquid precursor through the first vaporizing stage and (b) a second flow of the carrier gas through the second vaporizing stage in a direction opposed to a gravitationally directed seepage of the liquid precursor through the second vaporizing stage.
A separator within the vaporization chamber can be used to allow the liquid precursor to reach the second vaporizing stage and to allow the vaporized precursor to pass through the outlet. In addition, the separator can prevent the liquid precursor from passing through the outlet, preferably by diverting the liquid precursor from the outlet. For example, the separator can be formed as a roof over the outlet with pervious under-eaves structure for admitting the vaporized precursor under the roof.
The inlet arrangement also preferably includes a mixing valve that mixes the liquid precursor with the carrier gas in advance of the first vaporizing stage. The mixing valve regulates flow rates of the liquid precursor into the vaporizer. A signal from a flow meter to the mixing valve can be used to adjust the flow rates of the liquid precursor into the vaporizer.
The two vaporizing stages and the intermediate vaporizing chamber are preferably supported within a thermally conductive body that supports transfers of heat to the vaporization process. However, the mixing valve is preferably supported by a thermal isolator for insulating the mixing valve from the thermally conductive body. One or more heating elements positioned within the thermally conductive body heat the first and second vaporizing stages without substantially heating the mixing valve.
The second vaporizing stage preferably includes a trap for capturing the liquid precursor below a level of the outlet and a porous medium within the trap to increase surface area. A carrier gas passageway provides for conducting carrier gas through the porous medium to vaporize the liquid precursor captured in the trap. Preferably, the carrier gas passageway is arranged to convey the precursor vaporized by the second vaporizing stage in a direction opposed to gravity en route to the outlet in the vaporizing chamber.
During operation, the mixer preferably combines a liquid precursor with a carrier gas at a first temperature low enough to avoid significant decomposition of the liquid precursor. The first and second vaporizing stages promote vaporization of the liquid release agent at a second temperature high enough to avoid significant condensation of the vaporized precursor. The mixing is preferably carried out at ambient temperatures to prevent the mixing valve from becoming clogged with prematurely decomposed solids. The vaporizing stages, however, are preferably heated well above ambient temperatures to prevent condensation of the vaporized precursor.
A precursor for a low-pressure processing system can be vaporized in accordance with our invention by a series of steps for increasing vaporization efficiency and overall processing rates. A liquid precursor and a carrier gas are admitted into a vaporizer. A portion of the liquid precursor is vaporized into the carrier gas at a first vaporizing stage. A remaining liquid portion of the precursor from the first vaporizing stage is separated from the vaporized portion of the precursor. The remaining liquid portion of the precursor is passed to a second vaporizing stage. At least a portion and preferably all of the remaining liquid portion of the precursor are vaporized at the second vaporizing stage. The vaporized precursor from both vaporizing stages is passed through an outlet located gravitationally below the first vaporizing stage and gravitationally above the second vaporizing stage.
Preferably, the admission of the liquid precursor and the carrier gas includes mixing the liquid precursor with the carrier gas at a temperature low enough to avoid significant decomposition of the liquid precursor. Flow rates of the liquid precursor into the vaporizer can be regulated by a mixing valve that accepts a feedback signal from a flow meter. The mixing valve is preferably thermally isolated from the first and second vaporizing stages to conduct the mixing operation at ambient temperature.
Both vaporizing stages conduct flows of the carrier gas in opposite directions. The carrier gas is conducted through the first vaporizing stage in a direction corresponding to a gravitationally directed seepage of the liquid precursor through the first vaporizing stage and the carrier gas is conducted through the second vaporizing stage in a direction opposed to a gravitationally directed seepage of the liquid precursor through the second vaporizing stage.
The separation of the two states of the precursor between vaporizing stages preferably includes allowing the vaporized precursor from the first vaporizing stage to pass through the outlet and preventing the remaining liquid precursor from the first vaporizing stage from passing through the outlet. The liquid precursor remaining from the first vaporizing stage is preferably diverted from the outlet to the second vaporizing stage. The separation preferably takes place within a vaporization chamber interconnecting the two vaporizing stages. The vaporized precursor from both vaporizing stages preferably passes through the same outlet within the vaporizing chamber.
The remaining liquid portion of the precursor from the first vaporizing stage is captured in a trap at the second vaporizing stage below a level of the outlet. The carrier gas is preferably conducted through a porous medium within the trap to vaporize the liquid precursor captured in the trap. The carrier gas is flowed through the trap in a direction opposed to gravity en route to the outlet.
DRAWINGS
FIG. 1 is a diagram of an exemplary chemical vaporization system incorporating a vaporizer system arranged in accordance with our invention.
FIG. 2 is a perspective view of the vaporizer system showing more specific components of the system including a vaporizer, a mixing valve, a shut-off valve, and a flow meter.
FIG. 3 is an exploded view of the vaporizer showing the various components of its assembly.
FIG. 4 is a side cross-sectional view of the vaporizer oriented as intended with respect to a vertical axis of gravity.
DETAILED DESCRIPTION
An exemplary chemical vapor deposition (CVD) system 10 useful for depositing thin layers of metal or other materials on substrates such as single-crystal substrates is depicted in FIG. 1 . Thermochemical vapor-phase reactions necessary for forming the thin layers take place with a reactor 12 in the form of an evacuatable processing chamber. A handling system 14 moves substrates 16 (e.g., wafers) into and out of the reactor 12 . An exhaust pump 18 evacuates gas from the reactor 12 for supporting low-pressure processing within the reactor 12 . A waste treatment system 20 (e.g., an abatement module) safely manages the exhaust including byproducts of the reactions. A power supply 22 is regulated for temperature control and other powered functions of the reactor 12 .
A supply 24 of liquid precursor containing constituents of the intended film and a supply 26 of a carrier gas are mixed together by a mixing valve 28 and delivered into a vaporizer 30 . The carrier gas supply 26 is also connected directly to the vaporizer 30 . Within the vaporizer, the liquid-phase precursor is converted into a vapor-phase precursor at an elevated temperature. The vaporized precursor is dispersed into the reactor 12 through a delivery manifold (e.g., an injector plate) 32 that functions as a diffuser. At a further elevated temperature within the reactor 12 , the film constituents of the vaporized precursor deposit onto the substrate 16 according to a process of disproportionation.
A variety of liquid precursors can be used containing constituents including metal agents incorporated into metallorganic complexes for transportation in the vapor phase. Examples include PEMAT: Pentakis(ethylmethylamino)Tantalum, CUPRA SELECT: Hfac(Cu)TMVS, and Cobalt Tricarbonyl nitroso. An inert gas such as helium is preferably used as the carrier gas; but a variety of gases including argon, nitrogen, hydrogen, and oxygen can also be used.
A perspective exterior view of the mixing valve 28 and vaporizer 30 in FIG. 2 shows more specific components involved with vaporization. Just in advance of the mixing valve 28 , the liquid precursor passes through both a flow meter 36 and a shut-off valve 38 along a liquid supply line 40 . The mixing valve 28 , which can be piezoelectrically actuated, receives a feedback signal from the flow meter 36 to control flow rates through the mixing valve 28 . A separate gas supply line 42 conducts the carrier gas to the mixing valve 28 . All of the liquid and gas regulating components including the mixing valve 28 , the flow meter 36 , and the shut-off valve 38 can be of conventional design for managing liquid flow rates of 0 through 5 cubic centimeters/min (ccm) and gas flow rates of 0 through 700 standard cubic centimeters per minute (sccm). Suitable components are available from Porter Instrument Company, Inc. of Hatfield, Pa.
A delivery tube 44 conducts the pre-mixed liquid precursor and carrier gas into the vaporizer 30 . Additional gas lines 46 and 48 conduct preheated carrier gas directly to two different locations within the vaporizer 30 . Four sets of electrical lines 52 supply power to heating elements within the vaporizer 30 . The heating elements, though not shown, are preferably 50 watt cartridge heaters; but a variety of other heating elements could also be used. Other interior structures of the vaporizer 30 can be seen in the exploded view of FIG. 3 and the cross-sectional view of FIG. 4 .
The delivery tube 44 passes with wide clearance through a top flange 54 but is engaged with or itself terminates with a thermal isolator that limits transfers of heat from the vaporizer 30 to the delivery tube 44 and mixing valve 28 . Thin walls 56 (see FIG. 4) of the flange 54 inhibit the conduction of heat to the delivery tube 44 from a vaporizer body 60 and a two-part surrounding block 62 , which are both made of heat-conducting materials. The top flange 54 , the vaporizer body 60 , and other structural fittings that come into contact with the precursor are preferably made of stainless steel or other materials that are chemically inert to the precursor and support the use of metal seals. The two-part surrounding block 62 , which is intended for supporting the heating elements, can be made of aluminum or other less expensive thermal conductors.
A copper gasket 64 seals the top flange 54 to a top of the vaporizer body 60 , which itself has the form of a flanged-end pipe. However, a central hole in the gasket 64 permits (a) the premixed liquid precursor and carrier gas, which enter the top flange 54 through the delivery tube 44 , and (b) additional preheated carrier gas, which enters the top flange 54 through the gas line 46 , to both enter the vaporizer body 60 . The heating elements (not shown) within the two-part surrounding block 62 provide for elevating the temperature of the vaporizer body 60 to support vaporization of the liquid precursor. A resistance temperature detector 58 monitors the temperature of the vaporizer body 60 to provide feedback control to the heating elements. Side insulating panels 66 , together with top insulating panels 68 and bottom insulating panels 70 , trap heat within the two-part surrounding block 62 to support more even heating of the vaporizer body 60 .
Typically, the temperature of the vaporizer body 60 is raised with respect to an ambient temperature (approximately 24 degrees centigrade, ° C.) of the delivery tube 44 to between 55° C. and 65° C. for supporting and maintaining vaporization of the precursor. However, the preferred vaporization temperature can be varied in accordance with the vaporization characteristics of particular precursors.
A first vaporizing stage 72 within the vaporizer body 60 contains a porous frit 74 having a large surface area formed by voids and passages to facilitate vaporization of the liquid precursor. The frit 74 is made of an inert material, such as sintered nickel, to avoid chemically reacting with the precursor. Suitable frits are available from Mott Industrial. Passages through the frit 74 are sized large enough to allow the liquid precursor to seep through the frit 74 without pooling. The number and size of the passages and the overall dimensions (e.g., diameter and thickness) of the frit 74 are set to maximize surface area for vaporization while limiting pressure drops accompanying passage of vaporized precursor through the frit 74 . The total pressure drop through the vaporizer is preferably less than 20 Torr.
The vaporized precursor transported by the flow of the preheated carrier gas through the frit 74 and any remaining liquid precursor moved in the same direction through the frit 74 by the force of gravity enter a vaporization chamber 76 within the vaporizer body 60 . Within the vaporization chamber 76 is an opening 78 of an outlet tube 80 that extends through a bottom of the vaporizer body 60 . The outlet tube 80 passes through a bottom flange 82 that is sealed to the bottom of the vaporizer body 60 through a copper gasket 84 . An extension of the outlet tube 80 connects the vaporizer 30 to the delivery manifold 32 of the reactor 12 .
A splash cone 86 forms a roof over the outlet opening 78 to prevent any of the remaining liquid precursor seeping through the frit 74 of the first vaporizing stage 72 from passing through the opening 78 of the outlet tube 80 . However, the splash cone 86 is elevated on posts 88 above the outlet opening 78 to provide gaps 90 under eaves of the roof structure of the splash cone 86 for admitting the vaporized portion of the liquid precursor through the outlet opening 78 .
The remaining liquid precursor that is diverted from the outlet opening 78 by the splash cone 86 descends through the vaporization chamber 76 to a second vaporizing stage 92 within the vaporizer body 60 . Another frit 94 , which is preferably more porous that the frit 74 but occupies more volume, exposes the remaining liquid precursor to a substantially increased surface area. The gas line 48 directs a flow of the preheated carrier gas opposed to the seepage direction of the remaining liquid precursor through the frit 94 for returning the remaining precursor in a vaporized form to the vaporization chamber 76 . The flow of vaporized precursor from the second vaporizing stage 92 is combined with the flow of vaporized precursor from the first vaporizing stage 72 through the outlet opening 78 for delivery to the reactor 12 .
The more porous frit 94 can be made of a less dense material such as aluminum foam and has an annular shape surrounding the outlet tube 80 . A suitable media for the frit 94 is available from Energy Research and Generation, Inc. under the trade name DUOCELL.
The second vaporizing stage 92 occupies a trap 96 within the vaporizer body 60 for capturing the remaining liquid precursor below a level of the outlet opening 78 . The trap 96 within the vaporizer body 60 is enclosed by the bottom flange 82 surrounding the outlet tube 80 , which passes without interruption through the trap 96 . The frit 94 fills the trap 96 to support vaporization of the liquid precursor captured within the trap 96 . Any of the liquid precursor reaching the second vaporizing stage 92 remains captured within the trap 96 until transformed into a vapor state and transported by the preheated carrier gas into the vaporization chamber 76 .
The vaporization process can be initiated by preheating the vaporizer body 30 and initiating flows from the precursor and carrier gas supplies 24 and 26 . The mixing valve 28 combines the liquid precursor with the carrier gas at a first temperature low enough to avoid significant decomposition of the liquid precursor. Ambient temperature is usually adequate for this purpose. The premixed liquid precursor and carrier gas are kept at ambient temperature until the mixture is admitted into the vaporizer 30 , which is preferably heated well above ambient temperatures (e.g., 55° C. to 65° C.) to promote vaporization and to avoid any subsequent condensation of the vaporized precursor. The temperature of the vaporizer 30 , however, is kept well below the temperature required for decomposition of the precursor in the reactor 12 .
The admission of the premixed liquid precursor and carrier gas into the vaporizer 30 is accompanied by the admission of additional carrier gas, which is preheated to promote immediate vaporization of the liquid precursor. Some of the liquid precursor may actually be vaporized even prior to reaching the porous frit 74 associated with the first vaporizing stage 72 . However, the increased surface area provided by the frit 74 combined with the flow of preheated carrier gas through the frit 74 vaporizes a more significant portion of the liquid precursor.
The vaporized portion of the liquid precursor is transported by the carrier gas through the frit 74 in the same direction as the gravitationally directed seepage of the remaining portion of the liquid precursor through the frit 74 . Both portions exit the frit 74 into the vaporization chamber 76 connecting the first and second vaporizing stages 72 and 92 .
Within the vaporization chamber 76 , the liquid portion of the precursor is separated from the vaporized portion of the precursor. The liquid portion descends into the second vaporizing stage 92 , and the vaporized portion escapes through an outlet opening 78 for delivery to the reactor 12 . The splash cone 86 positioned over the outlet opening 78 prevents the liquid portion of the precursor from entering the outlet opening 78 . Any liquid precursor that would otherwise drip into the outlet opening 78 is diverted from the opening by the roof-like structure of the splash cone 86 . However, gaps 90 formed by posts 88 that support the splash cone 86 above the outlet opening 78 admit the vaporized portion of the liquid precursor into the outlet pipe 80 through passages under the eaves of the roof-like splash cone 86 .
The remaining liquid portion reaching the second vaporizing stage 92 continues to descend by gravitationally directed seepage through the frit 94 . Although more porous than the frit 74 , the frit 94 occupies substantially more volume to avoid becoming saturated by any temporary accumulations of the liquid precursor within the trap-like structure of the second vaporizing stage 92 . The preheated carrier gas from the gas line 48 enters the trap 96 of the second vaporizing stage 94 near the bottom of the frit 94 and flows towards the vaporization chamber 76 in a direction opposed to the gravitationally directed seepage of the liquid precursor. The remaining precursor vaporized by the conditions of the second vaporizing stage 92 is transported by the oppositely directed carrier gas into the vaporization chamber 76 and combined with the precursor vaporized by the first vaporizing stage for escape through the common outlet opening 78 en route to the reactor 12 .
The two vaporizing stages together with the premixing of the liquid precursor and carrier gas can increase vaporization efficiency and deposition rates. Overall processing time can be reduced by avoiding the passage of liquid precursor into the reactor 12 .
Vaporization processing includes three main controls for regulating the concentration of precursor delivered to the reactor 12 . These include the flow rate of the precursor, the flow rate of the carrier gas, and the temperature of the vaporizer body 30 . Increased flow rates of the precursor can support higher deposition rates of the film constituents of the precursor within the reactor 12 . For example, precursor flow rates of 1.5 ccm of a metallorganic compound of copper (CUPRA SELECT) together with carrier gas (helium) flow rates of 120 sccm can support copper deposition rates of around 1700 Angstroms per minute (A/min). The vaporizer 30 is expected to support precursor flow rates of 2.5 ccm or more without clogging.
Between deposition operations, the carrier gas can be left flowing through the vaporizer 30 to purge any fluids left within the vaporizer 30 . The flow of liquid precursor is stopped by the shut-off valve 38 . However, the flow of carrier gas can be maintained to purge the mixing valve 28 and delivery line 44 . Both porous frits 74 and 94 can be replaced or cleaned on regular intervals.
The invention is expected to be especially useful for metallorganic chemical vapor deposition (MOCVD) operations used for such purposes as flat panel display manufacturing or thin film head production.
Although the invention has been illustrated with respect to a single embodiment, the invention can be practiced with a variety of other components and component configurations to achieve similar benefits. More than one of our new vaporizers can be used for supplying the same reactor with either multiple precursors or an increased amount of a single precursor along parallel delivery paths.
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A two-stage vaporizer includes two vaporizing stages joined by a vaporization chamber located gravitationally below the first vaporizing stage and gravitationally above the second vaporizing stage. A separator covering an outlet within the vaporization chamber allows vaporized precursor from both vaporizing stages to pass through the outlet to chemical vapor deposition system and prevents any remaining liquid precursor from passing through the outlet. The liquid precursor is premixed with carrier gas just prior to entry into the vaporizer. Additional flows of carrier gas pass through the two vaporizing stages in opposite directions to carry the vaporized precursor to the outlet.
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REFERENCE TO RELATED PATENT APPLICATION
This application is a division of application Ser. No. 11/062,659 filed Feb. 23, 2005, now U.S. Pat. No. 7,178,265, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/630,165, filed on Nov. 22, 2004.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to automated devices for drying clothing and laundry. More specifically, the ambient air clothes dryer is a clothes dryer devoid of any dedicated heating elements or systems for heating the air.
2. Description of the Related Art
The development of the automatic clothes dryer has been a great labor saving device for most households and, along with the automatic washing machine, has served to facilitate the commercial laundry industry as well. Automatic clothes dryers were initially developed when energy costs were relatively low, and accordingly make use of gas or electrical heat to accelerate the drying process. As a byproduct of the heat developed, the home or other structure is also heated, even though most of the heat is ducted to the exterior of the structure during dryer operation. Still, the residual heat output into the structure was not considered to be particularly undesirable, even in warmer conditions, as the energy costs required to operate air conditioning systems were much lower in the past.
However, with ever-increasing energy costs, the cost of operation of such conventional dryers has climbed considerably over the years, and even more so when the energy required to dissipate their heat output is considered. While conventional hot air clothes dryers have their place in very damp and/or cool climates, the heat they develop is an undesirable side effect of the drying operation in many parts of the country during much of the year. The alternative of the conventional clothes line is not suitable for many households due to the frequency of damp weather in many areas and seasons, and the time and labor required to tediously pin up each garment or article to the line and remove them, perhaps several hours later, when they are dry.
While some clothes dryers have been developed in the past that do not provide a source of heat during the drying operation, such dryers have not been found entirely satisfactory. Thus, an ambient air clothes dryer solving the aforementioned problems is desired.
SUMMARY OF THE INVENTION
The ambient air clothes dryer is an automated device including a motor-powered rotating drum having a fan providing axial airflow through the drum. No dedicated heating element is provided. Some embodiments include a fan motor and an additional motor to rotate the drum, while other embodiments utilize a belt or other drive from the fan output shaft to drive a jackshaft to rotate the drum, thereby saving weight, complexity, and energy. Yet another embodiment may be devoid of any fan or air circulation device, and may include only a motor to rotate the drum. This embodiment includes means for the removable and temporary installation of a conventional “box fan” therewith, to provide the air circulation required. Any or all of the embodiments may include a timer and/or humidity detector to provide for automatic shutoff of the fan and drum when the laundry is dry and/or a predetermined time has been reached.
The portability of the device allows it to be used indoors or outdoors, as desired. The device may take advantage of ambient heating sources within the home or other structure if so desired, e.g., a heat register, radiator, Franklin stove, etc., to provide some heating of the air, which then passes through the dryer drum. This also provides the beneficial effect of humidifying the air within the structure in colder weather. The device may be constructed to utilize twelve-volt power, if so desired, for use in camping when an automotive electrical system is available.
These and other features of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially broken away perspective view of a first embodiment of an ambient air clothes dryer according to the present invention, showing various details thereof.
FIG. 2 is a simplified side elevation view of an alternative embodiment of the present dryer, illustrating an alternative drum drive system.
FIG. 3 is another simplified side elevation view showing another alternative embodiment of a drum drive system.
FIG. 4 is an exploded perspective view of yet another alternative embodiment of the present dryer, in which a separate portable box fan is used to provide airflow through the drum.
FIG. 5 is a simplified schematic diagram of an exemplary electrical and control system that may be incorporated with the present dryer.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention comprises various embodiments of an ambient air clothes or laundry dryer, in which unheated air at ambient temperature is blown through the dryer drum to dry clothing therein. While some slight amount of heat may be provided from the fan motor, the present ambient air dryer device does not include any form of dedicated, specific heating apparatus, as is found in conventional clothes dryers.
FIG. 1 of the drawings illustrates a first embodiment of the present dryer 10 , in which a separate fan motor 12 and drum rotation motor 14 are employed. The dryer 10 includes a housing or shell 16 having a hollow dryer drum 18 therein. The drum 18 rotates within the housing 16 , and is supported by drum support wheels 20 or other mechanism installed internally within the housing 16 . The dryer drum 18 has an impervious, generally cylindrical wall 22 having a diameter D. A screened airflow inlet end 24 is positioned adjacent the fan motor 12 with its fan 26 and fan drive shaft 28 , with a screened airflow outlet end door 30 located opposite the inlet end 24 of the drum 18 . The two screened ends 24 and 30 are preferably of a sufficiently fine mesh or gauge as to preclude the passage of small articles (e.g., loose change, buttons, etc.) therethrough, and have diameters closely approaching the diameter D of the dryer drum 18 . The screen of the outlet door 30 may have a mesh or gauge sufficiently fine to serve as a lint trap for the dryer.
The fan drive motor 12 with its fan drive shaft 28 and circular, rotary fan 26 are concentrically disposed externally to the airflow inlet end 24 of the dryer drum 18 , but within the housing 16 . The fan 26 preferably has a diameter closely approaching the diameter D of the dryer drum 18 and the inlet and outlet ends 24 and 30 of the drum 18 , in order to maximize airflow through the drum 18 . A fan guard 32 is preferably installed across the air inlet opening of the dryer housing 16 , with at least the blades of the fan 26 being captured between the guard 32 and the screened inlet opening 24 of the drum 18 .
The separate drum drive motor 14 of the embodiment 10 of FIG. 1 drives an output shaft 34 , which in turn causes the drum 18 to rotate when the drum drive motor 14 is in operation. A common switch may be used to simultaneously actuate and deactivate the fan motor 12 and drum drive motor 14 , if so desired. In the case of the embodiment 10 of FIG. 1 , the output shaft 34 has a drum belt pulley 36 at its distal end, with a drum drive belt 38 extending around the pulley 36 and around a circumferential groove 40 in the dryer drum 18 .
The configuration of the ambient air clothes dryer 10 , as well as the configurations of other embodiments disclosed herein, requires no heavy, stiff high voltage and/or high amperage electrical cable, as is universally required for the heating elements of conventional electric clothes dryers. Moreover, no gas line connection is required, as there is no use of a gas heater for the incoming air of the present dryer. Thus, the present dryer is relatively lightweight in comparison to conventional dryers with their heating systems, and requires no more power than is capable of being supplied by a conventional household electric cord. (In some embodiments, the motor(s) may be 12-volt DC, enabling them to be powered from a motor vehicle electrical system if so desired.) The light weight and simple power requirements of the present ambient air dryer allow it to be moved about readily to various locations as desired. Accordingly, external transport wheels 42 may be provided beneath one or both ends of the housing 16 , with a pair of support legs 44 being shown beneath the opposite end of the housing 16 in the embodiment of FIG. 1 . A handle 46 may be provided across one side of the housing shell 16 , to facilitate lifting of that side for rolling the device 10 as desired by means of the wheels 42 .
FIG. 2 provides a side elevation view of an alternative drum drive system, in which the fan drive is also used to rotate the drum. In FIG. 2 , the fan motor 112 drives an output shaft 128 to which the fan 126 is connected, as in the corresponding components 12 , 28 , and 26 of the embodiment 10 of FIG. 1 . However, the fan motor output shaft 128 may include a drive belt pulley 129 thereon, with a jackshaft drive belt 131 extending from the fan motor shaft pulley 129 to a driven pulley 133 on a radially offset jackshaft or drum drive shaft 134 . The shaft 134 includes a drum drive belt pulley 136 at its distal end, with a drum drive belt 138 extending around the pulley 136 and riding in a circumferential groove 140 around the dryer drum 118 . It will be seen that the dryer drum 118 and drum drive belt 138 may be identical to the corresponding components 18 and 38 illustrated in FIG. 1 and described further above. The distinction between the configuration of FIG. 1 and that of FIG. 2 is the use of a shaft and belt system driven from the concentric fan motor to rotate the dryer drum in the embodiment of FIG. 2 .
FIG. 3 provides a side elevation view of an embodiment similar to that of FIG. 2 , differing in the means used to impart rotary motion directly to the drum. In FIG. 3 , the fan motor 212 drives an output or fan drive shaft 228 and fan 226 , with the shaft 228 having a drive belt pulley 229 thereon, just as in the case of the equivalent components 112 , 128 , 126 , and 129 of the embodiment of FIG. 2 . The pulley 229 , in turn, drives a jackshaft or drum drive shaft 234 by means of a jackshaft driven pulley 233 on one end of the shaft 234 , just as in the embodiment of FIG. 2 . However, rather than driving the drum 218 by means of a belt extending around the drum, as shown in FIGS. 1 and 2 , the jackshaft or drum drive shaft 234 has a friction wheel 236 (rubber-coated, etc.) at its distal end which bears against a circumferential friction band 238 surrounding the dryer drum 218 . Rotation of the friction wheel 236 imparts rotational motion to the dryer drum 218 by means of the friction between the wheel 236 and friction band 238 around the drum. It will be seen that such a drum drive system may also be incorporated in the embodiment of FIG. 1 , with the drum drive shaft 34 having a friction wheel 236 at the distal end thereof in lieu of the pulley 36 shown, and the dryer 10 incorporating the drum 218 of FIG. 3 with its friction band 238 .
FIG. 4 provides an illustration of an additional embodiment of the present ambient air dryer, in which a portable fan is used to supply the air through the dryer drum. The dryer 310 of FIG. 4 includes a housing 316 which contains the drum 18 and drum drive mechanism comprising motor 14 , drum drive shaft 34 , shaft output pulley 36 , and drum drive belt 38 , just as in the embodiment illustrated fully in FIG. 1 . However, rather than incorporating a fan integrally therewith, as in the embodiments of FIGS. 1 through 3 , the housing 316 of the dryer 310 includes a fan receptacle 317 in the rear wall thereof, i.e., adjacent the screened air inlet end 24 of the drum. The fan receptacle 317 is configured to fit a conventional portable fan F, commonly known as a “box fan,” therein. The fan receptacle 317 may be configured to accept other types of fans, as desired. A suitable electrical outlet 319 may be provided on the housing 316 , allowing the fan F to be plugged in for operation. Power to the outlet 319 may be provided through appropriate control circuitry on or in the dryer housing or cabinet 316 , as desired, to provide control of the fan F from the ambient air dryer controls.
FIG. 5 provides a basic electrical schematic diagram of circuitry that may be incorporated with the present ambient air clothes dryer in its various embodiments. In FIG. 5 , a conventional electrical power source 410 , e.g., 115-volt ac power from the power grid, or perhaps 12-volt dc power from an automotive or other electrical source when the ambient air dryer is manufactured to accept such power, provides electrical power to the dryer through a master switch 412 . The master switch provides power to the fan motor, e.g., motor 12 of FIG. 1 , and the drum drive motor, e.g., motor 14 of FIG. 1 , through a solenoid or other appropriate switch 414 . The switch 414 may incorporate the electrical outlet 319 for incorporation in the portable fan embodiment of FIG. 3 , if so desired.
The solenoid switch 414 is not required in the simplest embodiments of the present ambient air dryer. However, the dryer in any of its embodiments may include a timer and/or humidity sensor 416 , if so desired. These components are conventional in clothes and laundry dryers, and need not be described in detail herein. The timer may be incorporated in combination with a rotary on/off switch to serve the function of the master switch 412 , if so desired. In any event, the timer and/or humidity sensor 416 is normally closed when electrical power is applied for operation of the dryer, with the electrical contacts opening when a predetermined time is reached (for the timer) or when the air flow from the dryer reaches a predetermined low level of humidity (for the humidity sensor). If either of these conditions occurs, power to the solenoid switch 414 is interrupted, thereby interrupting power to the fan and drum drive motors 12 and 14 and shutting off the dryer. The opening of the solenoid switch 414 may also trigger the operation of a buzzer, bell, or other audible or visual signaling means to alert the user of the dryer that the drying operation is complete, much as in the case of conventional clothes dryers. Where the circuit of FIG. 5 is incorporated with the portable fan embodiment of FIG. 4 , the switch 414 may control power to the outlet 319 to shut off power to the outlet 319 , thereby shutting off the fan F plugged into the outlet 319 .
In conclusion, the present ambient air laundry and clothes dryer in its various embodiments provides a significant advance in efficiency for such machines, particularly in relatively warm and/or dry environments where the device may take advantage of the ambient air conditions.
It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.
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The ambient air clothes dryer is an automated device providing axial flow of unheated ambient air through the dryer drum. The dryer may include different drum drive systems, timer and/or humidity detector controls, and a configuration utilizing a separate, portable fan for temporary, removable installation with the dryer housing to provide airflow through the drum. The ambient air dryer greatly reduces energy requirements for drying laundry when compared to conventional heated air dryers, and is quite effective in warm and/or dry climates. The ambient air dryer is portable and may be used indoors or outdoors. The device may be configured to use twelve-volt power from a motor vehicle for use in camping. When used indoors, the device may be placed with a heat source (heat register, etc.) to draw warm air through the drum while humidifying the air as it passes through damp laundry in the drum.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a National Stage of German Patent Application No. DE 103 16 677.7, filed on Apr. 10, 2003. The disclosure of the above application is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a motor vehicle having a system for reproduction of sound, said sound reproduction system including at least one bass reflection box equipped with a bass reflection tube and/or a bass reflection opening, and with at least one built-in speaker.
BACKGROUND AND SUMMARY OF THE INVENTION
[0003] A bass reflection box, that is to say a Helmholz resonator, consists as a rule of an air-filled housing, a built-in speaker and a bass reflection tube or a bass reflection opening. The speaker represents the first oscillatory system, while the volume of air represents the second oscillatory system. Between the driving speaker and the driven volume of air, proper design results in a resonance feedback, such that the compression wave emerging from the bass reflex opening experiences a phase shift to amplify the direct compression wave. By a suitable choice of resonance frequency, an amplification of the low-pitch reproduction is achieved with simultaneous reduction of the speaker diaphragm deflection. For an optimal bass reflection box, a cavity of large volume is required in the motor vehicle, without decreasing the volume of the passenger and baggage compartments.
[0004] The present invention, then, is addressed to the problem of finding a suitable cavity in the motor vehicle in which a bass reflection box can be accommodated, while at the same time a portion of the space in the bass reflection box or a portion of the wall of the bass reflection box can serve some other use.
[0005] This problem is solved by the features of the principal claim. For this purpose, the bass reflection box is arranged in a side compartment of the interior of the vehicle, and a wall of the bass reflection box oriented towards the interior of the vehicle is at least partially covered with a sound-transmissive cover, the service tool and emergency aids being arranged between depressions in that wall and the cover.
[0006] In the case of motor vehicles, generally a service tool kit is included in the delivery. The minimum scope of this kit includes at least the tools required to repair tire damage, at least temporarily. These tools, or emergency aids, are commonly accommodated in the trunk compartment, in the spare wheel well, or in a side compartment. The same adjoining spaces are often used in motor vehicles, in particular station wagons, having a more elaborate sound reproduction system, for bass boxes. In these vehicles, it has been necessary heretofore to accommodate service tools and other emergency aids elsewhere. This has led as a rule to greater difficulty of access or unavailability in serious emergency situations. Finally, the tool was to be found in a location unfamiliar to the average operator.
[0007] By the integration of the service tool kit with or into a bass reflection box installed in a side compartment, any separate unaccustomed accommodation is unnecessary. A, generally for the most part, unused space is used to improve the system sound, and, at the same time, the service tool kit becomes readily and handily accessible.
[0008] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0010] [0010]FIG. 1 is a perspective view of a bass reflection box arranged in a station wagon; and
[0011] [0011]FIG. 2 is a perspective view of the bass reflection box of FIG. 1 with a cover opened.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0013] [0013]FIGS. 1 and 2 show the tail portion of a station wagon with hatchback open. For example, on the driver's side, a bass reflection box ( 30 ) is arranged behind the backrest ( 16 ) of the second row of seats between the wheel box and the opening ( 17 ) of the hatchback.
[0014] The bass reflection box ( 30 ) fills the body compartment in lengthwise direction of the vehicle between the C- and D-columns ( 12 ) below the rear side window ( 13 ). In this embodiment, by way of example, the bass reflection box ( 30 ) terminates downward at the level of the baggage compartment floor ( 11 ). Optionally, it may also extend below the floor level. The cavity of the bass reflection box ( 30 ) can be additionally connected to the cavities underneath the baggage compartment floor ( 11 ).
[0015] The bass reflection box ( 30 ) here has essentially the shape of an obliquely truncated rectangular solid, the oblique face being the surface in contact with the backrest ( 16 ). Towards the baggage compartment ( 10 ), it has an e.g. largely plane wall ( 31 ) oriented perpendicular to the transverse direction of the vehicle. The vertical extent of the wall ( 31 ) lies between the baggage compartment floor ( 11 ) and the bottom edge ( 14 ) of the rear side window ( 13 ). As top covering, the bass reflection box ( 30 ) has a wall ( 35 ) extending along the side window sill ( 14 ) and oriented parallel in transverse direction to the baggage compartment floor ( 11 ). Towards the hatchback, the bass reflection box ( 30 ) terminates at a wall ( 36 ), matching the inclination and/or contour of the hatchback surfaces in that area. As a rule, the edges at which the walls ( 31 , 35 , 36 ) abut are configured as curved surfaces ( 37 , 38 , 39 ), whose minimum radii lie in the lower centimeter range.
[0016] In the area of the curved surface ( 37 ) between the e.g. vertical wall ( 31 ) and the upper top ( 35 ), whose minimal radius of curvature is, for example, greater than five centimeters, there is a bass reflection tube opening ( 47 ). It is e.g. the outer end of a bass reflection tube laid in the bass reflection box ( 30 ), acoustically connecting the back of the speaker to the passenger compartment ( 10 ). The bass reflection tube opening ( 47 ) is of funnel-shaped configuration, with oval cross-section ( 48 ). The horizontal cross-sectional extent of the opening ( 47 ) is e.g. about eight centimeters.
[0017] Between the funnel ( 48 ) and the edge ( 39 ), an unlocking key ( 45 ) is arranged. On the same level, there may be another key ( 46 ) between the funnel ( 48 ) and the backrest ( 16 ).
[0018] Underneath the funnel ( 48 ) and the keys ( 45 , 46 ), the wall ( 31 ) has the conformation of a lid ( 40 ). The lid ( 40 ) is a hinged lid, openable about an axis of swing ( 44 ), located e.g. offset some millimeters parallelwise above the baggage compartment floor ( 11 ), cf. FIG. 2. The lid ( 40 ) in closed condition lies with its inside ( 60 ) in front of a receptacle wall ( 50 ) of the bass reflection box ( 30 ). For the configuration of two hinges, in the lower portion of the receptacle wall ( 50 ), two hooks ( 33 ) are arranged which extend downward, whence each engages an angled hinge recess ( 43 ) of the lid ( 40 ). The lid ( 40 ), locked to the receptacle wall ( 50 ), for example, in closed condition can be opened by pressing the unlocking key ( 45 ).
[0019] The geometrically rigid, unbreakable and, for example, plain lid ( 40 ), consisting at least partly of a sound-transmissive material or a suitable composite material, is e.g. approximately 10 millimeters thick. It protectively covers, among other things, a speaker ( 5 ) set into the mid-portion of the receptacle wall ( 50 ).
[0020] The lid ( 40 ) on the inside ( 60 ) has a plurality of depressions ( 62 - 66 ). Some of the depressions in the lid, when the lid ( 40 ) is closed, face other depressions in the receptacle wall ( 50 ). Between opposed depressions, parts of the service tool kit ( 3 ) and other emergency aids ( 2 , 4 ) are arranged.
[0021] For example, directly beside the edge ( 39 ) there is a depression ( 51 ) in which a jack is inserted. In a depression ( 58 ), near the backrest ( 16 ), a warning triangle ( 2 ) is placed. In the upper part of the receptacle wall ( 50 ), there is a, for example, horizontal depression ( 57 ) in which an e.g. battery-operated pocket lamp ( 3 ) is inserted. These three depressions ( 51 , 57 , 58 ) in the embodiment, by way of example according to FIG. 2, are not faced by any lid depressions. The depression ( 57 ) for the pocket lamp ( 3 ) has in its middle depression area e.g. three clamps ( 77 ) effecting a clamping around the pocket lamp ( 3 ).
[0022] In the inside ( 60 ) of the lid, opposed to the jack depression ( 51 ), e.g., an installation guide ( 4 ) for a wheel change is attached. Beside the installation guide ( 4 ), there is a depression ( 62 ) for a plug pipe wrench to free the wheel nuts, a depression ( 63 ) for the plug pipe wrench lever, a depression ( 64 ) for a smaller plug pipe wrench with swing-out lever, a clamp attachment ( 69 ) for a monkey wrench, and a depression ( 66 ) for a cross-slot screwdriver. All depressions ( 62 - 66 ) and the clamp attachment ( 69 ) face depressions in the receptacle wall ( 50 ).
[0023] Into the lid-side depression ( 62 ) above and below, in each instance a face clamp ( 72 ) projects. Each face clamp ( 72 ) engages a frontal hexagonal recess of the plug pipe wrench to be accommodated. The two depressions ( 63 , 64 ) offset towards the backrest ( 16 ) have dampers ( 73 ) in their mid-region on either side for clapless grasping of the tools to be inserted. Above the dampers ( 73 ) and the clamp attachment ( 69 )—viz. shifted towards the upper edge of the lid—there are grip recesses ( 78 ) for readier removal of tools embedded with clamping effect. The depression ( 66 ) has two clamp teeth ( 76 ) on either side, matching the clamp teeth ( 77 ) of the pocket lamp holder.
[0024] By the arrangement of the depressions in the lid ( 40 ) and in the receptacle wall ( 50 ), and by the alternate complementation, i.e., some of the tools and emergency aids ( 2 , 4 ) are accessible in the opened lid ( 40 ), while the rest are arranged in the receptacle wall ( 50 ), a greater handiness and better accessibility result.
[0025] Alternatively, it is of course possible to accommodate all tools and aids in the receptacle wall ( 50 ) only. Also, in that case, among other things, the clamp teeth ( 72 - 77 ) may be held by a plurality of elastic straps stretched e.g. horizontally over the receptacle wall ( 50 ). In that case, the depressions would become nearly perpendicular to the straps.
[0026] The bass reflection box ( 30 ) as so far described is fixedly installed in the rear side compartment. The bass reflection box ( 30 ) may alternatively be of removable construction. In this modified embodiment, the bass reflection box ( 30 ) is constructed as an enclosed container. The bass reflection box ( 30 ) is connected by a cable at least five meters in length to the vehicle cable tree, the cable being bridged in the case of a built-in bass reflection box ( 30 ), optionally by an electrical bridge.
[0027] Through the availability of a long cable, the bass reflection box ( 30 ) e.g. in an emergency, can be carried to the site with its tools. In this bass reflection box ( 30 ), additionally a cardanically suspended searchlight—supplied by the vehicle circuit—may be installed. The latter may serve to light the emergency site, or by blinking, possibly with color filter, secure the emergency site. Additionally, in such a bass reflection box ( 30 ), a receptacle carrying current from the vehicle circuit may be integrated as well.
[0028] At the same time, during repairs, the sound reproduction system may be in operation. Further, the bass reflection box ( 30 ) can be employed to enhance the vehicle leisure-time quality for external audio.
[0029] With the externally usable bass reflection box ( 30 ), the latter is released from the vehicle superstructure by the key ( 46 ). The funnel ( 48 ) serves as grip trough in transport. To avoid contact of the lid ( 40 ) with the commonly soiled roadway surface, the lid ( 40 ) can be secured, against too wide opening, with a tether. In another modification, provision may be made to hang the lid ( 40 ) out on the bass reflection box ( 30 ) in order to bring it to the site with the tools like a tablet. The separate lid ( 40 ) may also serve on the spot as a knee pad.
[0030] Of course, the bass reflection box ( 30 ) may alternatively be arranged in the step or rear of a vehicle. Here, the upper wall ( 35 ) of the bass reflection box ( 30 ) will extend into the neighborhood of the hat rack. That is where the bass reflection tube terminates ahead of the rear panel in the direction of travel ( 9 ). At the same time, a portion of the hat rack or of the backrest ( 16 ) must be sound-transmissive for the direct sound of the speaker ( 5 ).
[0031] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
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The invention relates to a motor vehicle having a system for reproduction of sound, said system for reproduction of sound including as least one bass reflection box equipped with a bass reflection tube and/or a bass reflection opening and with at least one built-in speaker. For that purpose, the bass reflection box is arranged in a side compartment of the interior of the vehicle, and a wall of the bass reflection box, oriented towards the interior of the vehicle, is at least partially coverable with a sound-transmissive lid, the service tools and emergency aids being arranged between depressions in said wall and the lid.
With the present invention, a motor vehicle having a sound reproduction apparatus is created in which a large-volume bass reflection box is optimally accommodated in the trunk compartment. Here the bass reflection box is additionally utilized to accommodate the service tool kit.
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FIELD OF THE INVENTION
[0001] This invention relates generally to cassettes for containing and dispensing photosensitive film material and, more particularly, to a reusable cassette that can be reloaded with a roll of film by the user.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] Disposable cassettes are known in the prior art for containing and dispensing rolls of photosensitive film used by the printing industry in image setters like the DPM 2340 manufactured by A.B. Dick Company, for example. Typical of such prior art cassettes is that described in U.S. Pat. No. 4,842,211 to Robbins. The film cassettes commercially available today are expensive because they are proprietary to the current single-source manufacturer, are disposable, and, therefore, do not permit reloading with film of the user's choice. Thus, the user of these disposable cassettes would experience a shutdown in his printing operations during periods of short supply or total unavailability of cassettes. Moreover, the disposal of these cassettes, which are fabricated of cardboard, plastic, and foam rubber, presents an environmental concern.
[0003] It would therefore be advantageous to provide a reusable cassette in accordance with the present invention for containing and dispensing rolls of photosensitive film. An exhausted roll of film may be easily replaced by the user with a new roll, and the cassette will automatically accommodate film rolls of different width. The reusable film cassette of the present invention allows the user to obtain photosensitive film from any one of multiple vendors, thus reducing cost and avoiding reliance on today's single source of disposable film cassettes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] [0004]FIG. 1 is an overall pictorial diagram of a reusable cassette for containing and dispensing a roll of photosentive film, in accordance with the present invention.
[0005] [0005]FIG. 2 is a pictorial diagram of the reusable cassette of FIG. 1, with the cover cut away to illustrate the details of the interior self-centering drum mechanism.
[0006] [0006]FIG. 3 is an exploded view of the reusable cassette of FIGS. 1 and 2, with the cover removed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0007] Referring now to FIG. 1, there is shown an overall pictorial diagram of a reusable film cassette 100 for containing and dispensing a roll of photosensitive film 10 . Cassette 100 includes a pair of end caps 12 , 14 and a cover 16 positioned therebetween. Cover 16 includes a frontal longitudinal film slot 18 through which film 10 exits cassette 100 . A foam rubber covered cloth material is preferably positioned along film slot 18 to provide a light seal to prevent exposure of film 10 within cassette 100 that would othewise be caused by the entry of light through film slot 18 . End caps 12 , 14 , as well as cover 16 , may be conventionally fabricated of any of a number of plastic materials, such as Lexan, for example.
[0008] Referring now to the detailed pictorial diagrams of FIGS. 2 and 3, each of the end caps 12 , 14 includes an inwardly facing groove 20 along its peripheral edge, into which corresponding ends of cover 16 fit. Cover 16 is fixedly attached to end cap 12 by means of an adhesive or other means. A rod 22 , centrally positioned between end caps 12 , 14 serves to secure end caps 12 , 14 in spaced relationship to each other. One end of rod 22 is fixedly attached to end cap 12 by means of a bolt or other fastener 24 , while the other end of rod 22 is removably attached to end cap 14 by means of a thumb screw 26 , for example. Each of the end caps 12 , 14 includes an inwardly facing, circular protrusion 28 over which are fixedly mounted respective outer ends of a pair of drum members 30 , 32 that, when butted together as illustrated in FIG. 2, form a circular drum. Drum members 30 , 32 may be conventionally fabricated of a transparent plastic or other desirable material. A circular film centering member 34 is positioned on rod 22 within drum member 30 proximate end cap 12 . A second circular film centering member 36 , constructed like film centering member 34 , is similarly positioned on rod 22 within drum member 32 proximate end cap 14 . The diameter of film centering members 34 , 36 is selected to be slightly smaller than the inner diameter of drum members 30 , 32 so that film centering members 34 , 36 can move longitudinally within drum members 30 , 32 , respectively. Each of the film centering members 34 , 36 includes a plurality of longitudinally and outwardly extending foot members 38 . The outwardly extending portion of each of the plurality of foot members 38 is positioned for travel within a corresponding plurality of longitudinal slots in drum members 30 , 32 . The longitudinal distance between inner ends of a corresponding pair of the slots in drum members 30 , 32 represents the width of the narrowest roll of photosensitive film 10 to be accommodated within cassette 100 , while the overall length of drum members 30 , 32 , when cassette 100 is assembled, represents the width of the widest roll of film 10 to be accommodated within cassette 100 . A spring member 40 is positioned between circular protrusion 28 of each of the end caps 12 , 14 and each of the film centering members 34 , 36 . The spring members 40 serve to urge foot members 38 of film centering members 34 , 36 inwardly along the slots in drum members 30 , 32 and against the respective ends of a roll of photosensitive film when it has been loaded into position over drum members 30 , 32 . A plurality of indentations 42 on the inner surface of end caps 12 , 14 receive foot members 38 when a maximum width roll of photosensitive film is loaded into cassette 100 .
[0009] In preparation for loading a roll of photosensitive film 10 , cassette 100 is preferably positioned on end with end cap 12 resting on a flat surface. Thumb screw 26 is then removed, and end cap 14 , with drum member 32 fixedly attached thereto, is also removed. A roll of photosensitive film, typically supplied on a spool, is then positioned over drum member 30 , the free end of the film 10 is then guided through slot 18 in cover 16 , end cap 14 is placed into position with drum member 32 inserted within the spool on which the roll of photosensitive film is supplied, and thumb screw 26 is tightened. Each roll of photosensitive film preferably includes a daylight leader which allows the user to load the roll in normal ambient light, without the need for a darkroom. Subsequent rolls of film are loaded in the same manner. While the present invention has been described in the context of photosensitive film, it should be noted that cassette 100 may be used to contain and dispense rolls of other types of film materials, as well as other sheet materials, such as paper.
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A reusable cassette for containing and dispensing rolls of photosensitive film may be easily reloaded by the user. The cassette includes a self-centering drum mechanism to accommodate film rolls of different widths.
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BACKGROUND OF THE INVENTION
The present invention relates to a synthetic fiber rope, preferably of aromatic polyamide material.
Especially in materials handling technology, for example on elevators, in crane construction, and in open-pit mining, etc., ropes are an important element of machinery and subject to heavy use. An especially complex aspect is the loading of driven or over pulleys deflected ropes, for example as they are used in elevator construction.
Specifically, on elevator installations the lengths of rope needed are large, and considerations of energy lead to the demand for smallest possible masses. High-tensile synthetic fiber ropes, for example of aromatic polyamides or aramides with highly oriented molecule chains, fulfil these requirements better than conventional steel ropes.
Specifically, ropes constructed of aramide fibers have a substantially higher lifting capacity than conventional steel ropes of the same cross section, and only between one fifth and one sixth of the specific gravity. However, the atomic structure of aramide fiber causes it to have a low ultimate elongation and a low shear strength.
Such an aramide fiber rope with parallel lay is known, for example, from European patent document EP 0 672 781 Al. There, between the outermost and inner layers of strands there is an intersheath which prevents contact between the strands of different layers and thereby reduces the wear due to their rubbing against each other. The aramide rope described so far has satisfactory values of service life, resistance to abrasion, and fatigue strength under reversed bending stresses. However, when loaded under tension the twisted stranded synthetic fiber rope has a tendency to rotate about its longitudinal axis and/or untwine. The undesirable untwining of the stranded rope can lead to an unevenly distributed loading of the strands of different strand length over the cross section of the rope and thereby to a reduction in the breaking load of the rope or even to failure of the rope.
SUMMARY OF THE INVENTION
An objective of the present invention is to avoid the disadvantages of the known synthetic fiber rope and to specify a permanently dependable twisted synthetic fiber rope.
The advantages resulting from the present invention relate to the fact that the intersheath, by having sheath surfaces adapted to the contours of adjacent layers of strands, provides a larger area of contact with the strands and thereby also completely bridges the interstices between the strands of the layers of strands adjacent to it. The tight bond between inner and outer layers of strands results in a higher torsional rigidity of the stranded rope. This prevents a loaded rope with contoured intersheath according to the invention from twisting irrespective of the type of torque acting on it. With the invention there is therefore a greater supporting and/or load-bearing area of sheath available even when the rope is in the loaded state. This in turn results in a homogenized transfer of torque over the entire circumferential area of the sheath to the interior of the rope. As a result, the constrictive force of the covering layer of strands no longer acts mainly as a transverse force on the highest points of individual strands, but is spread widely, i.e. with reduced pressure, over the entire circumferential surface of the sheath of the adjacent layers of strands.
With appropriately selected elasticity, the intersheath can absorb differing longitudinal movements of adjacent strands without the strands moving relative to the intersheath, from which advantages are derived in relation to the flexibility of the rope and its behavior under reversed bending.
BRIEF DESCRIPTION OF THE DRAWINGS
The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment when considered in the light of the accompanying drawings in which:
FIG. 1 is a perspective view of a traction rope with an intersheath in accordance with the present invention; and
FIG. 2 is a cross-sectional view of the traction rope shown in the FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a rope 1 such as is used as a means of suspension and hoisting in elevator installations, for example by being driven via a rope sheave or rope drum. In such installations the car sling of the car, which is moved in an elevator hoistway, and a counterweight are connected together by a rope. To raise and lower the car and the counterweight, the rope runs over a traction sheave which is driven by a drive motor. The drive torque is transferred by friction to the section of the rope which at any moment is lying in the angle of wrap. At this point the rope is subjected to high transverse forces. A typical elevator installation having a car and a counterweight supported by a rope is shown in the U.S. Pat. No. 5,566,786 which is incorporated herein by reference.
The rope 1 is constructed of a core strand 2 around which in a first direction of lay 3 five identical strands 4 of a first layer of strands 5 are laid helically, and on them ten strands 4 and 7 of a second layer of strands 8 laid in parallel lay with a balanced ratio between the direction of twist of the strands and the rope lay.
The second layer of strands 8 comprises an alternating arrangement of two types of five identical strands 4 and 7 each. The cross-section through the rope 1 illustrated in FIG. 2 shows five further strands 7 with a larger diameter which lie helically in the hollows of the first layer of strands 5 which supports them, while five strands 4 with the smaller diameter of the strands 4 of the first layer of strands 5 lie on the highest points of the first layer of strands 5 that supports them and thereby fill the gaps between two adjacent strands 7 having a greater diameter. In this way, a doubly parallel laid rope core 9 receives the second layer of strands 8 with an almost circular external profile, which in combination with an intersheath 13 affords advantages which are subsequently described below. When the rope 1 is loaded longitudinally, the parallel lay of the rope core 9 creates a torque in the opposite direction to the first direction of lay 3 . On the rope core 9 , seventeen strands 10 are laid in hawser manner in a second direction of lay 11 opposite to the first direction of lay 3 to form a covering layer of strands 12 . In the illustrated embodiment, the ratio of the length of lay of the strands 10 lying on the outside of the rope 1 to the strands 4 and 7 of the inner layers of strands 5 and 8 is approximately 1.6. Under load, the lay of the covering layer of strands 12 develops a torque in the opposite direction to the second direction of lay 11 .
Between the covering layer of strands 12 laid in the second direction of lay 11 and the strands 4 and 7 of the second layer of strands 8 is the intersheath 13 . The intersheath 13 consists of an elastically deformable material, such as polyurethane or polyester elastomers, and is molded or extruded onto the stranded rope core 9 . During this process the freshly applied intersheath 13 is plastically deformed, lying tight against contours of the circumferential sheath of the layers of strands 8 and 12 , filling all the interstices, and forming grooves 18 and 19 impressed on it by the adjacent layers of strands 12 and 8 respectively. Thus, each of the grooves 18 and 19 receives an associated one of the strands of the layers 12 and 8 respectively.
The contoured intersheath 13 takes the form of a tube enveloping the second layer of strands 8 and thereby prevents contact of the strands 4 and 7 with the strands 10 . In this way it prevents wear of the strands 4 , 7 and 10 being caused by the strands 4 , 7 and 10 rubbing against each other as a result of moving relative to each other when the rope 1 runs over the traction sheave, such relative movement taking place to compensate differences in tensile stress which occur, for example, when the direction of the rope is reversed under load on the traction sheave.
By virtue of friction and its shape, the intersheath 13 also transmits the torque which is developed in the covering layer of strands 12 when the rope 1 is under load to the second layer of strands 8 , and thereby to the rope core 9 , whose parallel lay develops a torque in the opposite direction to the direction of lay 3 .
At the same time, the frictional resistance μ>0.15 between the strands 4 , 7 and 10 and the intersheath 13 is so chosen that practically no relative movement occurs between the strands and the intersheath, but so that the intersheath 13 follows the compensating movements by deforming elastically. The elasticity of the intersheath 13 is greater than that of the strand impregnation and that of the supporting strand material and thereby prevents their becoming prematurely damaged. On the other hand, the overall extension of the material selected for the intersheath 13 is in all cases greater than the maximum movement that occurs of the strands 4 , 7 and 10 relative to each other.
A thickness 20 of the intersheath 13 can be used to set in a controlled manner a radial distance 17 of the covering layer of strands 12 from the center of rotation of the rope 1 and thereby to neutralize the torque ratio between the torque of the covering layer of strands 12 and of the parallel laid rope core 9 which act in opposite directions to each other in the loaded rope 1 . The thickness 20 selected for the intersheath 13 must be increased with increasing diameter of the strands 10 and/or the strands 4 and 7 . In all cases, the thickness 20 of the intersheath 13 must be given such a dimension as to ensure that under load, when interstices 21 and 22 between the strands are completely filled, there is a remaining sheath thickness of 0 . 1 mm between strands 4 , 7 and 10 of the adjacent layers of strands 8 and 12 . The plastically deformed intersheath 13 causes a homogenized transmission of torque over the entire circumferential surface of the sheath. The volume of the interstices between the strands can be minimized by an alternating arrangement of strands of large diameter 7 and strands 4 of smaller diameter in the second layer of strands 8 .
As well as being used purely as a suspension rope, the rope can be used in a wide range of equipment for handling materials, examples being elevators, hoisting gear in mines, building cranes, indoor cranes, ship's cranes, aerial cableways, and ski lifts, as well as a means of traction on escalators. The drive can be applied by friction on traction sheaves or Koepe sheaves, or by the rope being wound on rotating rope drums. A hauling rope is to be understood as a moving, driven rope, which is sometimes also referred to as a traction or suspension rope.
A rope sheath 14 is provided as a protective sheath for the aramide fiber strands. The rope sheath 14 consists of synthetic material, preferably polyurethane, and ensures that the coefficient of friction on the traction sheave is of the required value μ. Furthermore, the abrasion resistance of the sheath of synthetic material is also a rigorous requirement so that no damage occurs as the elevator rope runs over the traction sheave. The rope sheath 14 bonds so well with the covering layer of strands 12 that as the traction rope I runs over the traction sheave with the transverse and pressure forces which arise between them no relative movement occurs. Apart from the rope sheath 14 which encloses the entire covering layer of strands 12 , each individual strand 10 can in addition be provided with a separate, seamless sheath 15 . The remaining structure of the traction rope 1 remains unchanged, however.
Beside in elevators and aerial cableways, the rope according to the present invention is applicable in various installations for material handling, for example for elevators, hoisting, cranes for house construction, factories or ships, ski lifts or for escalators. The rope can be driven by a traction device such as a traction sheave or a turning drum on which the rope is coiled up.
In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.
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A synthetic fiber rope having load-bearing aramide fiber strands laid together in parallel in concentric layers of strands and an intersheath with sheath surfaces adapted to the external contours of the adjacent layers of strands. By positively bonding the inner and outer layers of strands a higher torsional rigidity is achieved as well as a rope structure of the stranded rope which is less susceptible to twisting. Furthermore, the elastic intersheath between the layers of stands serves to protect the strands against abrasion and assists in transmitting torque within the rope over a large area.
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FIELD OF THE INVENTION
[0001] The present invention relates to methods of measuring protein product from recombinant protein production based on the dry weight of an inclusion body harvest.
BACKGROUND OF THE INVENTION
[0002] High level expression of recombinant proteins produced in bacteria, such as E. coli , often results in formation of insoluble aggregates within the bacterial cell, known as inclusion bodies (Shein et al., Bio/Technology 7:1141-49, 1989). An inclusion body protein is one that is, in general, overexpressed in the host, which at later stages of expression or purification is visible by phase contrast microscopy as a precipitate. Inclusion bodies are electron-dense amorphous particles which have a discrete border to the cytoplasm but are not surrounded by a membrane (Schoemaker et al., EMBO J. 4:775-780, 1985). During the preparation of inclusion bodies, various types of interactions may lead to secondary adsorption of other contaminants such as, endotoxins, cell wall debris, and lipids (Marston FAO, Biochem. J. 240:1-12, 1986). The average particle size of inclusion bodies is dependent on the particular target protein expressed, the host strain, the expression system and the culture medium used and may be in the range from 0.07 μm for human growth hormone (Blum P et al., Bio/Technology 10: 30)-304, 1992) to 1.5 μm for β-lactamase (Bowden et al., Bio/Technology 9: 725-730, 1991). A further description of inclusion body can be found in U.S. Pat. No. 4,512,922, which refers to inclusion bodies as “refractile bodies.”
[0003] Inclusion bodies are generally harvested from cell lysate through several centrifugation and wash steps after the cells are lysed (e.g., by lysis by lysozyme, ultrasound treatment or high pressure homogenization). See, for example, U.S. Pat. Nos. 4,511,503; 4,518,526; 5,605,691; and 6,936,699. The purified inclusion bodies are then dissolved or denatured, with, e.g., a detergent or other solution (urea. SDS, guanidine hydrochloride), which causes the insoluble protein molecules to unfold and become soluble. The denaturant may subsequently removed, for example, by dialysis, by molecular sieve, or by centrifugation at high speed to remove higher molecular weight components and decant the denaturant. The recombinant protein is then isolated and refolded to form correct high order structures which are biologically active.
[0004] In order to insure the most efficient refolding reaction, it is important to control the amount and concentration of the proteins in the refolding reaction. The protein recovered from the inclusion bodies is typically determined by high performance liquid chromatography (HPLC) analyses of an aliquot of the inclusion body harvest. However, real-time analysis by HPLC methods are complex and time-consuming nature of the process.
[0005] Thus, there remains a need in the art for more efficient and accurate methods of determining recombinant protein levels produced during recombinant protein production.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to improved methods for measuring the protein produced and shuttled to inclusion bodies in recombinant protein (bacterial) cultures.
[0007] In one aspect, the invention provides a method for calculating recombinant protein concentration in bacterial inclusion body (IB) harvests comprising the step of multiplying total concentration of dry solids in an aliquot of an IB harvest slurry and a protein productivity conversion factor (PPCF) in a formula wherein the product of the formula provides total recombinant protein concentration in said aliquot of said IB harvest slurry, and wherein the PPCF for said recombinant protein is determined from an aliquot of an IB harvest slurry by multiplying the ratio of recombinant protein in said aliquot to total dry solids in said aliquot by 1000. The total recombinant protein may be calculated according to the formula:
[0000] [(total dry solid, mg)/(IB harvest slurry aliquot, g)×PPCF]×total IB harvest slurry weight, g=(total recombinant protein, mg).
[0008] The protein productivity conversion factor may be calculated according to the formula:
[0000] (PPCF)=[recombinant protein (mg) in said aliquot/total dry solids in said aliquot (mg)]×1000.
[0009] In an alternative embodiment, the conversion factor may be calculated based on alternative units to be determined. For example, concentrations may be expressed as g/kg, g/L, mg/g, mg/ml, and are generally equivalent since the densities of the material are very close to one. As such, a concentration in mg/ml is equivalent to mg/g, assuming the density is close to 1 g/ml.
[0010] In one aspect, the recombinant protein may be any protein that is expressed in bacteria in the form of insoluble inclusion body in transformed bacteria, i.e., bacteria which have been transformed or transfected with recombinant DNA vectors that direct the expression of genes coding for heterologous proteins. Recombinant proteins contemplated for use in the method of the invention include, but are not limited to, an antibody (such as a polyclonal antibody, a monoclonal antibody, a human antibody, a humanized antibody, Fab, F(ab′) 2 ; Fv; Sc Fv or SCA antibody fragment, bispecific antibody, diabody, peptibody, chimeric antibody; and linear antibody), an enzyme, a hormone, a cytokine, a chemokine, a growth factor, a transcription factor, a transmembrane protein, a cell-surface receptor, a cell-adhesion protein, a cytoskeletal protein, a fusion protein, or a fragment or analog of any of the above proteins.
[0011] In one embodiment, the PPCF for one inclusion body harvest aliquot is used to calculate recombinant protein concentration from different fermentation inclusion body harvests carried out following the same protocol.
[0012] In another aspect, the invention contemplates that the total recombinant protein in said aliquot of inclusion body harvest slurry is first determined by HPLC assay. In one embodiment, the titer of protein is determined after solubilization of the inclusion bodies in an inclusion harvest aliquot and the recombinant protein in the sample is determined by HPLC analysis.
[0013] In a further aspect, the inclusion bodies within the inclusion harvest aliquot are not solubilized before drying.
[0014] The invention further contemplates that the dry weight of the inclusion body aliquot is calculated by drying the isolated inclusion body slurry via microwave radiation. In one embodiment, the drying further comprises use of heat. In a further embodiment, the drying is performed on a CEM LabWave 9000. It is further contemplated that the dry weight of the recombinant protein may be determined using techniques common in the art, including heating, microwave radiation, air drying, lyophilization, freeze-drying, and vacuum drying. Once the sample is dried, the dry weight of the solid may be measured using a standard balance mechanism.
DETAILED DESCRIPTION
[0015] The present invention is directed to improved methods for determining the protein produced and shuttled to inclusion bodies in recombinant protein host cell cultures.
[0016] As disclosed herein, it has been discovered that, under the same or essentially identical fermentation conditions, inclusion body formation is essentially an ordered process and the recombinant protein composition of inclusion bodies is very consistent. Having discovered this consistency of inclusion body formation and composition, a method was proposed and verified to determine recombinant protein concentration in inclusion bodies by measuring the dry weight, or percent solids, of an inclusion body harvest slurry and then multiplying this dry weight measurement by a pre-determined conversion factor. Relying on the consistency of inclusion body composition, the method determines recombinant protein concentration in only a small aliquot of an inclusion body harvest to calculate the protein-specific conversion factor, and eliminates the need to measuring protein in the entire inclusion body harvest using time-consuming and complex methods such as HPLC. Once a fermentation process is designed and established for producing a given recombinant protein in a given host cell, the conversion factor for that protein can be used to extrapolate total recombinant protein for different inclusion body batch harvests without the need to perform the calculation for every batch, as long as the fermentation process remains essentially unchanged. This finding offers a fast, robust and less expensive way of controlling the amount/concentration of proteins before key process steps such as refolding. Additionally, the pre-determined conversion factor can be used to monitor fermentation process consistency.
[0017] The term “recombinant protein” refers to a heterologous protein molecule which is expressed in host cells transfected with a heterologous DNA molecule.
[0018] The term “inclusion body” refers to an insoluble aggregate within the bacterial host cell which contains protein that is expressed in the host cell. While protein in inclusion bodies in transfected host cells is largely recombinant (heterologous) protein, endogenous (or homologous) host cells proteins can make up a portion of the total protein.
[0019] The term “inclusion body harvest” refers to the collected inclusion bodies produced during a fermentation process for production of a recombinant protein. The inclusion body harvest may have varying degrees of purification. Post Kill samples refers to a sample of the bacterial culture before lysis, but after killing of the bacteria using techniques known in the art. Cell Paste refers to a sample of the inclusion body harvest collected, typically by centrifugation, before lysing the bacterial host cells to release the inclusion bodies. The washed inclusion body (WIB) portion refers to an inclusion body harvest after washing the inclusion bodies at least one time, or two times (double washed inclusion body, DWIB).
[0020] The term “inclusion body slurry” or “inclusion body harvest slurry” refers to the inclusion body harvest which contains the volume of the inclusion body pellet and any residual volume remaining after collection of the inclusion body, e.g., by centrifugation and decanting of the supernatant. An inclusion body slurry may comprise a resuspended or partially resuspended inclusion body pellet in water.
[0021] The term “dry weight” refers to the weight of an inclusion body slurry aliquot after all liquid has been removed from the sample, either by microwave, heating or other techniques known in the art. The dry weight may also refer to the total inclusion body solids or weight of the recombinant protein, based on the percent of recombinant protein in the inclusion body solid.
[0022] The term “percent solids” refers to the amount of solids in an inclusion body harvest slurry aliquot after drying the sample and removing all liquid in the sample.
[0023] The term “protein productivity conversion factor” (PPCF) refers to a number specific for a recombinant protein being purified from an inclusion body harvest under specific fermentation conditions, and is proportional to the ratio of the weight of recombinant protein in a sample relative to the total inclusion body dry sold weight in the same sample. This protein productivity conversion factor allows determination of the total recombinant protein recovered from the inclusion body harvest. In one aspect, a protein productivity conversion factor is determined by HPLC assay. The PPCF is calculated by the formula:
[0000] PPCF=[(total recombinant protein in a IB harvest aliquot, mg)/(total dry solids in the same IB harvest aliquot, mg)]×1000.
[0024] The term “total recombinant protein concentration” refers to the total protein recovered from a fermentation process, based on the weight of recombinant protein in inclusion bodies in the total weight of dry solids of the inclusion body harvest. Total recombinant protein may be calculated using the following formula:
[0000] [(total dry solid, mg)/(IB harvest slurry aliquot, g)×PPCF]×total IB harvest slurry weight (g)=(total recombinant protein, mg).
[0025] The present invention is useful to determine the protein productivity conversion factor for any recombinant protein that is produced in a designed fermentation process. Recombinant proteins contemplated for use in the method of the invention include, but are not limited to, an antibody (such as a polyclonal antibody, a monoclonal antibody, a human antibody, a humanized antibody, a Fab, F(ab′) 2 , Fv; Sc Fv or single chain antibody fragment, a bispecific antibody, a diabody, a peptibody, a chimeric antibody; and a linear antibody), an enzyme, a hormone, a cytokine, a chemokine, a growth factor, a transcription factor, a transmembrane protein, a cell-surface receptor, a cell-adhesion protein, a cytoskeletal protein, a fusion protein, or a fragment or analog of any of the above proteins.
[0026] Purification and Isolation of Inclusion Bodies
[0027] Techniques for isolating inclusion bodies, purifying recombinant protein from inclusion bodies, and techniques for refolding or renaturing protein are well known to those skilled in the art. For example, see Sambrook, J. et al., Molecular Cloning: a Laboratory Manual, pp. 17.37-17.41, Cold Spring Harbor Laboratory Press (1989); Rudolph, R. et al., FASEB J. 10:49-56 (1995).
[0028] Purification of the inclusion bodies may be carried out using well-known techniques in the art. See, for example, Ausubel et al., (Current Protocols in Molecular Biology, John Wiley and Sons, New York, N.Y., Ch, 1994). Cells are first centrifuged resulting in a cell pellet. The pellet is then resuspended in an appropriate buffer and the inclusion bodies released by lysing cells under high pressure, sonication, or chemical means, such as addition of lysozyme or denaturing agents. In the present invention, it is contemplated that cells are lysed under conditions that do not lead to solubilization of the inclusion bodies.
[0029] For purposes of calculating the PPCF for a protein in a fermentation process, proteins in an aliquot of inclusion body harvest may be solubilized using reagents commonly used in the art, including guanidinium salts, urea, detergents, and other organic solvents (See e.g., U.S. Pat. No. 5,605,691 and Bruggeman et al., Biotechniques 10:202-209 (1991)). It is noted that the efficacy of the solubilizing agent varies with the physical characteristics of the protein. Exemplary guanidinium salts include guanidine-HCl. Exemplary detergents include sodium dodecyl sulfate (SDS), Triton-X, caprylic acid, cholic acid, 1-decanesulfonic acid, deoxycholic acid, glycocholic acid, glycodeoxycholic acid, taurocholic acid, taurodeoxycholic acid, and members of the family of sodium salts of sulfate detergents (e.g., sodium tetradecy) sulfate and sodium hexadecyl sulfate) (see U.S. Pat. No. 5,605,691). These reagents may be used alone or in combination with each other, or other reagents as appropriate for the recombinant protein being purified.
[0030] Protein Expression
[0031] Inclusion bodies of interest in the present invention are formed by recombinant protein expression in bacterial host strains. Bacterial hosts strains contemplated for use in the invention include E. coli strains, including, but not limited to, BL21 (DE3), BL21 (DE3) pLysS, and BL21 (DE3) pLysE (F. W. Studier et al., Methods in Enzymology 185:60-89 (1990)), MC1061, AG1, AB1157, BNN93, BW26434, CGSC Strain # 7658, C60, C600 hflA150 (Y1073, BNN102), D1210, DB3.1, DH1, DH5α, DH10B, DH12S, DM1, ER2566 (NEB), HB101, IJ1126, IJ1127, JM83, JM101, JM103, JM105, JM106, JM107, JM108, JM109, JM109(DE3), JM110, JM2.300, LE392, Mach1, MC4100, MG1655 Rosetta(DE3)pLysS, Rosetta-gami(DE3)pLysS, RR1, STBL2, STBL4, SURE, SURE2, TG2, TOP10, Top10F′, W3110, XL1-Blue, XL2-Blue, XL2-Blue MRF′, XL1-Red, XL10-Gold, XL10-Gold KanR. Other bacterial strains known in the art suitable for recombinant protein production and which form inclusion bodies may be used in the methods of the invention.
[0032] Recombinant proteins are expressed in a selected strain according to standard fermentation procedures known in the art. The procedures are adaptable for the bacterial strain being used and the recombinant protein to be expressed. For example, bacterial cultures may be grown to a selected density (OD 600 ) of culture, and in an appropriate selection medium prior to harvest of inclusion bodies. See Ausubel et al., (Current Protocols in Molecular Biology, John Wiley and Sons, New York, N.Y., 1994). Methods of recombinant protein production are described in, for example, U.S. Pat. No. 6,759,215 and U.S. Pat. No. 6,632,426.
[0033] Determination of Protein in Inclusion Body Harvests
[0034] Recombinant protein concentration in an aliquot of an inclusion body harvest can be determined using methods known in the art, including high performance liquid chromatography (HPLC), ion exchange chromatography, Bradford assay, UV absorbance, fluorescent techniques, or Western blot analysis. Of the above methods, the HPLC methods allows for calculation of both protein concentration and purity of the sample in the same test run. As such, in the present invention, in one aspect it is contemplated that the concentration of a protein in a sample is carried out using HPLC.
[0035] In order to determine the amount of protein in an aliquot of the fermentation culture and the inclusion body harvest, an HPLC titer is performed. In the HPLC titer, a sample aliquot of the IB harvest is collected, the inclusion bodies solubilized and the protein denatured. The sample is then prepared for HPLC to determine protein purity/concentration in a protein sample using methods and techniques well-known in the art (Current Protocols in Protein Chemistry, John Wiley and Sons, New York, N.Y., 1994), and as described herein. Regardless of how recombinant protein concentration in the IB harvest aliquot is determined, the calculated concentration is then used to determine the protein productivity conversion factor.
[0036] Methods for Determining Inclusion Body Dry Weight or Percent Solids
[0037] The dry weight or percent solids of the inclusion body harvest may be determined using any method in the art, including heating, microwave radiation, air drying, lyophilization, freeze-drying, and vacuum drying. Once the sample is dried, the dry weight of the solid is measured using a standard balance mechanism.
[0038] A combination of heating and microwave radiation is efficient for drying the sample aliquot and determining the percent solids therein. In one aspect, the inclusion body harvest may be dried using microwave radiation and heat. The CEM LabWave 9000 instrument (CEM Corporation, Matthews, N.C.) is designed to reach a Moisture/Solids Range of 0.01% to 99.99% in liquids, solids, and slurries, up to 0.01% resolution. The instrument provides protein output to 0.1 mg readability, and provides microwave power from 0 to 100% of full power (630 watts) in 1% increments. In related embodiment, the inclusion body sample may be dried using other moisture analyzer equipment known in the art, including but not limited to CEM AVC-80 Microwave Moisture Analyzer, CEM Smart System, Denver Instrument M2 Microwave Analyzer (Denver Instruments, Denver, Colo.), Omnimark uWave (Sartorius-Omnimark, Goettingen, Germany), and the Sartorius MMA30 (Sartorius, Goettingen, Germany).
[0039] The following examples illustrate various non-limiting embodiments of the invention and/or provide support therefore.
Example 1
[0040] Recombinant protein is often expressed in E. coli as insoluble inclusion bodies. In the past, inclusion bodies were thought to be a random precipitation of over-expressed recombinant proteins. Recently, however, it has been suggested that inclusion bodies may form in an ordered aggregation process, and if these inclusion bodies were found to have a consistent recombinant protein composition, it may no longer be necessary to quantitate recombinant protein concentration in an inclusion body harvest using complex and time-consuming HPLC methods for every fermentation and inclusion body harvest. Thus, in order to determine if inclusion bodies are produced in an ordered manner having recombinant protein in a consistent composition, initial experiments were designed to attempt formulation of a mathematical model which would allow for quantifying protein content with minimal experimental effort.
[0041] At the end of a cell fermentation process for making recombinant human granulocyte colony stimulating factor (r-metHuG-CSF), E. coli host cells were lysed using high pressure and inclusion bodies were harvested through multiple centrifugation processes prior to protein solubilization and refolding. This inclusion body broth was then first used for protein concentration analysis.
[0042] In order to determine the amount of r-metHuG-CSF protein compared to host protein and other contaminants in the dried sample, the inclusion body “productivity” is determined. Productivity is defined as the ratio between sample protein and total dry weight of the inclusion body sample and this ratio, when multiplied by 1000 provides a protein productivity conversion factor (PPCF) fora desired recombinant protein expressed in a set fermentation process:
[0000] PPCF=[(total recombinant protein, mg)/(total dry solids, mg)]×1000.
[0043] In determining this ratio. RP-HPLC was carried out using an aliquot of the IB harvest slurry. A portion of the IB harvest slurry was suspended by vortexing in a tube or stirring in a beaker, and 1 mL of the suspension broth was added to 30 mL of incubation/denaturation buffer (8 M Guanidine HCl, 50 mM Tris, 5 mM EDTA, 50 mM D 11, pH 8.4±0.1). The mixture was incubated in a water bath at 65±3° C. for approximately 30 minutes, after which 40 μL of the denatured and reduced r-metHuG-CSF was injected onto a 4.6×100 mm POROS R1/10 column (Applied Biosystems, Foster City, Calif.) on an Agilent 1100 HPLC (Agilent, Santa Clara, Calif.). Recombinant protein eluted at approximately 6.2 min under a rapid gradient using 60% mobile phase A [0.1% (v/v) TFA (sequanal grade, Pierce, Rockford, Ill.), 7% (v/v) IPA in water] to 55% mobile phase B [0.1% (v/v) TFA, 5% (v/v) IPA in acetonitrile (Sigma-Aldrich, St. Louis, Mo.)] over 9 minutes at a flow rate of 2 mL/min. Throughout the analysis, an on-line UV detector set at 214 nm was used to quantify the protein peak. The r-metHuG-CSF protein content in each sample was calculated from the standard calibration curve constructed by linear regression.
[0044] Cell fermentation samples taken prior to cell breakage, such as Post Kill samples and Cell Paste samples, i.e., a sample taken from the cell pellet following centrifugation of the fermentation broth, contain large amount of E. coli components, including host cell proteins. HPLC analysis showed that recombinant r-metHuG-CSF protein in Cell Paste averages approximately 29% of the total dry weight of cell paste (Tables 1 and 2). Further analysis also showed that the ratio between E. coli host cell proteins and the sample protein in this cell paste is variable, which is reflected by the relatively large variability in Cell Paste Productivity (Tables 1 and 2). Table 1 is a comparison of productivity between Double Washed Inclusion Bodies (DWIB) and productivity in Cell Paste from which the DWIB were obtained. Productivity is expressed as the ratio of sample protein to total dry weight times 100%. Table 2 shows a comparison of Productivity in Washed Inclusion Bodies (WIB) also compared to Cell Paste from which the WIB were obtained.
[0000]
TABLE 1
Sample 1
Sample 2
Difference
Cell Paste Productivity
26%
30%
~14%
DWIB Productivity
68.62%
66.43%
~3%
[0000]
TABLE 2
WIB Lot #
WIB Productivity
Cell Paste Lot #
Cell Paste Productivity
xxx418
67.13%
xxx657
23.9%
xxx233
67.47%
xxx225
29.6%
xxx363
65.50%
xxx225
29.6%
xxx232
68.27%
xxx225
29.6%
xxx595
69.20%
xxx225
29.6%
xxx394
30.2%
xxxpp1
69.46%
xxxsd2
26%
xxxpp2
67.53%
xxxsd0
30%
xxxpp3
63.87%
xxxsd2
26%
xxxpp5
63.17%
xxxsd0
30%
Average
66.84%
28.5%
RSD
3.3%
7.9%
[0045] These results and the HPLC analyses show that after the cells are lysed, a majority of the host cell proteins are removed from the inclusion body fraction through the centrifugation steps. The inclusion bodies, washed inclusion bodies and double washed inclusion bodies elute with almost the same profile, with the recombinant r-metHuG-CSF protein demonstrating a tight elution profile. Analysis showed that the recombinant protein accounted for almost 93% of the total protein in the inclusion bodies.
[0046] The average recombinant protein productivity increases from 29% in Cell Paste to 67% in Inclusion Bodies. In addition, the variability (RSD) in productivity decreases from 8% in Cell Paste to 3% in Inclusion Bodies (Tables 1 and 2).
[0047] With the present invention, in the instances that recombinant proteins form inclusion bodies in an ordered and consistent manner between fermentation harvests, and fermentation is carried out following the same or essentially the same protocol, the protein productivity conversion factor determined for an aliquot of the IB harvest slurry can be used to determine the protein in the other fermentation harvests. For example, once calculated as presented herein, the total protein in a given amount of IB harvest slurry could readily be determined by multiplying the dry solid in the slurry by the PPCF determined above without having to perform HPLC on every IB harvest produced under the same fermentation conditions.
Example 2
[0048] In order to determine if the dry weight analysis described above allows for accurate prediction of recombinant protein concentration in an IB harvest, the predicted recombinant protein concentration obtained with dry weight samples as above was compared to the sample concentration as measured using HPLC.
[0049] HPLC sample preparation was identical to the titer assay described above wherein 40 μL of a denatured and reduced IB harvest slurry sample was injected onto a 4.6 mm ID×150 mm C4 bonded phase silica column with 5 μm particle diameter and 300 Å pore size (YMC, Shimogyo-ku, Kyoto, Japan) on an Agi lent 1100 HPLC (Agilent, Santa Clara, Calif.). The reduced protein mixture was separated under a full gradient using 20% mobile phase A [0.1% (v/v) TFA in water] to 85% mobile phase B [0.1% (v/v) TFA in 90% acetonitrile] over 80 minutes at a flow rate of 0.8 ml/min. Throughout the analysis an on-line UV detector set at 214 nm was used to monitor the protein peaks.
[0050] When compared to the traditional HPLC assays, the dry weight assay correlated with the results in the HPLC assay (Table 3). For correlation between the HPCL assay and dry weight assay, 670 was used as the conversion factor.
[0000]
TABLE 3
Dry weight result
HPLC result
% difference
Lot
(mg/mL)
(mg/mL)
(Dry weight against HPLC)
xxx001
104.16
104.56
−0.4%
xxxpp3
25.25
25.85
−2.3%
xxxpp5
16.24
16.10
0.9%
xxxpp6
15.82
16.45
−3.8%
xxxpp7
17.38
17.92
−3.0%
xxx776
10.50
10.09
4.1%
xxx779
10.74
10.10
6.3%
xxx454
9.68
9.29
4.2%
xxx780
9.83
9.96
−1.3%
xxx781
9.63
9.40
2.5%
xxx782
10.17
10.49
−3.1%
xxx458
9.95
9.79
1.6%
xxx793
10.39
9.98
4.0%
xxx783
9.63
9.61
0.2%
xxx784
9.70
9.78
−0.9%
xxx785
8.66
9.00
−3.7%
Average
0.3%
[0051] The difference between the two assays was a combination of inherent variability, and mainly due to the HPLC assay, since it was a single determination and in general has larger variability. The average difference between these two assays was as small as 0.3%. The accuracy of the dry weight assay is probably within ±3%.
[0052] These results demonstrated that the method of determining dry weight of a protein by calculating the protein concentration based on the inclusion body protein content is an accurate and fast method for determining protein concentration before proceeding into the protein refolding steps. Determining the protein concentration using this method saves time needed to prepare an HPLC sample and also money in preparing these samples. Additionally, using the dry weight measurement is an accurate method to determine protein concentration before calculating the reagents necessary for the protein refolding step. Therefore, the present method provides a faster, cheaper method for determining protein concentration in large scale protein production.
Example 3
[0053] In order to identify factors that may influence the dry weight assay described above, the assay was performed on IB samples subjected to different preparative steps.
[0054] To determine the degree of variability in the inclusion body samples, the r-metHuG-CSF protein concentrations obtained via the new dry weight measurement were compared to those obtained by conventional HPLC measurement. A minor factor on variability was the concentration of the sample. When IB harvest slurry samples are extremely diluted, the weighing variability increases. The dry weight assay was usually performed in duplicate on two instruments for a total of four determinations per sample. The HPLC assay was usually a single determination due to its complexity.
[0055] For dry weight and percent solids measurements, inclusion body broth was suspended by vortexing in a tube or stirring in a beaker. Approximately 2 mL of the suspended broth was loaded on to a pre-tared sample pad in a CEM Smart System Solids and Moisture Analyzer, CEM LabWave 9000 (CEM Corporation, Matthews, N.C., USA). The r-metHuG-CSF sample was heated and dried at 100% power level for 5 minutes. Percent Solids is automatically calculated by the instrument.
[0056] Results of the comparisons between dry weight measurements are shown in Tables 4 and 5. Table 4 shows the precision of the dry weight assay using frozen samples.
[0000]
TABLE 4
Determination
Instrument
Percent Solids
Determination
Instrument
Percent Solids
1
2
3.707%
2
1
3.850%
3
2
3.749%
4
1
3.827%
5
2
3.679%
6
1
3.832%
7
2
3.762%
8
1
3.737%
Average of
3.724% (n = 4)
Average of
3.812% (n = 4)
Instrument 2
Instrument 1
RSD of
1.0% (n = 4)
RSD of
1.3% (n = 4)
Instrument 2
Instrument 1
Overall
3.768% (n = 8)
Average
Overall RSD
1.7% (n = 8)
[0057] The precision of the dry weight was also assayed using fresh samples. Two measurements per lot were performed using two separate instruments for a total of four measurements per lot. The average of the fresh sample measurements in shown in Table 5.
[0000]
TABLE 5
xxxpp6
xxxpp7
Average
2.361% (n = 4)
2.594% (n = 4)
RSD
0.6% (n = 4)
0.9% (n = 4)
[0058] In general, it was found that the precision of the dry weight assay is impacted by two factors. The major factor is the freshness of the sample; inclusion bodies tend to aggregate upon freeze-thaw or long term storage at 4° C., which leads to sample heterogeneity and higher assay variability.
[0059] The results shown above demonstrate that inclusion body dry weight measurements are comparable to those obtained using typical HPLC measurements, and are still accurate whether the IB harvest sample was first frozen or stored at 4° C. Although the percent solids detected may vary due to sample preparation before the measurements, the dry weight measurements are consistent and in-line with those obtained using traditional HPLC protein measurements. Thus, the present invention provides an accurate, efficient method for determining protein concentration in an inclusion body harvest in order to reduce the quantity of sample that needs to be taken before the refolding reaction, thereby increasing the amount that is available for the refold reaction, and also provides better control of the protein input into the refolding step in recombinant protein production, and ultimately improve recombinant protein yield and quality.
[0060] Numerous modifications and variations in the invention as set forth in the above illustrative examples are expected to occur to those skilled in the art. Consequently only such limitations as appear in the appended claims should be placed on the invention
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The present invention is directed to improved methods for efficiently producing recombinant proteins. More specifically, the invention relates to a process for calculating the protein in inclusion bodies before the refolding step in large scale recombinant protein production, thereby improving the efficiency of the refolding step and overall yield and quality of the sample protein.
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FIELD OF THE INVENTION
The present invention relates to an apparatus and method for acquisition and retrieval of resected biological specimens. More specifically, the present invention is concerned with a vacuum mouthpiece for the acquisition and retrieval of resected biological specimens from a body cavity, a self-closing pouch for entrapment and retrieval of resected biological specimens from a body cavity, and a laparoscopic system incorporating such a mouthpiece and such a pouch.
BACKGROUND OF THE INVENTION
Laparoscopy, also known as “keyhole surgery,” is today increasingly complementing and even replacing conventional surgery, especially in the abdominal region, for resection and removal of diseased organs such as a gall bladder, ovaries, or diseased parts of such organs, cysts, and the like. The small incisions required for laparoscopic procedures minimize skin scarring, reduce the risk of infection, and greatly speed up would healing.
Laparoscopic devices for the removal of resected specimens are known, most of which are based on the use of a pouch and propose ways of closing that pouch with the specimen inside it, such as a drawstring thread (U.S. Pat. Nos. 5,647,372 and 5,465,731) as well as grasping means to control the pouch edges, but do not address the cardinal issue of getting hold of the resected specimen, putting it into the pouch, and withdrawing it from the body cavity.
U.S. Pat. No. 5,480,404 teaches a belt-like loop with a flexible pouch which enables the scooping up of the specimen, closing the pouch and removing it from the body cavity. This disclosure too, only partially resolves the issue of “catching” the specimen, and does not deal satisfactorily with the withdrawal of the specimen from the body cavity.
Instead of a pouch, U.S. Pat. No. 5,176,687 uses a flexible membrane which has a collapsed and an expanded state, but it does not deal with the retrieval of the specimen.
U.S. Pat. No. 5,215,521 discloses an envelope sheath to entrap the resected specimen as well as a morcellator allowing for safe morcellation of the specimen, and provides both for the catching and the retrieval thereof, but the apparatus and auxiliaries described are highly complex and require the services of two experienced laparoscopists.
U.S. Pat. No. 5,279,548 teaches a method for use in a peritoneal or pelvis surgery, in which a funnel-like membrane introduced into the body cavity is positioned vertically below the organ to be resected, allowing the resected tissue to fall into the membrane.
WO 97/17021 discloses a device for retrieving tubular parts such as stents from blood vessels. The gripping members of the device are provided with hooked ends adapted for engaging the stent.
U.S. Pat. No. 5,196,003 teaches a surgical instrument for endoscopic surgery having an elastically deformable suction cup communicating with a rubber bulb, whereby a suction effect can be applied to retain resected tissues.
WO 97/26828 discloses a laparoscopic instrument for handling parencynmatous and cavum organs. The device is provided with a funnel-like suction cup tiltably articulated to a tubular member and serving to retrieve resected tissue. The assembly is a single unit, and the suction cup cannot be moved independently of the retrieval member.
U.S. Pat. No. 5,417,697 teaches a polyp retrieval assembly comprising a cauterizing loop and a cup-shaped web member for retrieving resected tissue. The assembly is a single unit, and the web member cannot be moved independently of the retrieval member.
It is thus one of the objects of the present invention to provide a mouthpiece introducible into a body cavity for acquisition and retention of a resected biological specimen by vacuum suction.
It is a further object of the present invention to provide a pouch that is self-closing after being introduced into a body cavity, thereby entrapping a resected biological specimen for retrieval.
It is yet another object of the present invention to provide a relatively simple laparoscopic device that facilitates the vacuum capture and retention of a resected biological specimen, its entrapment in a self-closing pouch and its retrieval, and that can be operated by a single surgeon with no more than moderate experience in laparoscopy.
According to the invention, there is therefore provided a device for the acquisition and retention of resected biological specimens for retrieval from a body cavity, said device comprising a bowl-shaped mouthpiece made of an elastically resilient material; a first tubular member having a distal end connected to said mouthpiece and a proximal end connectable to a vacuum pump; characterized in that a plurality of openings are distributed over said mouthpiece, said openings leading to the distal end of said first tubular member, thereby facilitating the retention and retrieval of resected biological specimens by vacuum suction.
The invention also provides a closable pouch for the entrapment and retrieval of a resected biological specimen from a body cavity, said pouch comprising pliable, pre-shaped, membranous material attached at selected points substantially along meridian lines, to a plurality of pre-shaped, finger-like elements, said elements having distal ends and proximal ends, the proximal ends of said finger-like elements being connected to a tubular member slidably located inside an outer tubular member, characterized in that said finger-like elements exhibit different responses in different states, a first state response in which the distal ends of said finger-like elements flex away from each other, thereby causing the pouch to open and to engulf and entrap said specimen, and a second state response in which the distal ends of said finger-like elements flex toward each other, thereby causing the pouch to close, thereby retaining said specimen for retrieval.
The invention further provides a laparoscopic system for acquisition and retrieval of resected biological specimens, said system comprising at least three telescoping tubular members having distal and proximal ends, including an outer tubular member, an inner tubular member defining with said outer tubular member an annular space and being connectable at its proximal end to vacuum-producing means, and an intermediate tubular member slidably fitting said outer tubular member; a bowl-like mouthpiece having a front face and a rear face, for capturing and retaining a resected specimen, said mouthpiece being connected at its rear face to the distal end of said inner tubular member and being made of an elastically resilient material, said mouthpiece having a diameter in a non-deformed state exceeding the inside diameter of said outer tubular member but fitting into the distal end of said outer tubular member by elastic deformation; a plurality of finger-like elements fixedly connected to the distal end of said intermediate tubular member; a pouch made of pliable, membraneous material fixedly attached at a plurality of points to said plurality of finger-like elements; characterized in that, in the non-active, telescoped state of said system, said pouch, connected to said plurality of finger-like elements, is collapsed and disposed inside said annular space behind the rear face of said mouthpiece, and in the active state of said system, when said intermediate tubular member is pushed out of the outer tubular member, the distal ends of said finger-like elements first flex away from each other, thereby causing the pouch to open and to engulf said mouthpiece, and thereafter, the distal ends of said finger-like elements flex toward each other, thereby causing the pouch to close, entrapping and retaining said specimen for retrieval.
The invention still further provides a method for acquisition and retrieval of resected biological specimens, using the laparoscopic system described above, the method comprising the steps of introducing the distal end of the telescoped device into the body cavity; pushing out the inner tubular member, thereby removing the mouthpiece from the outer tubular member and causing said mouthpiece to assume its full diameter; actuating the vacuum-producing means and moving mouthpiece to a location in close proximity to the specimen to be resected, causing the resected specimen to cling to said mouthpiece; pushing out the intermediate tubular member, thereby causing the distal ends of finger-like elements to emerge from the annular space between the outer tubular member and the inner tubular member, said finger-like elements carrying along and opening up the pouch attached to them for engulfing the specimen retained by said mouthpiece; allowing the distal ends of said finger-like elements to close over said mouthpiece, thereby closing the pouch over said specimen, and withdrawing the device from the body cavity.
The invention will now be described in connection with certain preferred embodiments with reference to the following illustrative figures so that it may be more fully understood.
With specific reference now to the figures in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an enlarged, cross-sectional view of a first embodiment of the vacuum mouthpiece according to the invention in its free state;
FIG. 2 is a similar view of the embodiment of FIG. 1 when elastically deformed to fit the tubular member;
FIG. 3 is an enlarged cross-sectional view of a substantially hollow embodiment of the vacuum mouthpiece according to the present invention;
FIG. 4 is a perspective view of the open pouch;
FIG. 5 is a perspective view of the closed pouch;
FIG. 6 is a top view showing a tubular member accommodating the finger-like elements and the folded pouch prior to their use;
FIG. 7 is an enlarged, partial cross-section of the laparoscopic system according to the present invention in its non-active, fully telescoped state;
FIG. 8 is a more enlarged view in cross-section along plane XIII—XIII of the system of FIG. 7;
FIG. 9 schematically illustrates the flaring open of the finger-like elements and the resulting opening of the pouch;
FIG. 10 schematically illustrates the inward flexing of the finger-like elements and the resulting closure of the pouch; and
FIG. 11 shows a morcellator used for the fragmentation and liquefaction of solid specimens.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings, there is seen in FIG. 1 a first embodiment of a vacuum mouthpiece 2 according to the invention in its fully expanded state. Mouthpiece 2 is attached, e.g., by adhesive bonding, to a first tubular member 4 connectable to a vacuum pump (not shown). Mouthpiece 2 has a bowl-like shape and is made of an elastically resilient material such as synthetic rubber or the like. Active surface 6 is concave and is provided with a plurality of openings 8 which, via ducts 10 , communicate with a first tubular member 4 . Also seen is a second tubular member 24 into which, as shown in FIG. 2, mouthpiece 2 can be inserted by elastic deformation.
A second embodiment of the mouthpiece, shown in FIG. 3, is substantially hollow. To prevent the collapse of hollow space 14 under the effect of underpressure produced by the above-mentioned vacuum source, which collapse would affect the communication of peripheral openings 8 with the vacuum source, there are provided a plurality of protrusions 16 integral with either he bottom and/or the roof of hollow space 14 , that will limit the amount by which the roof and the bottom of space 14 may approach one another. Protrusions 16 could also have the shape of crenellated ribbing that would also enhance the stiffness of mouthpiece 2 .
Further seen in FIG. 3 is a central opening 18 in active surface 6 , which is much larger than the peripheral openings 8 and which facilitates the passage therethrough of various implements, such as a morcellator or a suction needle.
FIG. 4 shows a pouch according to the invention, in the open state. Pouch 20 is made of a pliable, membranous material, is advantageously pre-shaped like the canopy of an umbrella, and is fixedly attached, e.g., by adhesive bonding, at selected points along substantially meridianal lines, to a plurality of finger-like elements 22 . Since the purpose of pouch 20 is first to engulf and then to enclose the resected specimen, e.g., a cyst, means must be at hand to first spread the pouch open to enable it to entrap the specimen, and then to close the pouch, retaining the specimen for imminent retrieval.
Therefore, the elements 22 are constituted by any suitable material or a combination of materials, e.g., plastic, metal or plastic-coated metal. The elements 22 are pre-shaped and adapted to assume a first state in which they flex outwardly and a second state in which they flex inwardly towards each other.
The finger-like elements advantageously may be made of a shaped-memory alloy, i.e., an alloy which “remembers” one or more shapes imparted to it at one or more predeterminable temperatures, and which reverts to those shapes whenever it is subjected to those temperatures. Such alloys are commercially available, for instance, Nitinol, a nickel-titanium alloy, or the like. Hence, in operation, when the elements 22 are exposed to a first temperature, e.g., room temperature, or a lower temperature obtained by cooling, they are caused to flex outwardly, i.e., to flare open. Since pouch 20 is attached to the elements 22 , the pouch is likewise caused to open, as shown in FIG. 4 . When the elements 22 are exposed to a second, higher temperature, e.g., body temperature, or heated, however, they are caused to flex inwardly towards each other. This change of shape of the elements is, of course, also imparted to pouch 20 , causing it to close as shown in FIG. 5 . The higher (transition) temperature could also be effected by passing a weak electric current through elements 22 , thereby achieving better control of the procedure.
Prior to use, finger-like elements 22 and pouch 20 are retained in a tubular member 24 as seen in the top view of FIG. 6, showing pouch 20 folded in its fully collapsed condition.
FIGS. 7-11 illustrate a laparoscopic system for acquisition and retrieval of resected biological specimens. As this system also incorporates the vacuum mouthpiece and pouch illustrated in FIGS. 1-5, reference will be made to some of these Figures in discussing the laparoscopic system according to the invention.
Referring now to FIG. 7, there is seen an outer tubular member 24 , the distal end 25 of which is designed to be introduced into a body cavity from which a previously resected specimen is to be retrieved. Introduction is effected in a per se known manner, using a trocar. The outside diameter of member 24 is of an order of 10 mm.
Further seen is an inner tubular member 4 of a length exceeding the length of member 24 and connectable at its proximal end to a vacuum pump (not shown). To the distal end of tubular member 4 is fixedly attached a vacuum mouthpiece 2 made of an elastically resilient material such as synthetic rubber or the like. In its free state as shown in FIG. 3, its outside diameter is much larger than the inside diameter of tubular member 24 .
Freely sliding inside outer tubular member 24 , there is arranged an intermediate tubular member 26 which also projects beyond the proximal end of member 24 . To the distal end of member 26 are fixedly attached, e.g., by welding or brazing, a plurality of finger-like elements 22 which cause pouch 20 to be first spread open and then, after it has engulfed the specimen to be retrieved, to close with the specimen inside, as explained above.
As further seen in FIG. 7, pouch 20 is provided at its center with an opening 28 , through which passes tubular member 4 . In its initial state, pouch 20 is fully collapsed, i.e., folded, its folds filling the annular space between tubular members 24 and 4 , as can be seen in FIG. 8 .
In actual operation, after the distal portion of the device, still in the state depicted in FIG. 7, is introduced into the body cavity using a per se known trocar, inner tubular member 4 is pushed out, thereby releasing vacuum mouthpiece 2 from its confinement in outer tubular member 24 . At the same time, the vacuum pump to which member 4 is connected is switched on. Due to the suction effect of the approaching mouthpiece 2 , the previously resected specimen will be drawn close and cling to it. More or less simultaneously, intermediate tubular member 26 is pushed out and elements 22 , previously restrained by tubular member 24 from assuming their flaring shape, now flare open, thereby opening pouch 20 . This situation is schematically illustrated in FIG. 9, showing specimen S clinging to vacuum mouthpiece 2 and finger-like elements 22 flexing outwardly, thereby opening pouch 20 , which now surrounds specimen S. The specimen can now be resected through the use of any suitable surgical instrument and the pouch 20 closed to engulf the resected specimen for safe retrieval (FIG. 10 ). In a case when shaped-memory elements are used, after the elements 22 have been largely exposed to the higher body temperature for a while (or have been electrically heated), they are affected by the high-temperature memory and flex inwardly, thereby closing pouch 20 and thus effectively capturing specimen S.
Further proceedings depend on the nature of the specimen. Fairly low-viscosity specimens, such as exudates, can be drawn off by a suction needle introduced into pouch 20 via opening 18 in mouthpiece 2 , or even by the latter itself. More solid specimens must be liquefied, which is best done with the aid of a morcellator 30 , as shown in FIG. 11 . This implement is introducible into closed pouch 20 via opening 18 in mouthpiece 2 and, driven at high speed by any suitable drive means, acts like a blender. Closed pouch 20 prevents spilling of the liquid into the abdominal cavity. The thus liquefied specimen can then be drawn off, either by the above-mentioned suction needle or directly by mouthpiece 2 .
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrated embodiments and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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The invention provides a vacuum mouthpiece ( 2 ) for the acquisition and retention of resected biological specimens for retrieval from a body cavity, the mouthpiece being attached to a first tubular member ( 4 ) connectable to a vacuum source and having an active surface including at least one opening communicating with the first tubular member; the mouthpiece ( 2 ) being made of an elastically resilient material and having, in a free state, an outside diameter larger than the inside diameter of a second tubular member ( 24 ) into which it is insertible by elastic deformation. The invention further provides a closable pouch ( 20 ) for the entrapment and retrieval of a resected biological specimen from a body cavity, and a laparoscopic system and method utilizing the above.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to methods for repairing a damaged area of a fabric with a patch taken from fabric which is like the damaged material.
2. Description of the Prior Art
It is well known to repair a damaged garment by first punching a hole in the fabric at the damaged site of sufficient size to include all of the damaged area, and to then punch out a patch identical in size and shape to such hole for use in making the repair from fabric which is the same as the damaged fabric. The patch is preferably obtained from an unnoticable part of the damaged fabric to assure a match at the damaged site. A support pad impregnated with a thermoplastic adhesive is placed under the hole, and the patch is placed in the hole, after which heat is applied to the patch to melt the thermoplastic adhesive and cause it to flow into the interstices of adjacent portions of the fabric and patch to complete the repair. Fabric repairing methods of the kind described are disclosed, for example, in U.S. Pat. No. 3,271,217, for "Method of Mending Holes in Fabrics" of D. L. Mapson, issued Sept. 6, 1966, in U.S. Pat. No. 3,513,048, for "Method of Making a Patch Structure for Fabrics" of B. L. Synder issued May 19, 1970, and in copending patent application of The Singer Company for "Fabric Repairing Assembly" of Gerhard Reinert, Ser. No. 284,877, filed July 20, 1981 and now U.S. Pat. No. 4,358,335.
In general, such methods have proved unsatisfactory for repairing a lined garment since they do not include a procedure enabling a damaged area or a patch to be conveniently removed from the garment without damage to the lining. The damaged area and patch would be removed from the garment with an impact punch, or cutting tool, the operation of which necessitated also punching or cutting a hole in the lining unless it was first ripped away from inside the garment.
It is a prime object of the present invention to provide an improved method for repairing a fabric permitting a damaged area and patch to be conveniently removed from a lined garment without damage to the lining.
It is another object of the invention to provide an improved method for individually removing a damaged area and patch from a garment during a repairing procedure in a one-shot shearing operation.
Other objects and advantages of the invention will become apparent during a reading of the specification taken in connection with the accompanying drawings.
SUMMARY OF THE INVENTION
In accordance with the invention, a damaged garment or other article is repaired by folding the fabric of the article so as to include the damaged area in layers of the fold. In a lined garment, the lining is pinched away from the fabric with the fingers so as not to be included in the fold. A portion of the fabric including the damaged area is removed from the folded layers as in a one-shot shearing operation. A patch corresponding in size and configuration to the hole left in the garment by removal of the damaged area is then similarly removed from a folded inconspicuous part of the same fabric or from a like piece of material. A thermoplastic adhesive pad is placed in overlapping relationship with said hole on the normally unexposed side of the damaged fabric. The patch is disposed in the hole and is bonded to the pad and surrounding fabric with the application of heat.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing a piece of damaged fabric with the lining therefor separated from the fabric;
FIG. 2 is an inside perspective view of a fabric clamp for use in carrying out the method of the invention;
FIG. 3 is an outside perspective view of the clamp;
FIG. 4 is a perspective view showing the damaged fabric in the clamp;
FIG. 5 is a fragmentary perspective somewhat diagrammatic view showing apparatus for cutting a hole by means of a one shot shearing operation in the fabric held by the clamp;
FIG. 6 is a perspective view showing the fabric with a hole formed therein, a thermoplastic pad for insertion through the hole, and a formed patch for the hole; and
FIG. 7 is a vertical sectional view indicating the application of said patch to the damaged fabric.
DESCRIPTION OF THE INVENTION
Referring to the drawings, reference character 10 designates a piece of fabric in which there is nondescript hole 12 requiring repair. A lining 14 is shown separated from the damaged area defined by the hole 12. The fabric piece 10 and lining 14 may, for example, be considered part of garment such as a suit, skirt or other piece of wearing apparel.
In order to effect a repair in such a garment in accordance with the invention, it is necessary to remove a portion of the fabric which includes the damaged area from the garment. This is accomplished with any lining such as the lining 14 pulled back from the damaged area, and with the fabric folded directly through the damaged area or close thereto into overlying layers 16 and 18.
In preparation for the removal of the damaged area, the fabric is preferably folded with and secured in a plastic clamp 20 of the kind disclosed in the patent application of Michael Laude et al. for "Fabric Shearing and Heating Tool" Ser. No. 372,496, filed concurrently herewith. As shown, clamp 20 is formed on one side with aligned grooves 22 and 24 which are scored at 23 and 25 to define a fold line 26 for the clamp extending centrally between the grooves, and through a central opening 28 in the clamp as well as through rectangular openings 30 and 32 provided therein. Opening 28 includes perimetal edge portions defined by circular arcs 34 and 36 having different radii, but having a common center on the fold line 26. Circular arc 34 having the greater radius extends beyond a semicircle to slits 38 and 40. Circular arc 36 with the smaller radius also extends to slits 38 and 40 as shown. The slits 38 and 40 communicate with the rectangular openings 30 and 32 which extend to the grooved portions 22 and 24, respectively of the clamp. The slits 42, 44, 46 and 48 render portions 50 and 52 of the clamp bracketing the opening 28 slightly spreadable.
Before the clamp is used to fold the fabric, inside areas 49 and 51 thereon are rendered sticky to the fabric as with an applied facing 53 having an adhesive coating on each of the opposite sides thereof. Fabric piece 10 may then be disposed on clamp 20. The fabric piece is positioned so as to locate the edge of hole 12 and a margin of surrounding fabric within opening 28. The clamp includes grid lines 54 and 56, and if the fabric is patterned, the pattern is also located in a recallable manner with respect to such grid lines. Once the fabric piece has been suitably positioned, the lining is pinched back by the user as the clamp is folded to bring fabric layers 16 and 18 into a contiguous relationship.
After the fabric piece has been folded, the overlying contiguous layers of fabric in the clamp may be cut as in a shearing operation to remove the damaged area and a surrounding margin of fabric. The fabric is preferably sheared rather than punched out because a cleaner cut is more readily obtainable in multiple layers of fabric in a shearing operation, especially when the fabric is of a substantial thickness. The damaged area and surrounding margin of fabric are best removed from a fabric piece 12 with a cutting tool 62 of the kind disclosed in the aforementioned patent application Ser. No. 372,496. Such tool includes a cylindrical cutter 64 with a sharp cutting edge 66 in an oblique plane. The cutter is slidable in the cylindrical bore 68 of a member 70 which is affixed in the housing 72 of the tool. The radius of the bore 68 substantially corresponds to the radius of circular arc 36. Member 70 and housing 72 include aligned transverse slots 74 and 76. The folded clamp with fabric therein may be located in slots 74 and 76 with the perimetal edge of opening 28 along arc 34 in engagement with an outer cylindrical surface 78 on member 70 projecting into slot 76, with the ends 80 and 82 of clamp portions 50 and 52 at the bottom of a slot 84 in the housing 72 of the tool, with outer surface 85 of the clamp against the housing at the end of slot 76 and with outer surface 86 of the clamp engaged by a spring 88 which is provided to maintain the clamp in a closed condition. When the clamp has been located as described the perimetal edge of the clamp along arc 36 is aligned with cylindrical bore 68 and the clamp cannot move in the slots 74 and 76.
With the clamp suitably located in tool 62, the cutter may be caused to move down bore 68 as described in the aforesaid patent application Ser. No. 372,496 and cut through the folded layers of fabric in a one shot operation. Following the cutting operation, the clamp is removed from the tool and unfolded to permit removal of the fabric piece 12 which then has a clean cut circular hole 90 requiring repair rather than the nondescript hole 12. The diameter of such hole will substantially correspond to the diameter of the cutter 64.
A patch 92 is obtained for hole 90 by removing a disc of fabric substantially equal in diameter to the diameter of the hole from an inconspicuous part, such as a cuff, hem or internal seam of the damaged garment, or by removing such a disc of fabric from some other like piece of material. A patch of the proper size and configuration is best obtained with the aid of clamp 20 and the fabric cutting mechanism of FIG. 4, that is, by folding a portion of the fabric from which the patch is to be obtained with the clamp while pinching back any lining, locating the clamp in slots 74 and 76, and causing the cutter 64 to cut out the patch from the fabric folds. As previously indicated, when a damaged portion of a patterned fabric is located in clamp 20 the pattern is positioned with respect to grid lines 54 and 56. By similarly locating the patterned fabric for the patch with respect to such grid lines in the clamp a patch may be obtained, which when suitably positioned in hole 90, will continue the pattern of the surrounding area.
Patch 92 may be conveniently applied to fabric piece 10 in the manner shown in FIGS. 6 and 7. A pad 94, impregnated with a thermoplastic adhesive and somewhat larger than the hole 90, is first folded, and is then inserted through the hole to the normally unexposed side of the fabric piece where the pad is permitted to unfold. The fabric piece is then slightly manipulated as with the aid of a central top locator mark on the pad into a position wherein the mark is centrally located in the hole and the pad completely overlaps the hole on the underside of the fabric. Patch 92 is positioned in the hole 90 and a heated platten 96 in tool 62 is pressed down upon the fabric piece 10 over the patch while the thermoplastic pad 94 is supported as through lining 14 on a table 97. Heat from the platten melts thermoplastic adhesive in the pad 94 and causes the adhesive to flow into the interstices of adjacent portions of the fabric piece 10 to complete a repair. The platten 96 is controlled as described in the aforesaid patent application, Ser. No. 372,496 to a temperature which while sufficient to melt the adhesive in the upper portion of the pad as required to bond the pad to the patch 92 and fabric piece 10, is not so high as to permit the adhesive in the lower portion to melt and cause the pad to adhere to a lining 14, or to damage the fabric.
It is to be understood that the present disclosure relates to a preferred embodiment of the invention which is for purposes of illustration only, and is not to be construed as a limitation of the invention. Numerous alterations and modifications of the method herein disclosed will suggest themselves to those skilled in the art, and all such modifications which do not depart from the spirit and scope of the invention are intended to be included within the scope of the appended claims.
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A damaged area of a fabric is repaired by removing the damaged area from the fabric while folded across the damaged site, and thereafter bonding a patch and underlying thermoplastic impregnated pad to each other and to the fabric with the application of heat.
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This is a continuation of application Ser. No. 630,514, filed Dec. 20, 1990 abandoned.
BACKGROUND OF THE INVENTION
This invention relates to the technical field of automatic machines which carry out the packaging of various items (e.g. medicinal preparations, such as capsules, pills and the like) into sealed portions of a blister band; said portions are commonly called blister packs.
DESCRIPTION OF THE PRIOR ART
The machines mentioned above, in a sequence, form blisters on a band of thermoformable material, fill the blisters with products, check the presence of products in the blisters, apply a film to seal the blisters, cut the sealed blister band into single blister packs and discard the blister packs which are defective.
In particular, this invention provides improvements of the device by which the sealing film is applied on the blister band.
Such application is carried out by heat sealing, i.e. by clamping the film and the blister band between an upper sealing plate and a lower plate provided with hollows shaped like the blisters.
Therefore, the need arises to check the perfect centering of the blister band with respect to the means for carrying out the heat sealing, since improper centering causes the crushing, total or partial, of the blisters.
Therefore, the conventional machines usually comprise means having the purpose to check the centering of the blister band with respect to the heat-sealing means, thereby detect any imperfection of the blister pack which was just completed, and when necessary, to stop the heat-sealing means. Then an operator can intervene and remove the reasons for the improper centering.
Several means are known which carry out such a control, in particular those mentioned in the preamble of EP No.89830505.7 filed 17 November 1989 in the name of the Applicant.
In that application a technical solution is proposed, which provides for sensor means, operating upstream of the sealing station, and suited to signal the passage of a relief made on the blister band when the blisters are formed, and positioned in a certain order with respect to a plurality of such blisters.
The technical solution covered by said European Patent Application solves, in an effective way, the technical problem concerning the control of the centering of the blister band with respect to the heat-sealing means.
In the case of blister bands made of PVC (polyvinyl chloride), used in the large majority of the machines for the packaging of items into blisters, the problems related to shrinkage (longitudinal shortening) of the PVC, which occurs in conditions of non-steady operation of the packaging machine, e.g. after stopping and subsequent starting of the machine, are totally "absorbed" by the tolerances allowed in said centering.
Therefore it is not necessary when the machine is started, to intervene and longitudinally move the heat-sealing means relative to the blister band, or vice versa, since the extent of shrinkage of the PVC is such as to remain within the range of allowable tolerances.
The PVC, as it is known, is not biodegradable, and this involves environmental problems connected with its disposal.
SUMMARY OF THE INVENTION
The Applicant, as a result of constant work in research, proposes blister bands made of materials at least partially biodegradable, e.g. polypropylene.
The shrinkage ratio of this material is substantially higher than that of PVC (about 6/8 times higher), therefore the longitudinal shrinkage of the blister band after its cooling (as occurs when the machine is stopped) is such as to cause translations of the blister band exceeding the tolerances allowed for centering the blisters relative to the sealing means.
More precisely, the translations of the blisters have their negative effects downstream of the heat-sealing means, since the means for advancing the sealed band, located downstream of the heat sealing means, define, with the machine stopped, a fastening point for the sealed band.
The reactivation of the sealing means, in synchronism with reactivation of the machine, is not feasible, since this would cause the crushing of the blisters. This crushing would continue until steady state operation of the packaging machine is restored, a situation detected, e.g. by means for checking the centering.
The resolution of the technical problem just mentioned above would allow the sealing of blister bands made of polypropylene to be accomplished in any operating condition of the packaging machine.
This is realized by the Applicant by the present invention, whose object is to provide improvements in the device suited to seal blister bands with a film. The improvement are such as to carry out said sealing in an optimal way independently of the type of material composing the blister band, and regardless of the operating situation of the associated packaging machine.
A further object of the invention is to provide improvements which allow the above process to be accomplished through a technical solution particularly simple and easily adaptable to the complex of elements defining the heat-sealing means.
The objects just mentioned above are achieved by the device that is the subject of the invention. The device is for heat sealing a film to a blister band in a line for packaging items into blister packs. The packs are obtained from a band of thermoformable material made to advance along said line, with the film being fed above the blister band and transversally centered with respect to the same, said line including: a thermoforming station for forming blisters on the band; a station for filling the blisters with items; advancing means, located downstream of said device, for advancing the blister band, already sealed with the film.
The device, designed to operate in particular with a band of polypropylene, comprises: a frame bearing an upper sealing plate and a lower plate, the lower plate being provided with hollows shaped like the blisters, said plates being designed to clamp the film and blister band at a sealing station in which said hollows of said lower plate are centered with respect to the blisters of the band. The frame is cyclically moved parallel to the advancement direction of the blister band from a withdrawn position, corresponding to said sealing station, to an advanced position by forward travel with the plates kept clamped, and from the advanced position to the withdrawn position, by backward travel with the plates moved away from each other; means for moving the sealing station, when the working of the packaging line, stops. This moving is along the advancing direction of the band in correspondence to a longitudinal shortening of the blister band, due to the stopping, calculated with respect to a length of the band, in the steady state operation of the packaging line, between the sealing station, at a position taken at steady state operation of the packaging line, and the advancing means, located downstream of said device.
The improved device proposed hereby heat seals a film to the blister band independently of both the type of material (e.g. polypropylene) of which the band is made, and independently of the operating conditions of the associated packaging line.
This is made possible by moving a sealing station in either direction, parallel to the advancement direction of the band.
In the drawings enclosed herewith a device is illustrated, which carries out the heat sealing of a band moved continuously by the means for advancing the band just sealed with the film.
The device that is the subject of the invention can be used also in situations where the band is moved step by step; in that case it is sufficient to provide for a frame supported by suitable means, with the capability of translating longitudinally, and a cross bar, integral with the frame.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the invention are pointed out below, with reference to the drawings enclosed herewith, where:
FIG. 1 shows a schematic front view of the sealing means in two limiting operating positions, respectively withdrawn and advanced;
FIG. 2 shows a top view of the improvements associated with the means for moving the sealing means;
FIG. 3 shows a view of the section III--III of FIG. 2;
FIGS. 4a, 4b show top view, in enlarged scale, of the detail X of FIG. 2 in the two limit positions of longitudinal regulation of the sealing means with respect to said moving means.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the figures, a device 1 effects heat-sealing of a film 2 to a blister band 3 (e.g. of polypropylene).
The device 1 operates along a line 4 for the packaging of items into blister packs, partially illustrated, along which the band 3 is pulled (sense or direction A).
Said line 4 comprises, upstream of the device 1, a station (not illustrated) for the forming of blisters 3a on said band 3, a station (also not illustrated) for the filling of blisters 3a with associated items 5, and means 6 for feeding said film 2, with this film positioned above the band 3 and transversally centered with respect to the same.
Furthermore, said line 4 is provided, downstream of the device 1, with means 50 for advancing the band 3, which has been just sealed with the film 2.
The device 1 includes a frame 7 supported by known means, not illustrated, with the capability for the same frame to slide longitudinally, i.e. parallel to the advancement direction A of the band 3.
The frame 7 bears an upper sealing plate 8 and a lower plate 9 provided with hollows 9a (turned upwards) which are complementary with the blisters 3a; said plates are moved vertically, in a known way, according to opposite senses (or direction) H1,H2 and K1,K2.
A cross bar 11 is integral with the frame 7. A pivot 12, normal to the sense A, is coupled to the cross bar 11 in a revolving mount.
The pivot 12 is borne eccentrically by a shaft 10 coupled in a revolving mount with a longitudinal bar 13 having the purpose to move the frame 7 cyclically (in the directions B1,B2).
A gear wheel 14 is splined to the shaft 10 and engages with a toothed belt 15, which in its turn engages a pinion 16 keyed on the output shaft 16a of a geared motor 17 supported by the bar 13.
The angular position of the shaft 10 is detected by an "encoder" 18; the relative position measurement is sent to a data processing unit 19 having the purpose, according to said measurement and to any further data supplied by an apparatus 20, to control the geared motor 17.
It is known that polypropylene shows, with the decreasing of temperature, a ratio of shrinkage substantially higher than the materials commonly used (usually PVC) to make the band 3.
In translation from the blister forming station to the device 1, the band 3 progressively cools down; in conditions of steady state operation of the packaging line 4, the portion of band 3 which undergoes the action of the plates 8,9 has a predetermined temperature.
In steady state conditions, the pivot 12 is positioned in the limit position E1 shown in FIG. 4a.
As it has been mentioned above, the longitudinal bar 13 can move the frame 7 in the directions B1,B2 from a withdrawn position Z1 (indicated by a continuous line in FIG. 1) to an advanced position Z2 (indicated by a broken line in FIG. 1); the amplitude of the travel is constant.
In steady state conditions in the withdrawn position Z1, the hollows 9a of the lower plate 9 are centered, within predetermined tolerances, with respect to the blisters 3a of the overlying band 3.
With the translation of the plates 8,9 in the directions K1, K2, said film 2 and band 3 are clamped between these plates; the position in which such clamping takes place defines a sealing station P to which corresponds the transverse position of the axis T1 of the pivot 12 (see FIG. 4a).
The plates 8,9 are kept clamped during the forward travel of the frame (sense B1). In the advanced position Z2, the plates are moved (senses H1,H2) away from each other; such a position is maintaned during the backward travel of the frame (sense B2); in this way it is possible to obtain the continuous heat sealing of the film 2 to the band 3.
When stopping, for whatever reason, the working of the packaging line 4, the band 3 cools down. Thus it shrinks, with reference to the fastening point of the sealed band defined, with the machine stopped, by said advancing means 50.
Said shrinkage is not "absorbed" by the allowed tolerances; in other words, clamping of the plates 8,9 in the position which previously defined the sealing station P, would cause crushing of the blisters 3a (and of the items contained there) subjected to the heat sealing.
This is avoided by the present improved device. In fact, rotation, as indicated by the arrow C, of the shaft 10 causes the axis T1 of the pivot 12 to advance with respect to the bar 13; a half revolution of the shaft 10 brings about the maximum advancement (of said axis T1) equal to twice the eccentricity existing between the axes of the shaft 10 and the pivot 12 (position E2, FIG. 4b).
The above-mentioned maximum advancement is such as to compensate for the maximum shrinkage (longitudinal shortening) of the band 3, a shrinkage which occurs between the position taken at steady state by the sealing station P and said advancing means 50.
The value of such advancement, determined by the data processing unit 19 and carried out through the geared motor 17, can be correlated with a thermal probe 22 measuring the environmental temperature or, more advantageously, the temperature of the band 3.
In this way the frame 7 is moved forward, with respect to a withdrawn position at steady state, therefore also the sealing station P is moved forward.
When the line 4 is started again, it is necessary that the sealing station P is progressively moved backward through a suitable rotation of the shaft 10 according to angular values determined by the data processing unit 19 and detected by the "encoder" 18.
Such rotation can be subjected, as an alternative to what has been said above, to an apparatus 20 which stores angular values (deduced from experimental tests), according to which the shaft 10 is rotated after every operating cycle of heat sealing (preferably during the backward travel of the frame), or such rotation of the shaft 10 can be subject to sensor means 21 which, detecting the position of prominences 25 equally spaced, on the band 3, supply the data processing unit 19 with data from which the extent of longitudinal shrinkage of the band 3 with respect to the steady state conditions is calculated.
As stated above, the device that is the subject of the invention can also be used in a construction where the band is moved step by step; in that case it is sufficient to provide for the frame 7 supported by suitable means, with the capability of translating longitudinally, and a cross bar, integral with the same frame, with which said pivot 12 is coupled in a revolving mount.
It is understood that the above has been described by way of example and it is not restrictive, therefore any variations of construction are to be considered as covered by the present invention, as described above and according to the claims here below.
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In a line for packaging products in blisters made in a band of polypropylene, a device for heat sealing a film onto the blister band comprises a frame supporting an upper plate and a lower plate with hollows suited for receive the blisters. When the hollows match against the blisters of the band the plates are brought near to each other so as to clamp, in a sealing station, the interposed film and blister band, while the device allows the moving of the sealing station along an advancement direction of the band according to a longitudinal shortening of the band with respect to the steady state operation of the line.
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BACKGROUND OF THE INVENTION
This invention relates to α-substituted ketonitrone derivatives useful as intermediates for the preparation of antifungal isoxazolidine compounds.
BRIEF SUMMARY OF THE INVENTION
In accordance with this invention there are provided compounds of the formula: ##STR1## wherein; R 1 is selected from 2-naphthyl, 2-furanyl, 2-thienyl, phenyl, and substituted phenyl having one or more of the meta and para hydrogens substituted by halogen, lower alkoxy, lower alkyl or combinations thereof,
R 2 is selected from hydrogen and phenyl, and X is selected from nitrogen and a methyn (CH═) group.
DETAILED DESCRIPTION OF THE INVENTION
The α-substituted ketonitrone derivatives (2) of the invention can be obtained as illustrated in the following diagram by reaction of an appropriately substituted ketone precursor (1) with N-methyl(or benzyl)-hydroxylamine hydrochloride in absolute ethanol at room or elevated temperature in the presence of base, for example, alkali metal carbonates, bicarbonates or acetates. Preferably, potassium carbonate or sodium acetate are used.
As used herein the terms "lower alkyl" and "lower alkoxy" refer to straight and branched chain alkylene groups having 1 to 4 carbon atoms and halogen refers to chlorine, bromine, iodine and fluorine (preferably chlorine or fluorine). ##STR2##
The preparation of the compounds of the invention is further illustrated by the following examples. The appropriately substituted ketone precursors are prepared according to known procedures, for example, Godefroi et al., J. Medicinal Chem. 12 784 (1969), and Nardi et al., J. Medicinal Chem. 24 727 (1981).
EXAMPLE 1
2-(1H-Imidazol-1-yl)-N-methyl-1-phenylethanimine N-oxide
(2, R 1 =C 6 H 5 , R 2 =H, X=CH)
Method A. A suspension of 18.70 g (0.100 mol) of 2-(1H-imidazol-1-yl)acetophenone (1, R 1 =C 6 H 5 , X=CH), N-methylhydroxylamine hydrochloride (9.78 g, 0.117 mol), and potassium carbonate (17.24 g, 0.125 mol) in 200 ml of absolute ethanol was stirred at 70°-75° C., under a nitrogen atmosphere, for 48 hours. The reaction mixture was then cooled to room temperature, filtered, and the solvent removed in vacuo, leaving a yellow oil which was dissolved in 400 ml of ethyl acetate and extracted with water (6×100 ml). The combined aqueous layer was back-extracted with chloroform (8×100 ml). The combined chloroform layer was dried over anhydrous sodium sulfate, filtered, and the solvent removed in vacuo to give nitrone 2 (R 1 =C 6 H 5 , R 2 =H, X=CH) as a white solid, 15.54 g (72%). An analytical sample was prepared by recrystallization from ethyl acetate, mp 126°-128° C. Anal. Calcd for C 12 H 13 N 3 O: C, 66.96; H, 6.09; N, 19.52. Found: C, 66.74; H, 6.18; N, 19.38.
Method B. A suspension of 5.58 g (0.0316 mol) of 2-(1H-imidazol-1-yl)acetophenone (1, R 1 =C 6 H 5 , X=CH), N-methylhydroxylamine hydrochloride (3.17 g, 0.0379 mol), and sodium acetate (6.24 g, 0.0760 mol) in 50 ml of absolute ethanol was stirred for 72 hours at room temperature, under a nitrogen atmosphere. The suspension was then filtered and the solvent removed in vacuo. The residual oily solid was taken up in chloroform, filtered and the solvent removed in vacuo. Crystallization from ethyl acetate gave 5.43 g (80%) of nitrone 2 (R 1 =C 6 H 5 , R 2 =H, X=CH).
EXAMPLE 2
1-(4-Chlorophenyl)-2-(1H-imidazol-1-yl)-N-methylethanimine N-oxide
(2, R 1 =4-ClC 6 H 4 , R 2 =H, X=CH)
Compound 2 (R 1 =4-ClC 6 H 4 , R 2 =H, X=CH) was prepared by the procedures described in Example 1, Methods A and B by reacting 2-(1H-imidazol-1-yl)-4'-chloroacetophenone (1, R 1 =4-ClC 6 H 4 , X=CH) with N-methylhydroxylamine hydrochloride. Compound 2 (R 1 =4-ClC 6 H 4 , R 2 =H, X=CH) has a melting point of 98°-102° C. (ethyl acetate). Anal. Calcd for C 12 H 12 ClN 3 O: C, 57.72; H, 4.84; N, 16.83; Cl, 14.20. Found (method A prep): C, 57.53; H, 4.99; N, 16.87; Cl, 14.08.
EXAMPLE 3
1-(4-Fluorophenyl)-2-(1H-imidazol-1-yl)-N-methylethanimine N-oxide
(2, R 1 =4-FC 6 H 4 , R 2 =H, X=CH)
Compound 2 (R 1 =4-FC 6 H 4 , R 2 =H, X=CH) was prepared by the procedures described in Example 1, Methods A and B, by reacting 2-(1H-imidazol-1-yl)-4'-fluoroacetophenone (1, R 1 =4-FC 6 H 4 , X=CH) with N-methylhydroxylamine hydrochloride. Compound 2 (R 1 =4-FC 6 H 4 , R 2 =H, X=CH) has a melting point of 131°-134° C. (ethyl acetate). Anal. Calcd for C 12 H 12 FN 3 O: C, 61.79; H, 5.19, N, 18.02; F, 8.15. Found (method A prep.): C, 62.02; H, 5.39; N, 17.96; F, 8.22.
EXAMPLE 4
2-(1H-Imidazol-1-yl)-1-(4-methoxyphenyl)-N-methylethanimine N-oxide
(2, R 1 =4-CH 3 OC 6 H 4 , R 2 =H, X=CH)
Compound 2 (R 1 =4-CH 3 OC 6 H 4 , R 2 =H, X=CH) was prepared by the procedure described in Example 1, Method A, by reacting 2-(1H-imidazol-1-yl)-4'-methoxyacetophenone (1, R 1 =4-CH 3 OC 6 H 4 , X=CH) with N-methylhydroxylamine hydrochloride. Compound 2 (R 1 =4-CH 3 OC 6 H 4 , R 2 =H, X=CH) has a melting point of 81°-84° C. (ethyl acetate-ether, 1:1 by volume). Anal. Calcd for C 13 H 15 N 3 O 2 : C, 63.66; H, 6.16; N, 17.13. Found: C, 63.49; H, 6.28; N, 17.05.
EXAMPLE 5
2-(1H-Imidazol-1-yl)-1-(3-methoxyphenyl)-N-methylethanimine N-oxide
(2, R 2 =3-CH 3 O 6 H 4 , R 2 =H, X=CH)
Compound 2 (R 1 =3-CH 3 OC 6 H 4 , R 2 =H, X=CH) was prepared by the procedure described in Example 1, Method A, by reacting 2-(1H-imidazol-1-yl)-3'-methoxyacetophenone (1, R 1 =3-CH 3 OC 6 H 4 , X=CH) with N-methylhydroxylamine hydrochloride. Compound 2 (R 1 =3-CH 3 OC 6 H 4 , R 2 =H, X=CH) has a melting point of 87°-90° C. (ethyl acetate-hexane, 1:1 by volume). Anal. Calcd for C 13 H 15 N 3 O 2 : C, 63.66; H, 6.16; N, 17.13. Found: C, 63.70; H, 6.29; N, 17.08.
EXAMPLE 6
2-(1H-Imidazol-1-yl)-N-methyl-1-(3-methylphenyl)ethanimine N-oxide
(2, R 1 =3-CH 3 C 6 H 4 , R 2 =H, X=CH)
Compound 2 (R 1 =3-CH 3 C 6 H 4 , R 2 =H, X=CH) was prepared by the procedure described in Example 1, Method B, by reacting 2-(1H-imidazol-1-yl)-3'-methylacetophenone (1, R 1 =3-CH 3 C 6 H 4 , X=CH) with N-methylhydroxylamine hydrochloride. Compound 2 (R 1 =3-CH 3 C 6 H 4 , R 2 =H, X=CH) was obtained as a light yellow oil.
EXAMPLE 7
1-(4-Chloro-3-methylphenyl)-2-(1H-imidazol-1-yl)-N-methylethanimine N-oxide
(2, R 1 =4-Cl-3-CH 3 C 6 H 3 , R 2 =H, X=CH) Compound 2 (R 1 =4-Cl-3-CH 3 C 6 H 3 , R 2 =H, X=CH) was prepared by the procedure described in Example 1, Method A, by reacting 2-(1H-imidazol-1-yl)-4'-chloro-3'-methylacetophenone (1, R 1 =4-Cl-3-CH 3 C 6 H 3 , X=CH) with N-methylhydroxyamine hydrochloride. Compound 2 (R 1 =4-Cl-3-CH 3 C 6 H 5 , R 2 =H, X=CH) was obtained as a light yellow oil. EXAMPLE 8
2-(1H-Imidazol-1-yl)-1-phenyl-N-(phenylmethyl)ethanimine N-oxide
(2, R 1 =R 2 =C 6 H 5 , X=CH)
Compound 2 (R 1 =R 2 C 6 H 5 , X=CH) was prepared by the procedure described in Example 1, Method B, by reacting 2-(1H-imidazol-1-yl)acetophenone (1, R 1 =C 6 H 5 , X=CH) with N-benzylhydroxylamine. Compound 2 (R 1 =R 2 =C 6 H 5 , X=CH) was obtained as a light yellow oil.
EXAMPLE 9
1-(4-Fluorophenyl)-2-(1H-imidazol-1-yl)-N-(phenylmethyl)ethanimine N-oxide
(2, R 1 =4-FC 6 H 4 , R 2 =C 6 H 5 , X=CH)
Compound 2 (R 1 =4-FC 6 H 4 , R 2 =C 6 H 5 , X=CH) was prepared by the procedure described in Example 1, Method B, by reacting 2-(1H-imidazol-1-yl)-4'-fluoroacetophenone (1, R 1 =4-FC 6 H 4 , X=CH) with N-benzylhydroxylamine. Compound 2 (R 1 =4-FC 6 H 4 , R 2 =C 6 H 5 , X=CH) was obtained as a light yellow oil.
EXAMPLE 10
N-Methyl-1-phenyl-2-(1H-1,2,4-triazol-1-yl)ethanimine N-oxide
(2, R 1 =C 6 H 5 , R 2 =H, X=N) was prepared by the procedure described in Example 1, Method A, by reacting 2-(1H-1,2,4-triazol-1-yl) acetophenone (1, R 1 =C 6 H 5 , X=N) with N-methylhydroxylamine hydrochloride. Compound 2 (R 1 =C 6 H 5 , R 2 =H, X=N) has a melting point of 117°-119° C. (ethyl acetate).
EXAMPLE 11
1-(4-Chlorophenyl)-N-methyl-2-(1H-1,2,4-triazol-1-yl)ethanimine N-oxide
(2, R 1 =4-ClC 6 H 4 , R 2 =H, X=N)
Compound 2 (R 1 =4-ClC 6 H 4 , R 2 =H, X=N) was prepared by the procedure described in Example 1, Method A by reacting 2-(1H-1,2,4-triazol-1-yl)-4'-chloroacetophenone (1, R 1 =4-ClC 6 H 4 , X=N) with N-methylhydroxylamine hydrochloride. Compound 2 (R 1 =4-ClC 6 H 4 , R 2 =H, X=N) has a melting point of 119°-121° C. (ethyl acetate). Anal. Calcd for C 11 H 11 ClN 4 O: C, 52.70; H, 4.42; N, 22.35; Cl, 14.14. Found: C, 52.65; H, 4.44; N, 22.37; Cl, 13.93.
EXAMPLE 12
1-(4-Methoxyphenyl)-N-methyl-2-(1H-1,2,4-triazol-1-yl)ethanimine N-oxide
(2, R 1 =4-CH 3 OC 6 H 4 , R 2 =H, X=N)
Compound 2 (R 1 =4-CH 3 OC 6 H 4 , R 2 =H, X=N) was prepared by the procedure described in Example 1, Method A, by reacting 2-(1H-1,2,4-triazol-1-yl)-4'-methoxyacetophenone (1, R 1 =4-CH 3 OC 6 H 4 , X=N) with N-methylhydroxylamine hydrochloride. Compound 2 (R 1 =4-CH 3 OC 6 H 4 , R 2 =H, X=N) has a melting point of 128°-121° C. (ethyl acetate). Anal. Calcd for C 12 H 14 N 4 O: C, 58.53; H, 5.73; N, 22.75. Found: C, 58.61; H, 5.76; N, 22.86.
EXAMPLE 13
1-(4-Fluorophenyl)-N-methyl-2-(1H-1,2,4-triazol-1-yl)ethanimine N-oxide
(2, R 1 =4-FC 6 H 4 , R 2 =H, X=N)
Compound 2 (R 1 =4-FC 6 H 4 , R 2 =H, X=N) was prepared by the procedure described in Example 1, Method A, by reacting 2-(1H-1,2,4-triazol-1-yl)-4'-fluoroacetophenone (1, R 1 =4-FC 6 H 4 , X=N) with N-methylhydroxylamine hydrochloride. Compound 2 (R 1 =4-FC 6 H 4 , R 2 =H, X=N) was obtained as a light yellow oil.
EXAMPLE 14
N-Methyl-1-(3-methylphenyl)-2-(1H-1,2,4-triazol-1-yl)ethanimine N-oxide
(2, R 1 =3-CH 3 C 6 H 4 , R 2 =H, X=N)
Compound 2 (R 1 =3-CH 3 C 6 H 4 , R 2 =H=N) was prepared by the procedure described in Example 1, Method B, by reacting 2-(1H-1,2,4-triazol-1-yl)-3'-methylacetophenone (1, R 1 =3-CH 3 C 6 H 4 , X=N) with N-methylhydroxylamine hydrochloride. Compound 2 (R 1 =3-CH 3 C 6 H 4 , R 2 =H, X=N) has a melting point of 98°-100° C. (ethyl acetate).
EXAMPLE 15
2-(1H-Imidazol-1-yl)-N-methyl-1-(2-naphthyl)ethanimine N-oxide
(2, R 1 =2-C 10 H 7 , R 2 =H, X=CH)
Compound 2 (R 1 =2-C 10 H 7 , R 2 =H, X=N) was prepared by the procedures described in Example 1, Method A and B, by reacting 2-(1H-imidazol-1-yl)-1-(2-naphthyl)ethanone (1, R 1 =2-C 10 H 7 , X=CH) with N-methylhydroxylamine hydrochloride. Compound 2 (R 1 =2-C 10 H 7 , R 2 =H, X=CH) has a melting point of 112°-114° C. (ethyl acetate). Anal. Calcd for C 16 H 15 N 3 O: C, 72.43; H, 5.70; N, 15.84. Found: (method A prep.) C, 72.14; H, 5.79; N, 15.74.
EXAMPLE 16
1-(2-Furanyl)-2-(1H-imidazol-1-yl)-N-methylethanimine N-oxide
(2, R 1 =2-C 4 H 3 O, R 2 =H, X=CH)
Compound 2 (R 1 =2-C 4 H 3 O, R 2 32 H, X=CH) was prepared by the procedure described in Example 1, Method B, by reacting 1-(2-furanyl)-2-(1H-imidazol-1-yl)ethanone (1, R 1 =2-C 4 H 3 O, X=CH) with N-methylhydroxylamine hydrochloride. Compound 2 (R 1 =2-C 4 H 3 O, R 2 =H, X=CH) has a melting point of 130°-133° C. (ethyl acetate). Anal. Calcd for C 10 H 11 N 3 O: C, 58.53, H, 5.40; N, 20.48. Found: C, 58.60; H, 5.47; N. 20.49.
EXAMPLE 17
2-(1H-Imidazol-1-yl)-N-methyl-1-(2-thienyl)ethanimine N-oxide
(2, R 1 =3-C 4 H 3 S, R 2 =H, X=CH)
Compound 2 (R 1 =2-C 4 H 3 S, R 2 =H, X=CH) was prepared by the procedure described in Example 1, Method B, by reacting 2-(1H-imidazol-1-yl)-1-(2-thienyl)ethanone (1, R 1 =2-C 4 H 3 S, X=CH) with N-methylhydroxylamine hydrochloride. Compound 2 (R 1 =2-C 4 H 3 S, R 2 =H, X=CH) has a melting point of 162°-164° C. (ethyl acetate).
The compounds of this invention are useful intermediates for the preparation of substituted isoxazolidine derivatives having antifungal activity. Examples of such derivatives are disclosed, for example, in our concurrently filed copending applications entitled "Substituted 5-(Phenoxyalkyl)-3-phenyl-3-(1H-imidazol-1-ylmethyl)-2-methylisoxazolidines"; "Substituted 3,5-Diphenyl-3-(1H-imidazol-1-ylmethyl)-2-methylisoxazolidines" (U.S. Pat. No. 4,719,306), "3-(Substituted phenyl)-3-(1H-imidazol-1-ylmethyl)-2-methyl-5-{[(substituted phenyl)thio]methyl}isoxazolidine" Derivatives; and "3-(Substituted phenyl)-3-(1H-1,2,4-triazol-1-yl)methyl-2-methyl-5-[(substituted phenoxy)methyl]isoxazolidine Derivatives" whose disclosures are incorporated by reference herein.
The substituted isoxazolidines are prepared by reacting the compounds of the invention with an appropriate allyl benzene, allyl phenyl ether or allyl phenyl sulfide compound to provide the desired isoxazolidines. For example, 5-(4-chlorophenoxymethyl)-3-phenyl-3-(1H-imidazol-1-ylmethyl)-2-methylisoxazolidine can be prepared by reacting the compound of Example 1 with 4-chlorophenyl allyl ether in refluxing toluene in a nitrogen atmosphere for about 40 hours. Other compounds of the invention can be used to prepare corresponding isoxazolidines in a similar manner. The isoxazolidines have been determined to have in vitro antifungal activity against yeast and systemic mycoses and dermatophytes as determined by broth and agar testing techniques [(McGinnis, M. R., Laboratory Handbook of Medical Mycology, Academic Press, N.Y., N.Y. (1980)].
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α-Substituted ketonitrone derivatives containing substitutents selected from hydrogen, phenyl, substituted phenyl, naphythyl, furan, thiopen, imidazolylmethyl and triazolylmethyl are useful as intermediates for the preparation of biologically active isoxazolidine compounds.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation of co-pending application Ser. No. 12/372,862, filed Feb. 18, 2009.
FIELD OF THE INVENTION
This invention relates, in general, to equipment utilized and operations performed in conjunction with a subterranean well and, in particular, to an apparatus and method for controlling the connection and disconnection speed of downhole connectors.
BACKGROUND OF THE INVENTION
Without limiting the scope of the present invention, its background is described with reference to using optical fibers for communication and sensing in a subterranean wellbore environment, as an example.
It is well known in the subterranean well completion and production arts that downhole sensors can be used to monitor a variety of parameters in the wellbore environment. For example, during a treatment operation, it may be desirable to monitor a variety of properties of the treatment fluid such as viscosity, temperature, pressure, velocity, specific gravity, conductivity, fluid composition and the like. Transmission of this information to the surface in real-time or near real-time allows the operators to modify or optimize such treatment operations to improve the completion process. One way to transmit this information to the surface is through the use of an energy conductor which may take the form of one or more optical fibers.
In addition or as an alternative to operating as an energy conductor, an optical fiber may serve as a sensor. It has been found that an optical fiber may be used to obtain distributed measurements representing a parameter along the entire length of the fiber. Specifically, optical fibers have been used for distributed downhole temperature sensing, which provides a more complete temperature profile as compared to discrete temperature sensors. In operation, once an optical fiber is installed in the well, a pulse of laser light is sent along the fiber. As the light travels down the fiber, portions of the light are backscattered to the surface due to the optical properties of the fiber. The backscattered light has a slightly shifted frequency such that it provides information that is used to determine the temperature at the point in the fiber where the backscatter originated. In addition, as the speed of light is constant, the distance from the surface to the point where the backscatter originated can also be determined. In this manner, continuous monitoring of the backscattered light will provide temperature profile information for the entire length of the fiber.
Use of an optical fiber for distributed downhole temperature sensing may be highly beneficial during the completion process. For example, in a stimulation operation, a temperature profile may be obtained to determine where the injected fluid entered formations or zones intersected by the wellbore. This information is useful in evaluating the effectiveness of the stimulation operation and in planning future stimulation operations. Likewise, use of an optical fiber for distributed downhole temperature sensing may be highly beneficial during production operations. For example, during a production operation a distributed temperature profile may be used in determining the location of water or gas influx along the sand control screens. In a typical completion operation, a lower portion of the completion string including various tools such as sand control screens, fluid flow control devices, wellbore isolation devices and the like is permanently installed in the wellbore. As discussed above, the lower portion of the completion string may include various sensors, particularly, a lower portion of the optical fiber. After the completion process is finished, an upper portion of the completions string which includes the upper portion of the optical fiber is separated from the lower portion of the completion string and retrieved to the surface. This operation cuts off communication between the lower portion of the optical fiber and the surface. Accordingly, if information from the production zones is to be transmitted to the surface during production operations, a connection to the lower portion of the optical fiber must be reestablished when the production tubing string is installed.
It has been found, however, that wet mating optical fibers in a downhole environment is very difficult. This difficulty is due in part to the lack of precision in the axially movement of the production tubing string relative to the previously installed completion string. Specifically, the production tubing string is installed in the wellbore by lowering the block at the surface, which is thousands of feet away from the downhole landing location. In addition, neither the distance the block is moved nor the speed at which the block is moved at the surface directly translates to the movement characteristics at the downhole end of the production tubing string due to static and dynamic frictional forces, gravitational forces, fluid pressure forces and the like. The lack of correlation between block movement and the movement of the lower end of the production tubing string is particularly acute in slanted, deviated and horizontal wells. This lack in precision in both the distance and the speed at which the lower end of the production tubing string moves has limited the ability to wet mate optical fibers downhole as the wet mating process requires relatively high precision to sufficiently align the fibers to achieve the required optical transmissivity at the location of the connection.
Therefore, a need has arisen for an apparatus and method for wet connecting optical fibers in a subterranean wellbore environment. A need has also arisen for such an apparatus and method for wet connecting optical fibers that is operable to overcome the lack of precision in the axial movement of downhole pipe strings relative to one another. Further, a need has arisen for such an apparatus and method for wet connecting optical fibers that is operable to overcome the lack of precision in the speed of movement of downhole pipe strings relative to one another.
SUMMARY OF THE INVENTION
The present invention disclosed herein is directed to an apparatus and method for wet connecting downhole communication media in a subterranean wellbore environment. The apparatus and method of the present invention are operable to overcome the lack of precision in the axial movement of downhole pipe strings relative to one another. In addition, apparatus and method of the present invention are operable to overcome the lack of precision in the speed of movement of downhole pipe strings relative to one another. In carrying out the principles of the present invention, a wet connection apparatus and method are provided that are operable to control the connection speed of downhole connectors.
In one aspect, the present invention is directed to a method for controlling the connection speed of first and second downhole connectors in a subterranean well. The method includes positioning a first assembly in the well, the first assembly including the first downhole connector and a first communication medium; engaging the first assembly with a second assembly, the second assembly including the second downhole connector and a second communication medium; axially shifting an outer portion of the second assembly relative to an inner portion of the second assembly; and then operatively connecting the first and second downhole connectors to each other, thereby enabling communication between the first and second communication media.
In one embodiment, the method includes releasing a lock initially coupling the outer and inner portions of the second assembly. This step may be performed by radially inwardly compressing a collet assembly of the outer portion of the second assembly with an inner surface of the first assembly. In another embodiment, the method includes controlling the rate at which the outer and inner portions of the second assembly axially shift relative to one another with a resistance assembly. This step may be performed by metering a fluid through a transfer piston. In a further embodiment, the method includes anchoring the second assembly within the first assembly. This step may be performed by engaging a collet assembly of the outer portion of the second assembly with a profile of the first assembly. In yet another embodiment, the method may include disposing the first downhole connector of the first assembly at a location uphole of a packer of the first assembly. In any of the embodiments, the communication media may be optical fibers, electrical conductors, hydraulic fluid or the like. When the first communication medium is an optical fiber, this optical fiber may be operated as a sensor such as a distributed temperature sensor.
In another aspect, the present invention is directed to a method for controlling the connection speed of first and second fiber optic connectors in a subterranean well. The method includes positioning a first assembly in the well, the first assembly including the first fiber optic connector and a first optical fiber; engaging the first assembly with a second assembly, the second assembly including the second fiber optic connector and a second optical fiber; axially shifting an outer portion of the second assembly relative to an inner portion of the second assembly while metering a fluid through a transfer piston to control the rate at which the outer and inner portions of the second assembly axially shift relative to one another; and then operatively connecting the first and second fiber optic connectors to each other, thereby enabling light transmission between the optical fibers.
In a further aspect, the present invention is directed to an apparatus for controlling the connection speed of first and second downhole connectors in a subterranean well. The apparatus includes a first assembly that is positionable in the well. The first assembly includes the first downhole connector and a first communication medium. A second assembly includes the second downhole connector and a second communication medium. The second assembly has an outer portion and an inner portion that are selectively axially shiftable relative to one another such that upon engagement of the first assembly with the second assembly, the outer portion of the second assembly is axially shifted relative to the inner portion of the second assembly allowing the first and second downhole connectors to be operatively connected to each other, thereby enabling communication between the first communication medium and the second communication medium.
In one embodiment, the inner portion of the second assembly includes a lock and the outer portion of the second assembly includes a collet assembly. The lock initially couples the outer and inner portions of the second assembly together and the collet is operable to release the lock in response to being radially inwardly compressed by an inner surface of the first assembly. In another embodiment, the apparatus includes a resistance assembly that is positioned between the outer portion of the second assembly and the inner portion of the second assembly that controls the rate at which the outer and inner portions of the second assembly axially shift relative to one another by, for example, metering a fluid through a transfer piston. In a further embodiment, the outer portion of the second assembly includes a collet assembly and the first assembly includes a profile. In this embodiment, the collet assembly is operable to engage the profile to anchor the second assembly within the first assembly. In yet another embodiment, the first assembly includes a packer and the first downhole connector of the first assembly is positioned at a location uphole of the packer.
In yet another aspect, the present invention is directed to a method for controlling the disconnection speed of first and second downhole connectors in a subterranean well. The method includes establishing a predetermined tensile force between a first assembly and a second assembly in the well, the first assembly including the first downhole connector and a first communication medium, the second assembly including the second downhole connector and a second communication medium; axially shifting an outer portion of the second assembly relative to an inner portion of the second assembly; and operatively disconnecting the first and second downhole connectors from each other, thereby disabling communication between the first and second communication media.
In one embodiment, the method may include releasing an anchor of the second assembly from a profile in the first assembly. This step may be performed by radially inwardly compressing a collet assembly of the second assembly with an inner surface of the first assembly. In another embodiment, the method may include controlling the rate at which the outer and inner portions of the second assembly axially shift relative to one another with a resistance assembly. This step may be performed by metering a fluid through a transfer piston.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:
FIG. 1 is a schematic illustration of an offshore oil and gas platform operating an apparatus for controlling the connection speed of downhole connectors according to an embodiment of the present invention;
FIGS. 2A-2D are front views of consecutive axial sections of an apparatus for controlling the connection speed of downhole connectors in a running configuration according to an embodiment of the present invention;
FIGS. 3A-3D are cross sectional views of consecutive axial sections of an apparatus for controlling the connection speed of downhole connectors in a running configuration according to an embodiment of the present invention;
FIGS. 4A-4D are front views of consecutive axial sections of an apparatus for controlling the connection speed of downhole connectors in an anchored configuration according to an embodiment of the present invention; and
FIGS. 5A-5D are cross sectional views of consecutive axial sections of an apparatus for controlling the connection speed of downhole connectors in an anchored configuration according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts, which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the invention.
Referring initially to FIG. 1 , an apparatus for controlling the connection speed of downhole connectors deployed from an offshore oil or gas platform is schematically illustrated and generally designated 10 . A semi-submersible platform 12 is centered over submerged oil and gas formation 14 located below sea floor 16 . A subsea conduit 18 extends from deck 20 of platform 12 to wellhead installation 22 , including blowout preventers 24 . Platform 12 has a hoisting apparatus 26 , a derrick 28 , a travel block 30 , a hook 32 and a swivel 34 for raising and lowering pipe strings, such as a substantially tubular, axially extending production tubing 36 .
A wellbore 38 extends through the various earth strata including formation 14 . An upper portion of wellbore 38 includes casing 40 that is cemented within wellbore 38 . Disposed in an open hole portion of wellbore 38 is a completion that includes various tools such as packer 44 , a seal bore assembly 46 and sand control screen assemblies 48 , 50 , 52 , 54 . In the illustrated embodiment, completion 42 also includes an orientation and alignment subassembly 56 that houses a downhole wet mate connector. Extending downhole from orientation and alignment subassembly 56 is a conduit 58 that passes through packer 44 and is operably associated with sand control screen assemblies 48 , 50 , 52 , 54 . Preferably, conduit 58 is a spoolable metal conduit, such as a stainless steel conduit that may be attached to the exterior of pipe strings as they are deployed in the well. In the illustrated embodiment, conduit 58 is wrapped around sand control screen assemblies 48 , 50 , 52 , 54 . One or more communication media such as optical fibers, electrical conducts, hydraulic fluid or the like may be disposed within conduit 58 . In certain embodiments, the communication media may operate as energy conductors including power and data transmission between downhole a location or downhole sensors (not pictured) and the surface. In other embodiments, the communication media may operate as downhole sensors.
For example, when optical fibers are used as the communication media, the optical fibers may be used to obtain distributed measurements representing a parameter along the entire length of the fiber such as distributed temperature sensing. In this embodiment, a pulse of laser light from the surface is sent along the fiber and portions of the light are backscattered to the surface due to the optical properties of the fiber. The slightly shifted frequency of the backscattered light provides information that is used to determine the temperature at the point in the fiber where the backscatter originated. In addition, as the speed of light is constant, the distance from the surface to the point where the backscatter originated can also be determined. In this manner, continuous monitoring of the backscattered light will provide temperature profile information for the entire length of the fiber.
Disposed in wellbore 38 at the lower end of production tubing string 36 are a variety of tools including seal assembly 60 and anchor assembly 62 including downhole wet mate connector 64 . Extending uphole of connector 64 is a conduit 66 that extends to the surface in the annulus between production tubing string 36 and wellbore 38 and is suitable coupled to production tubing string 36 to prevent damage to conduit 66 during installation. Similar to conduit 58 , conduit 66 may have one or more communication media, such as optical fibers, electrical conducts, hydraulic fluid or the like disposed therein. Preferable, conduit 58 and conduit 66 will have the same type of communication media disposed therein such that energy may be transmitted therebetween following the connection process. As discussed in greater detail below, prior to producing fluids, such as hydrocarbon fluids, from formation 14 , production tubing string 36 and completion 42 are connected together. When properly connected to each other, a sealed communication path is created between seal assembly 60 and seal bore assembly 46 which establishes a sealed internal flow passage from completion 42 to production tubing string 36 , thereby providing a fluid conduit to the surface for production fluids. In addition, as discussed in greater detail below, the present invention enables the communication media associated with conduit 66 to be operatively connected to the communication media associated with conduit 58 , thereby enabling communication therebetween and, in the case of optical fiber communication media, enabling distributed temperature information to be obtained along completion 42 during the subsequent production operations.
Even though FIG. 1 depicts a slanted wellbore, it should be understood by those skilled in the art that the apparatus for controlling the connection speed of downhole connectors according to the present invention is equally well suited for use in wellbore having other orientations including vertical wellbores, horizontal wellbores, multilateral wellbores or the like. Accordingly, it should be understood by those skilled in the art that the use of directional terms such as above, below, upper, lower, upward, downward and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure. Also, even though FIG. 1 depicts an offshore operation, it should be understood by those skilled in the art that the apparatus for controlling the connection speed of downhole connectors according to the present invention is equally well suited for use in onshore operations. Further, even though FIG. 1 depicts an open hole completion, it should be understood by those skilled in the art that the apparatus for controlling the connection speed of downhole connectors according to the present invention is equally well suited for use in cased hole completions.
Referring now to FIGS. 2 and 3 , including FIGS. 2A-2D and FIGS. 3A-3D , therein is depicted successive axial section of an apparatus for controlling the connection speed of downhole connectors that is generally designated 100 . It is noted that FIGS. 2A-2D and FIGS. 3A-3D as well as FIGS. 4A-4D and 5 A- 5 D below are described with reference to optical fibers as the communication media. As discussed above, those skilled in the art will recognize that the present invention is not limited to this illustrated embodiment but instead encompasses other communication media including, but not limited to, electrical conductors and hydraulic fluid. Also, as described above, apparatus 100 is formed from certain components that are initially installed downhole as part of completion 42 and certain components that are carried on the lower end of production tubing string 36 . As illustrated in FIG. 2 , some the components carried on the lower end of production tubing string 36 have come in contact with certain components of completion 42 prior to connecting the respective wet mate connectors together. The entire apparatus 100 will now be described from its uphole end to its downhole end, first describing the exterior parts of the components carried on the lower end of production tubing string 36 , followed by the interior parts of the components carried on the lower end of production tubing string 36 then describing the components previously installed downhole as part of completion 42 .
Apparatus 100 includes a substantially tubular axially extending upper connector 102 that is operable to be coupled to the lower end of production tubing string 36 by threading or other suitable means. At its lower end, upper connector 102 is threadedly and sealingly connected to the upper end of a substantially tubular axially extending hone bore 104 . Hone bore 104 includes a plurality of lateral opening 106 having plugs 108 disposed therein. At its lower end, hone bore 104 is securably connected to the upper end of a substantially tubular axially extending connector member 110 . At its lower end, connector member 110 is securably connected to the upper end of an axially extending collet assembly 112 . Collet assembly 112 includes a plurality of circumferentially disposed anchor collets 114 , each having an upper surface 116 . In addition, collet assembly 112 includes a plurality of circumferentially disposed unlocking collets 118 . Further, collet assembly 112 includes a plurality of radially inwardly extending protrusions 120 and profiles 122 . At its lower end, collet assembly 112 is threadedly coupled to the upper end of a substantially tubular axially extending key retainer 124 . A portion of collet assembly 112 and key retainer 124 are both slidably disposed about the upper end of a substantially tubular axially extending key mandrel 126 . Key mandrel 126 includes a key window 128 into which a spring key 130 is received.
At its lower end, key mandrel 126 is threadedly coupled to the upper end of a substantially tubular axially extending spring housing 132 . Disposed within spring housing 132 is an axially extending spiral wound compression spring 134 . At its lower end, spring housing 132 is slidably disposed about the upper end of a substantially tubular axially extending connector member 136 . At its lower end, connector member 136 is threadedly coupled to the upper end of a substantially tubular axially extending splitter 138 . Splitter 138 includes an orientation key 140 disposed about a circumferential portion of splitter 138 . At its lower end, splitter 138 is coupled to the upper end of a substantially tubular axially extending fiber optic wet mate head 142 by threading, bolting or other suitable technique. Fiber optic wet mate head 142 includes a plurality of guide members 144 . In the illustrated embodiment, fiber optic wet mate head 142 has three fiber optic wet mate connectors 146 disposed therein. Each of the fiber optic wet mate connectors 146 has an optical fiber disposed therein. As illustrated, the three optical fibers associated with fiber optic wet mate connectors 146 passed through splitter 138 and are housed within a single conduit 148 that wraps around connector member 136 and extends uphole along the exterior of apparatus 100 . Conduit 148 is secured to apparatus 100 by banding or other suitable technique.
In the previous section, the exterior components of the portion of apparatus 100 carried by production tubing string 36 were described. In this section, the interior components of the portion of apparatus 100 carried by production tubing string 36 will be described. At its upper end, apparatus 100 includes a substantially tubular axially extending piston mandrel 200 that is slidably and sealingly received within upper connector 102 . Disposed between piston mandrel 200 and hone bore 104 is an annular oil chamber 202 including upper section 204 and lower section 206 . Securably attached to piston mandrel 200 and sealing positioned within annular oil chamber 202 is a transfer piston 208 . Transfer piston 208 includes one or more passageways 210 therethrough which preferably include orifices that regulate the rate at which a transfer fluid such as a liquid or gas and preferably an oil disposed within annular oil chamber 202 may travel therethrough. Preferably, a check valve may be disposed within each passageway 210 to allow the flow of oil to proceed in only one direction through that passageway 210 . In this embodiment, certain of the check valves will allow fluid flow in the uphole direction while other of the check valves will allow fluid flow in the downhole direction. In this manner, the resistance to flow in the downhole direction can be different from the resistance to flow in the uphole direction which respectively determines the speed of coupling and decoupling of the downhole connectors of apparatus 100 . For example, it may be desirable to couple the downhole connectors at a speed that is slower than the speed at which the downhole connectors are decoupled.
Disposed within annular oil chamber 202 is a compensation piston 212 that has a sealing relationship with both the inner surface of hone bore 104 and the outer surface of piston mandrel 200 . At its lower end, piston mandrel 200 is threadedly and sealingly coupled to the upper end of a substantially tubular axially extending key block 214 . Key block 214 has a radially reduced profile 216 into which spring mounted locking keys 218 are positioned. Locking keys 218 include a profile 220 . At its lower end, key block 214 is threadedly and sealingly coupled to the upper end of a substantially tubular axially extending bottom mandrel 222 . Bottom mandrel 222 includes a groove 224 . A pickup ring 226 is positioned around bottom mandrel 222 . Positioned near the lower end of bottom mandrel 222 is a key carrier 228 that has a no go surface 230 . Disposed within key carrier 228 is a spring mounted locking key 232 . Positioned between key carrier 228 and bottom mandrel 222 is a torque key 234 . At its lower end, bottom mandrel 222 is threadedly and sealingly coupled to the upper end of a substantially tubular axially extending seal adaptor 236 . At its lower end, seal adaptor 236 is threadedly and sealingly coupled to the upper end of one or more substantially tubular axially extending seal assemblies (not pictured) that establish a sealing relationship with an interior surface of completion 42 .
In the previous two sections, the components of apparatus 100 carried by production tubing string 36 were described. Collectively, these components may be referred to as an anchor or anchoring assembly. In this section, the components of apparatus 100 installed with completion 42 will be described. Apparatus 100 includes an orientation and alignment subassembly 300 that includes a locating and orienting guide 302 that is illustrated in FIG. 3 but has been removed from FIG. 2 for clarity of illustration. Locating and orienting guide 302 includes a locking profile 304 , a groove 306 and a plurality of fluid passageways 308 . In addition, locating and orienting guide 302 includes a receiving slot 310 . Disposed within locating and orienting guide 302 , orientation and alignment subassembly 300 includes a top subassembly 312 that supports a fiber optic wet mate holder 314 . In the illustrated embodiment, disposed within wet mate holder 314 are three wet mate connectors 316 . At its upper end, wet mate holder 314 includes a plurality of guides 318 . Positioned between top subassembly 312 and locating and orienting guide 302 is a key 320 . At its lower end, top subassembly 312 is threadedly and sealingly coupled to the upper end of a substantially tubular axially extending splitter 322 . At its lower end, splitter 322 is coupled to the upper end of one or more substantially tubular axially extending packers 324 by threading, bolting, fastening or other suitable technique. Each of the fiber optic wet mate connectors 316 has an optical fiber disposed therein. As illustrated, the three optical fibers associated with fiber optic wet mate holder 314 pass through splitter 322 and are housed within a single conduit 326 that extends through packer 324 and is wrapped around sand control screens 48 , 50 , 52 , 54 as described above to obtain distributed temperature information, for example.
The operation of the apparatus for controlling the connection speed of downhole connectors according to the present invention will now be described. After the installation of completion 42 in the wellbore and the performance of any associated treatment processes wherein the optical fibers associated with completion 42 and companion optical fibers associated with the service tool string may deliver information to the surface, the service tool string is retrieved to the surface. In this process, the optical fibers associated with completion 42 and the optical fibers associated with the service tool string must be decoupled. In order to reuse the optical fibers associated with completion 42 during production, new optical fibers must be carried with production tubing string 36 and optically coupled to the optical fibers associated with completion 42 .
In the present invention, conduit 148 is attached to the exterior of production tubing string 36 and extends from the surface to the anchor assembly. One or more optical fibers are disposed within conduit 148 which may be a conventional hydraulic line formed from stainless steel or similar material. The anchor assembly is lowered into the wellbore until the seal assemblies on its lower end enter completion 42 . As production tubing string 36 is further lowered into the wellbore, orientation key 140 contacts the inclined surfaces of locating and orientating guide 302 . This interaction rotates the anchor assembly until orientation key 140 locates within slot 310 which provides a relatively coarse circumferential alignment of fiber optic wet mate head 142 with fiber optic wet mate holder 314 . The anchor assembly now continues to travel downwardly in completion 42 until no go surface 230 of key carrier 228 contacts an upwardly facing shoulder 328 of top subassembly 312 . Prior to contact between no go surface 230 and upwardly facing shoulder 328 , guides 144 of fiber optic wet mate head 142 and guides 318 of fiber optic wet mate holder 314 interact to provide more precise circumferential and axially alignment of the assemblies.
Once no go surface 230 contacts upwardly facing shoulder 328 , further downward motion of the inner components of the anchor assembly stops. In this configuration, as best seen in FIGS. 2A-2D and 3 A- 3 D, unlocking collets 118 are radially inwardly shifted due to contact with the inner surface of locating and orienting guide 302 . This radially inward shifting causes the inner surfaces of unlocking collets 118 to contact unlocking keys 218 and compress the associated springs causing unlocking keys 218 to radially inwardly retract. In the retraced position, radially inwardly extending protrusions 120 are released from profile 220 , thereby decoupling the outer portions of the anchor assembly from the inner portions of the anchor assembly. Relative axially movement of the outer portions of the anchor assembly and the inner portions of the anchor assembly is now permitted.
As continued downward force is placed on the anchor assembly by applying force to the production tubing string 36 , upper connector 102 is urged downwardly relative to piston mandrel 200 . The movement of upper connector 102 relative to piston mandrel 200 is resisted, however, by a resistance member. In the illustrated embodiment, the resistance member is depicted as transfer piston 208 and the fluid within annular oil chamber 202 . Specifically, the speed at which upper connector 102 can move relative to piston mandrel 200 is determined by the size of the orifice within passageway 210 of transfer piston 208 as well as the type of fluid, including liquids, gases or combinations thereof, within annular oil chamber 202 . As the downward force is applied to upper connector 102 , the fluid from upper section 204 of annular oil chamber 202 transfers to lower section 206 of annular oil chamber 202 passing through passageway 210 . In this manner, excessive connection speed of fiber optic wet mate connectors 146 and fiber optic wet mate connectors 316 is prevented. Even though the resistance member has been described as transfer piston 208 and the fluid within annular oil chamber 202 , it should be understood by those skilled in the art that other types of resistance members could alternatively be used and are considered within the scope of the present invention, including, but not limited to, mechanical springs, fluid springs, fluid dampeners, shock absorbers and the like.
As best seen in FIGS. 4A-4D and 5 A- 5 D, continued downward force on upper connector 102 not only enables connection of fiber optic wet mate connectors 146 and fiber optic wet mate connectors 316 , but also, compresses the outer components of the anchor assembly and locks the anchor assembly within completion 42 . Once the connection between fiber optic wet mate connectors 146 and fiber optic wet mate connectors 316 is established, thereby permitting light transmission between the optical fibers therein, continued downward force on upper connector 102 compresses spring 134 . As spring 134 is compressed, spring housing 132 telescopes relative to connector member 136 . This shortening of the outer components of the anchor assembly allows spring key 130 to engage groove 224 of bottom mandrel 222 . Once spring key 130 has radially inwardly retracted, the outer components of the anchor assembly further collapse as collet assembly 112 and key retainer 124 telescope relative to key mandrel 126 . This shortening allows anchor collets 114 to engage locking profile 304 which couples the anchor assembly within completion 42 . Also, this shortening allows unlocking collets 118 to engage groove 306 which relaxes unlocking collets 118 . In addition, the inner portions of the anchor assembly are independently secured within completion 42 as extension 150 on the lower end of fiber optic wet mate head 142 is positioned under locking key 232 such that locking key 232 engages profile 330 of top subassembly 312 .
In this configuration, not only are fiber optic wet mate connectors 146 and fiber optic wet mate connectors 316 coupled together, there is a biasing force created by compressed spring 134 that assures the connections will not be lost. Specifically, compressed spring 134 downwardly biases connector member 136 which in turn applies a downward force on splitter 138 and fiber optic wet mate head 142 . This force prevents any decoupling of fiber optic wet mate connectors 146 and fiber optic wet mate connectors 316 . In addition, the interaction of surface 116 of anchor collets 114 with locking profile 304 of locating and orienting guide 302 prevents separation of the anchoring assembly and the completion 42 . If it is desired to detach production tubing string 36 from completion 42 , a significant tensile force must be applied to production tubing string 36 at the surface, for example, 20,000 lbs. This force is transmitted via upper connector 102 , hone bore 104 and connector member 110 to collet assembly 112 . When sufficient tensile force is provided, anchor collets 114 will release from locking profile 304 . Thereafter, the outer portions of anchor assembly that were telescopically contracted can be telescopically extended including the release of energy from spring 134 . In order to separate fiber optic wet mate connectors 146 and fiber optic wet mate connectors 316 , the outer portions of the anchor assembly must be shifted relative to the inner portions of the anchor assembly. The rate of the axial shifting is again controlled by the metering rate of fluid through transfer piston 212 . After the outer portions of the anchor assembly have been shifted relative to the inner portions of the anchor assembly, extension 150 no longer supports locking key 232 in profile 330 . As this point the entire anchor assembly may be retrieved to the surface.
While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.
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An apparatus ( 100 ) for controlling the connection speed of downhole connectors ( 316, 146 ) in a subterranean well. The apparatus ( 100 ) includes a first assembly that is positionable in the well. The first assembly includes a first downhole connector ( 316 ) and a first communication medium. A second assembly includes a second downhole connector ( 146 ) and a second communication medium. The second assembly has an outer portion and an inner portion. The outer portion is selectively axially shiftable relative to an inner portion, such that upon engagement of the first assembly with the second assembly, the outer portion of the second assembly is axially shifted relative to the inner portion of the second assembly allowing the first and second downhole connectors ( 316, 146 ) to be operatively connected to each other, thereby enabling communication between the first communication medium and the second communication medium.
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BACKGROUND OF THE INVENTION
The invention relates generally to a process for improving the electrical characteristics of semiconductor devices which employ silicon nitride and/or silicon oxynitride layers.
A typical fabrication sequence of the silicon nitride (or oxynitride) gate dielectric involves: (1) cleaning of Si wafer; (2) forming silicon nitride (or oxynitride) on Si wafer; (3) performing a post-deposition high-temperature anneal in nitrogen or oxygen and typically at temperatures >800° C.; (4) depositing a gate electrode; and (5) performing a post-gate electrode anneal in nitrogen or forming gas, typically between 400° C. and 500° C. A variety of dielectric deposition methods have been used in the past, including APCVD, LPCVD, PECVD, and JVD.
In addition to deposition, the silicon oxynitride mentioned above may be formed by nitridizing a thermal oxide layer at an elevated temperature in N 2 O or NH 3 ambient, or by directly oxidizing Si in an N 2 O ambient, or by reoxidizing a silicon nitride or oxynitride film, etc.
Relative to silicon dioxide, silicon nitride or silicon oxynitride possesses a number of attractive features as a gate dielectric for Field Effect Transistors (FET's), including (1) higher dielectric constant, (2) better barrier against impurity diffusion, and (3) better resistance to radiation damage and hot-carrier damage. Unfortunately, the electrical properties of the silicon/nitride interface are very poor due to the presence of very high densities of interface traps and bulk traps. Therefore, numerous attempts have been made by various research groups over the past 3 decades to improve the electrical properties of the silicon nitride layer and thereby produce FET's which out-perform conventional MOSFET's using silicon dioxide as the gate dielectric. However, none of these efforts has been truly successful.
SUMMARY OF THE INVENTION
In one aspect, the invention involves inserting a new process step in the fabrication of Metal-Insulator-Semiconductor Devices (MIS's) that contain silicon nitride or silicon oxynitride in their gate dielectrics, where the silicon oxynitride may contain as little as a fraction of a percent of nitrogen. For brevity, such devices will be called MNS devices in this document. This new process dramatically improves the performance of a variety of MNS devices.
The new process step is: (1) a water-vapor annealing treatment after the formation of the gate dielectric (i.e., after step 3 above); or (2) a water-vapor annealing treatment which replaces the conventional post-gate electrode annealing treatment (i.e., step 5 above); or (3) a water-vapor annealing treatment after subsequent metalization steps, or (4) a combination of the above. The water-vapor anneal may be performed at a temperature in the range of about 270-500° C. for 30 min. (approx.). The results of performing such a water-vapor anneal are remarkable. It greatly reduces the density of interface traps and it greatly enhances channel mobility in MNS devices, to the point that MNS devices should be commercially viable.
In general, in one aspect, the invention is a method of fabricating semiconductor devices including the steps of forming a silicon-based dielectric layer containing nitrogen having a concentration that is in a range of a fraction of a percent up to stoichiometric Si 3 N 4 ; and annealing the dielectric layer in a water vapor atmosphere.
Preferred embodiments have the following features. The method further includes the step of forming a gate-electrode on the dielectric layer. The water vapor anneal step is performed after forming the gate-electrode. alternatively, the water vapor anneal step is performed before forming the gate-electrode. The dielectric layer is made of silicon nitride, or silicon oxynitride, or a nitrided silicon oxide, or a nitrodized silicon oxide. The water vapor anneal step is performed at a temperature which is in the range of about 270° C. to 500° C.
In general, in another aspect, the invention is a semiconductor device fabricated in accordance with the above-described procedure (i.e., using a WVA step).
In general, in yet another aspect, the invention is a method of fabricating semiconductor devices including the steps of forming a dielectric layer made of a material that is selected from a group of materials consisting of silicon nitride, silicon oxynitride, nitrided oxide, and nitrodized oxide; annealing the dielectric layer in a water vapor atmosphere.
In general, in still another aspect, the invention is a method of improving electrical characteristics of a metal-insulator-semiconductor (MIS) device in which the insulating layer comprises a dielectric selected from the group of materials consisting of silicon nitride, silicon oxynitride, nitrided oxide, and nitrodized oxide. The method includes the step of annealing the device in a water vapor atmosphere.
The use of water vapor at a modest annealing temperature in the nitride fabrication process "passivates" the nitride/Si (or oxynitride/Si) interface. The advantage over the present technology is that it enables high-quality MOSFET's to be fabricated. The invention can be used in the fabrication of all semiconductor devices and IC's containing a silicon nitride or nitrided silicon oxide layer where the electrical properties of that layer and its interfaces are of concern. For example, it can be used to improve the performance and characteristics of: (1) gate dielectrics of FET's used in microprocessors, DRAMs, SRAMs, Flash Memories, and EEPROMs, just to name a few; (2) dielectrics for storage capacitors in DRAMs; (3) inter-poly dielectrics; and (4) thin-film transistors (used in SRAMs and flat panel display technologies, for example.)
Other advantages and features will become apparent from the following description of the preferred embodiment and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a representative fabrication sequence that been modified in accordance with the invention;
FIG. 2 is a plot of the quasi-static capacitance versus gate voltage for two MNS capacitors, one fabricated using the water-vapor anneal step (B) and the other fabricated without benefit of a water-vapor anneal step (A);
FIG. 3 shows a plot of capacitance versus gate voltage for the capacitor of curve B in FIG. 2 after it has had a further water-vapor anneal step performed as a post-gate electrode-anneal;
FIG. 4 is a plot of leakage current for two devices, one fabricated using the water-vapor anneal and the other fabricated without it;
FIG. 5 is a plot of the transconductance (Gm) of: (1) a control MOSFET (dashed curve); (2) a MOSFET with N 2 O oxynitride without WVA treatment (lower solid); and (3) MOSFET with N 2 O oxynitride with WVA treatment (upper solid);
FIG. 6 is a plot of the peak transconductance versus channel length for two sets of MOSFET's with an N 2 O annealed gate oxide, one of which benefitted from the WVA and the other of which did not; and
FIG. 7 are plots of charge pumping current versus gate voltage for: (I) a MOSFET having an N 2 O oxynitride as gate dielectric with no WVA treatment; (II) same device with WVA; (III) control device with oxide as gate dielectric.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
I have discovered that performing a water-vapor anneal on silicon nitride or silicon oxynitride layers substantially improves the quality of the devices. Experiments have been conducted which dramatically showed the benefits of adding such an anneal to the fabrication procedure.
For some of the experiments that are reported herein, we started with (100) oriented Si wafers which had a resistivity of about a few ohm-cm. We processed these substrates to fabricate metal-nitride-silicon capacitors using standard fabrication procedures. First, we performed a standard cleaning procedure to produce very clean bare silicon wafers with no native oxide on its surfaces (step 100). These wafers were then loaded into a silicon nitride deposition chamber. We deposited a silicon nitride film on the silicon substrate (step 102). The layers that were deposited were about 80-90 Å which is electrically equivalent to a SiO 2 layer of about 40-45 Å. After deposition, we transferred the wafer from the nitride deposition chamber to a furnace for post-deposition annealing at 800° C. for 30 minutes in a dry N 2 ambient (step 104).
We followed the post-deposition anneal with an aluminum evaporation and then used standard photolithography procedures to form the gate electrodes (i.e., the top electrodes) of the MNS capacitors (step 106). Then, we performed another aluminum evaporation on the backside of the wafers, thereby forming the other electrode of the MNS capacitors. Finally, we performed a post-electrode anneal in N 2 or forming gas (step 108).
Typically, the process might further include a phase during which metalizations and interconnects are formed for the devices (step 110) and then the chip is passivated by applying a passivation layer (e.g. SiN) (step 112).
Note that the procedure just described also generally describes the formation of devices which utilize an oxynitride layer for the dielectric, except that instead of using deposition equipment to form a SiN layer other fabrication equipment is used to form the dielectric layer. This is illustrated by the alternative path through box labeled 114.
In this general process, we inserted a water vapor anneal (WVA) step. We found that the WVA step can be inserted either before or after the electrode formation steps. The alternative locations for the WVA step are represented in FIG. 1 by the dashed boxes. Regardless of where the WVA step was inserted, it dramatically improved device performance.
We performed the WVA step in a standard steam oxidation furnace such as is typically found in many wafer fabrication facilities. The furnace tube which was at 380° C. and the total WVA anneal time was about 30 minutes. During the WVA anneal, we supplied water vapor to one end of the tube simply by using an infra-red lamp to heat up a tank of deionized (DI) water that was connected to the tube. The heated DI water evaporated and flowed through the tube and over the devices that were being annealed.
We fabricated two sets of MNS capacitors, one set made by using a post-deposition WVA and the other set made without any WVA. In both sets, the dielectric (i.e., the silicon nitride layer) had an equivalent oxide thickness of about 5.3 nm (nanometers). We compared the electrical characteristics of devices from both sets. For example, we measured quasi-static capacitance versus gate voltage for devices from each set (see the curves shown in FIG. 2). Curve A represents the performance of a device which was made without using a post-deposition WVA and Curve B represents the performance of a device that was made with a post-deposition WVA. As can be seen, there is a marked reduction in quasi-static capacitance for the device that benefitted from the WVA.
Referring to FIG. 3, the capacitor represented by curve B in FIG. 2 then received a WVA treatment again as a post-metal anneal and the high frequency and quasi-static capacitance versus voltage (C-V) curves were measured for this device. As can be seen, the high frequency C-V (HFCV) and the quasi-static CV curves perfectly match over much of the accumulation and depletion regions. This indicates a very low density of interface states. In addition, the measured flatband voltage of HFCV also indicated a low density of dielectric charge.
We also measured the impact of a WVA on leakage current in devices that had 2 mil diameter electrodes and an effective oxide thickness of about 47 Å. These results are shown in the I G versus V G curves of FIG. 4. The curve on the left is I G -V G before WVA and the curve on the right is after WVA. Again, a post-deposition WVA treatment significantly reduces leakage current.
We also evaluated the impact of the WVA on the electrical performance of MOSFET's that were fabricated and supplied by a third party. These MOSFET's had an N 2 O oxynitride layer as the gate dielectric. The oxynitride films were formed by either annealing a previously formed SiO 2 layer in an N 2 O ambient or by oxidizing Si directly in an N 2 O ambient. Their thicknesses were approximately 80 Å, and they contain small amounts of nitrogen, ranging from a fraction of a percent to a few percent. FIG. 5 shows the how much transconductance (Gm) improves when the WVA is used. The lower solid curve shows the performance of the MOSFET without using a WVA and the upper solid curve shows the performance of the MOSFET after using a WVA. The dashed line represents data from a control sample, which used a thermal oxide as a gate dielectric rather than a N 2 O oxynitride. As can be seen, the G m values of the WVA treated device are far superior to those of the untreated device. In fact, the peak G m value of WVA treated device is as good as that of the control sample and in the high field range, the G m values are much superior even to that of the control sample.
Referring to FIG. 6, a plot of the peak transconductance versus channel length also shows a similar consistent and substantial improvement from the WVA. The upper curve is for devices that benefitted from the WVA and the lower curve is for devices that did not use the WVA. In general, the WVA produces about a 10-20% increase in peak transconductance.
We measured charge pumping current of the various devices and found that the WVA produced a drastic decrease in charge pumping current. This is strong evidence that the improvement that we have seen in the other measurements is due to a reduction in interface trap density and oxide charge. FIG. 7 shows three curves of charge pumping current versus gate voltage. The top curve is for a N 2 O oxynitride MOSFET device which was not given a WVA treatment; the bottom curve is for the same device after it was given a WVA treatment; and for comparison purposes, the middle curve is for a MOSFET that used a thermal oxide (i.e., SiO 2 ) as the gate-dielectric.
We observed a positive effect over a temperature range of 270-500° C., with the best results occurring at about 380° C. We expect, however, that as further experiments are performed, we will see the beneficial effect of the WVA under other process conditions and at temperatures outside of this range.
The nitride or oxynitride may be formed by any number of ways, including chemical vapor deposition, physical vapor deposition, or by nitriding thermal SiO 2 (e.g. by introducing a fraction of a percent to a few percent of nitrogen into SiO 2 by annealing SiO 2 in N 2 O or NH 3 ambient at high temperatures). It is not intended that the invention be limited in any way with regard to how the SiN or silicon oxynitride layer is formed.
The WVA step has been inserted at various locations into the fabrication process, all producing positive results. The following illustrates the variety of ways in which the WVA step was inserted into the fabrication procedure:
(1) nitride (or oxynitride) formation+WVA+high-temperature (e.g. ˜800° C.) N 2 anneal+gate electrode deposition+post-gate electrode annealing @400° C.
(2) nitride (or oxynitride) formation+high-temperature N 2 anneal+WVA+gate electrode deposition+post-gate electrode annealing
(3) nitride (or oxynitride) formation+high-temperature N 2 anneal+gate electrode deposition+WVA (to replace post-gate electrode annealing)
(4) nitride (or oxynitride) formation+high-temperature N 2 anneal+WVA+gate electrode deposition+WVA (to replace post-gate electrode annealing)
Though all of the above-described combinations produced positive results, the last one tended to produce the best results.
Though we have described specific process steps and structures for which our experiments were performed, the invention is not limited to such process steps or to such structures. For example, though we used metalizations to form the gate electrodes in our experiments, today such electrodes are more typically formed by polysilicon layers. The invention is not limited to any particular manner of forming the gate electrodes. In addition, it is apparent that the water vapor anneal can be used in any structure that includes a nitride layer, an oxynitride layer, a nitrodized oxide layer, or a nitrided oxide layer, the electrical properties of which are important to device performance. Also, it appears that the water vapor anneal step can be inserted at any location(s) in the process after the formation of the dielectric layer and positive results will be achieved. This is meant to be illustrated by the different alternative locations at which the WVA steps have been inserted in the general flow diagram of the fabrication process (see FIG. 1).
This technique can be applied to any device that incorporates a dielectric layer that is composed of silicon and nitrogen atoms, including amorphous and crystal SiN and silicon oxynitride. There are many ways known in the art for forming such layers. For example, one might first grow a silicon oxide layer and then nitrodize the layer so as to introduce nitrogen into it (usually in amounts equal to only a few percent). Various techniques are known for nitriding the layer including using N 2 O, NO or NH 3 ambients. Alternatively, one might form a SiN layer (e.g. by a CVD process) and then reoxidize that layer by exposing it to an oxygen or oxygen containing ambient. Clearly the composition of these layers varies widely depending of course on the particular method of fabricating the layer. In general, among other things, the nitrogen serves a similar function including, for example, forming a barrier for the out diffusion of dopant from the underlying material. The invention can be applied to all of these structures with similar results.
Other embodiments are within the following claims.
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A method of fabricating semiconductor devices including the steps of forming a silicon-based dielectric layer containing nitrogen having a concentration that is in a range of a fraction of a percent up to stoichiometric Si 3 N 4 ; and annealing the dielectric layer in a water vapor atmosphere.
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FIELD OF THE INVENTION
[0001] This invention relates, generally, to portable table or countertop beverage dispensers. More particularly, it relates to beverage dispensers used for both display and dispensing of either cooled or heated beverages.
DESCRIPTION OF THE PRIOR ART
[0002] Many alcoholic and other beverages are cooled prior to consumption to enhance flavor. Many beverages are also best served warm or hot. The consumer, however, seldom sees the device that does the cooling or heating. With cold drinks, for example, the consumer might observe the beverage being removed from a refrigerator, or ice may be added to the drink to the detriment of the flavor. When sake is served, it is poured from a heated bottle but the consumer does not see the heating process In most cases, the consumer is unaware of the cooling or warming means because such means is not on display. The cooling or heating means is not on display because it is completely utilitarian and lacks aesthetic appeal.
[0003] If consumers were treated with an aesthetically-pleasing display of the cooling or heating means, it would increase consumption of the beverage. If the cooling or heating means were exceptionally pleasing to the eye, it would become a topic of conversation itself and attract more business.
[0004] Another drawback of prior art cooling or heating devices is that most of them lack temperature control means. If a beverage is cooled in a refrigerator or other cooling means, it is quite difficult to exercise complete control over the serving temperature thereof. Similarly, a beverage heated in a microwave or other heating means will eventually warm to a selected temperature but there is no carefully controlled means for exercising temperature control.
[0005] Accordingly, there is a need for an aesthetically-pleasing beverage dispenser for cooled and warmed drinks.
[0006] There is also a need for an aesthetically-pleasing beverage dispenser that includes a cooling means with a control means that enables a cooled beverage to be served at a precisely-controlled temperature.
[0007] An equal need is extant for an aesthetically-pleasing beverage dispenser that includes a heating means with a control means that enables a heated beverage to be served at a precisely-controlled temperature.
[0008] Piesch, in U.S. Pat. No. 93,001 entitled “Pitcher,” discloses a device that keeps the contents of a pitcher cool by providing an ice chamber in which chunks of ice are maintained. Although the device is functional, much of the interior of the pitcher is dedicated to the ice so the remaining volume dedicated to the beverage is substantially reduced.
[0009] U.S. Pat. No. 1,771,186 to Mock discloses a serving element having double walls to provide insulation against heat transfer. The space between the walls is partially filled with water. The serving element is placed upside down in a freezer and the water turns to ice.
[0010] U.S. Pat. No. 4,624,395 to Baron discloses a method of pre-heating stored water with a thermoelectric heat pump, followed by mixing the heated water with a concentrate of condensed coffee bean mixture, thereby creating coffee. It thus differs from conventional coffee makers that mix hot water and coffee grounds during the dispensing process. The Baron device is large and not portable; it therefore is unsuitable for use as a table or countertop unit.
[0011] A beverage cooling device is disclosed in U.S. Pat. No. 6,370,884 to Kelada. The device cools water by thermoelectric cooling but may not be suitable for cooling beverages other than water. It is unsuitable for use in a table or countertop environment due to its large footprint.
[0012] None of the prior art dispensers have aesthetic appeal.
[0013] In view of the prior art taken as a whole at the time the present invention was made, it was not obvious to those of ordinary skill in the art how a beverage dispenser for cooled drinks with a temperature control means and a beverage dispenser for warmed drinks with a temperature control means could be provided with a size suitable for table or counter top display and with an aesthetically-pleasing, conversation-generating appearance.
SUMMARY OF THE INVENTION
[0014] The long-standing but heretofore unfulfilled need for an apparatus and method for cooling and heating beverages with an aesthetically-appealing display device is now met by a new, useful, and non-obvious invention.
[0015] The inventive structure includes a self-contained, aesthetically-pleasing beverage display device capable of cooling or heating and dispensing any beverage that is properly positioned within the display dispensing device.
[0016] The novel device divides the aesthetically-pleasing display function from the utilitarian cooling, heating, and dispensing functions. In other words, the novel display in a cooled beverage mode displays a bottle of a beverage that is served cool or cold in an aesthetically-pleasing display that carries with it the idea of cold. For example, the bottle may be mounted on what appears to be an iceberg. The bottle is displayed upright, not inverted. When a conventional tap is operated to dispense the beverage, the bottle on display is unaffected because no liquid is dispensed from it. Instead, the cooled beverage is dispensed from a substantially concealed inverted bottle of the same beverage.
[0017] Similarly, the novel display in a warmed beverage mode displays a bottle of a beverage that is served warm or hot in an aesthetically-pleasing display that carries with it the idea of heat. For example, the bottle may be mounted on what appears to be a volcano. The bottle is displayed upright, not inverted. When a conventional tap is operated to dispense the beverage, the bottle on display is unaffected because no liquid is dispensed from it. Instead, the heated beverage is dispensed from a substantially concealed inverted bottle of the same beverage.
[0018] In both cooling and heating modes, the utilitarian cooling and heating means and the temperature control means associated therewith are not visible to the consumer. However, the aesthetically-pleasing display informs the consumer that the beverage dispensed therefrom is either cooled or heated.
[0019] The aesthetically-pleasing effects, in addition to providing the appearance of an iceberg, a volcanic mountain, or other cold or hot symbols, may include LED (light-emitting diode) lighting, atomizer vaporized liquid misting effects, exterior aesthetic effects, and the like.
[0020] A primary object of the invention is to provide an aesthetically-pleasing dispenser for cooled or heated beverages.
[0021] Another object is to provide such a dispenser with a temperature control means so that beverages may be cooled or heated to a preselected temperature.
[0022] Another important object is to display a beverage intended for consumption at a low temperature in a setting that provides a connotation of cold and to display a beverage intended for consumption at an elevated temperature in a setting that provides a connotation of heat.
[0023] Still another object is to provide such dispenser in a portable structure suitable for use on a table or counter top.
[0024] Additional objects include the provision of a beverage dispenser that incorporates a gravity flow control valve dispensing tap spigot to eliminate spillage.
[0025] Still further objects include the provision of a beverage dispenser that includes attractive features such as LED lighting effects, atomizer vaporized fluid mist effects, and a display pedestal for highly effective product and or advertising display.
[0026] These and other important objects, advantages, and features of the invention will become clear as this description proceeds.
[0027] The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts that will be exemplified in the description set forth hereinafter and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:
[0029] FIG. 1A is a front perspective view of the preferred embodiment;
[0030] FIG. 1B is a front perspective view of the preferred embodiment when a display bottle is on display;
[0031] FIG. 2 is a side perspective view when both a display bottle and a dispensing bottle are in use; and
[0032] FIG. 3 is a rear elevational view when both a display bottle and a dispensing bottle are in use.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] Referring now to FIGS. 1A and 1B , it will there be seen that a preferred embodiment of the invention is denoted as a whole by the reference numeral 10 . FIG. 1A depicts novel device 10 when it is not in use, i.e., when it holds no display bottle and no dispensing bottle. FIG. 1B depicts novel device 10 when holding display bottle 12 .
[0034] The novel structure includes base pedestal tray 14 and frusto-conical main body 16 that is supported by said base pedestal tray. Main body 16 is wider at its base than at its top as illustrated so that novel device 10 is highly stable and not easily knocked over even if bumped hard.
[0035] A first vertically-extending opening 18 is formed in main body 10 . Said opening 18 has a diameter slightly greater than an external diameter of display bottle 12 . As best understood by comparing FIGS. 1A and 1B , display bottle 12 is slideably received within opening 18 when novel device 10 is in use. The label of display bottle 12 should face forwardly for aesthetics and so that the contents of the bottle are known.
[0036] As depicted in FIG. 2 , a second vertically-extending opening 20 is also formed in main body 16 , preferably directly behind first vertically-extending opening 18 . Second opening 20 has a diameter slightly greater than an external diameter of dispensing bottle 22 . Display bottle 12 and dispensing bottle 22 should contain the same liquid fluid contents because display bottle 12 represents to consumers that its contents will be dispensed when device 10 is operated even though nothing is dispensed from display bottle 12 .
[0037] Note from the front elevational view of FIG. 1B that display bottle 12 conceals dispensing bottle 22 in a frontal view of said device. Note from the side elevational view of FIG. 2 and the rear elevational view of FIG. 3 that only a small part of dispensing bottle 22 is visible when device 10 is viewed from the side or rear.
[0038] As best understood in connection with FIG. 2 , dispensing bottle 22 is prepared for use by removing its conventional cap or stopper and replacing said conventional cap or stopper with novel bottle stopper 24 having an air valve formed therein. Conventional cap 12 a remains on display bottle 12 at all times.
[0039] Novel bottle stopper 24 is adapted to fit snugly within cavity 26 formed within bottle stopper reception unit 28 .
[0040] Bottle stopper reception unit 28 is supported by bottom wall 30 of thermo conductive cooling/heating chamber 32 and chamber 32 is supported by thermoelectric cooling/heating means 34 . Heat transfer from cooling/heating means 34 to cooling/heating chamber 32 is by conduction.
[0041] Dispensing bottle 22 is preferably in physical contact with cooling/heating chamber 32 although direct physical contact is not required. Heat transfer from cooling/heating chamber 32 to dispensing bottle 22 and its contents may take place by all three (3) methods of heat transfer, i.e., conduction, radiation and convection, or any combination thereof.
[0042] Since bottles do not have a standard size, the diameter of cooling/heating chamber 32 is made a little larger than the diameter of the bottle having the largest diameter. Bottles to be cooled or warmed may then be placed in a flexible gel cooling sleeve or a flexible gel warming sleeve so that they fit snugly within cooling/heating chamber 32 . Heat transfer (whether cooling or heating) will then take place more efficiently.
[0043] When dispensing bottle 22 is in its operative, inverted configuration as depicted in FIG. 2 , the air valve in bottle stopper 24 is in fluid communication with the lumen of dispensing tube 36 . Dispensing tap securing cap 38 secures dispensing tap spigot 40 to main body 16 of device 10 . Manipulation of handle 40 a of dispensing tap spigot 40 in a well-known way brings a lumen formed within dispensing tap spigot 40 into fluid communication with the lumen of dispensing tube 36 and liquid fluid flows under the influence of gravity from dispensing bottle 22 through the air valve formed in bottle stopper 24 , through the lumen of dispensing tube 36 , and through the lumen within dispensing tap spigot 40 into a beverage glass. The flow of said liquid fluid is terminated in a well-known way by further manipulation of handle 40 a.
[0044] A plurality of LED lights, collectively denoted 42 , may be mounted about the periphery of base pedestal tray 14 as depicted in FIGS. 1A , 1 B, and 2 . Incandescent lights and other forms of lighting are also within the scope of this invention. The illumination provided by lights 42 is for aesthetic effect and various colors of lights may be selected. For example, white or blue lighting that illuminates frusto-conical main body 16 in white or blue is suitable if said main body is iceberg-shaped and display and dispensing bottles 12 and 22 are containers for beverages that are to be dispensed at a low temperature. Red or orange lights are more suitable when main body 16 is volcano-shaped. However any configuration of main body 16 and any color of lights consistent with the configuration is within the scope of this invention.
[0045] Display bottle 12 may also be individually illuminated by a plurality of lights, also collectively denoted 42 because they are preferably controlled by the same on/off switch as base pedestal lights 42 although separate circuits and switches are within the scope of this invention. Said lights are preferably positioned below display bottle support platform 44 in surrounding relation to said bottle, i.e., in circumferential relation to one another. Additional lights may be placed radially inwardly of the circumferentially spaced lights to more directly illuminate the interior of display bottle 12 . Display bottle support platform 44 is therefore formed of a transparent or translucent material.
[0046] Hollow cavity 46 is a cup-like liquid containing compartment formed in main body 16 just below display bottle support platform 44 . It holds liquid water and also accommodates display bottle lighting means 42 as depicted, said lighting means not being submerged in said liquid. It also provides a containment area for atomizer 48 that is submerged and that creates and emits a non-toxic vaporized fluid mist for aesthetic effect. The depicted atomizer has the appearance of a small hockey puck but it may be of any functional configuration. The coloring of the mist is determined by the color of lights 42 . Thus, a white or blue mist might envelop display bottle 12 if a cooled beverage is to be dispensed by novel device 10 and a yellow, red, or orange mist might envelop said bottle if a heated beverage is to be dispensed. Purple, black, and mists of other colors are also within the scope of this invention.
[0047] Power is preferably supplied to thermoelectric cooling/heating means 34 by AC or DC power cord 50 but the use of batteries, power packs or other power sources is also within the scope of this invention.
[0048] In a basic embodiment of the invention, no lights 42 are provided to the aesthetic detriment of the device but power is still required to operate cooling/heating means 34 .
[0049] This invention is not limited to cooling/heating means of the thermoelectric type. Any conventional cooling or heating means such as compressor refrigeration, heating elements, cooling or heating sleeves and the like may be used, for example. However, an important object of the invention is to employ a cooling or heating means whereby the final temperature is under the control of the user.
[0050] In an even more basic embodiment of novel device 10 , neither lights 42 nor cooling/heating means 34 are provided. Such embodiment would be suitable for long term display and dispensing of beverages to be served at room temperature and in such event a misleading iceberg or volcano-like design would not be used. Such an embodiment could also be used for display and dispensing of a cooled or heated beverage that is cooled or heated in a conventional way unconnected to novel device 10 and then placed in said device for relatively rapid consumption.
[0051] FIG. 3 depicts AC/DC power cord 50 , thermo hot/cold switch 52 , atomizer on/off switch 54 , LED lighting on/off switch 56 , and air circulation vents 60 . Thermo cold/hot switch 52 also includes a neutral position where no power is delivered to the temperature control means 34 . This enables the display and dispensing of a beverage that is neither cooled nor heated, i.e., served at room temperature. In a very basic embodiment of the invention, no temperature control means is provided and thus no switch 52 for controlling such nonexistent temperature control means is provided. However, a preferred embodiment includes thermoelectric temperature control means 34 and switch 52 having three (3) positions for cooling, heating, or neutral.
[0052] Dispenser 10 may be formed of plastic, glass, metal, wood, or any other suitable material.
[0053] To use dispenser 10 , an operator fills the reservoir of atomizer 48 with water or other non-toxic liquid fluid to the recommended capacity. The operator then plugs in the device. Next, the cap or stopper is removed from dispensing bottle 22 and said cap or stopper is replaced by novel bottle stopper 24 having air valve formed therein. Dispensing bottle 22 is then inverted and inserted quickly but smoothly into bottle stopper reception unit 28 which is located within thermo conductive cooling/heating chamber 32 .
[0054] The operator waits until thermoelectric cooling and or heating device 34 cools or heats inverted dispensing bottle 22 and its contents.
[0055] The operator positions a filled or empty display bottle 12 within vertically-extending cavity 18 so that it rests upon support platform 44 . The display bottle must be a truthful representation of the substantially concealed dispensing bottle, i.e., the operator should not display a vodka bottle if a gin bottle is in the dispensing unit. Nor should a first brand of a beverage by displayed if a second brand of the same beverage is to be dispensed.
[0056] Dispenser 10 can be additionally aesthetically enhanced in many additional or alternative ways by various decorations including displays of corporate branding.
[0057] Dispenser 10 may be provided in any geometric configuration. For example, it may be shaped to resemble a mound of ice, an ice sculpture, a lava flow, a volcano, a palm tree, or any number of artistic configurations.
[0058] Dispenser 10 may be transparent, translucent, or opaque.
[0059] Moreover, it may be textured for function or aesthetics or non-textured. A lazy susan type of rotating platform mechanism could also be incorporated into base pedestal tray 14 , thereby facilitating self-service by a larger numbers of users.
[0060] In an alternative embodiment, more than one inverted dispensing bottle could be provided to increase the capacity of the device and reduce the number of re-filling operations.
[0061] Still another alternative embodiment includes the addition of voice, music, or other sound effects, by means of conventional technology.
[0062] Another alternative embodiment includes a second cooling/heating chamber 32 , a second cooling/heating means 34 , or a second dispensing tap spigot 18 for the purpose of delivering multiple cooled or heated beverages independently or simultaneously. Any number of such chambers, cooling/heating devices, or spigots is within the scope of this invention.
[0063] The novel structure also provides increased sanitation of beverage storage and delivery, by virtue of the completely contained beverage chamber that allows dispensing of beverages in a more sanitary fashion than conventional pitchers and dispensers.
[0064] It will thus be seen that the objects set forth above, and those made apparent from the foregoing description, are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
[0065] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention that, as a matter of language, might be said to fall therebetween.
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A device for dispensing a beverage includes a main body. A first vertically-extending opening formed in the main body receives and displays a display bottle in an upright configuration. A second vertically-extending opening formed in the main body receives an inverted dispensing bottle. A dispensing tap spigot is in valved fluid communication with the inverted dispensing bottle. Opening the dispensing tap spigot enables liquid fluid within the inverted dispensing bottle to flow from the dispensing tap spigot under the influence of gravity and closing of the dispensing tap spigot terminates the flow. A thermoelectric temperature control member selectively generates cold or heat and is positioned in heat transfer relation to the inverted dispensing bottle. The main body is aesthetically designed to provide a connotation of coolness when a cooled beverage is to be dispensed and of heat when a heated beverage is to be dispensed. (It is OK to say thermoelectric here. An Abstract does not limit the claims.)
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a lateral support device system for canister-launched missile, more particularly, to a lateral support device system of a canister-launched missile for removing the clearance between a missile and a canister thereby inducing no relative movement therebetween.
2. Description of the Related Art
For all the lateral support device system for canister-launched missile developed up to the present, there always exist some clearances between the inner surface of the canister and the outer surface of missile. Therefore, some lateral movement of the missile relative to the canister occurs during the handling, transportation and operation, and the lateral movement causes the harmful effects on the missile and the missile detent.
Sabots are installed on an outer circumferential surface of the missile so that they can support the missile when the missile is insertedly installed and operated in the canister, and guide the missile within the canister when the missile is launched from the canister. The sabots allow a gap between the missile and the canister in order to prevent the missile from being caught in the canister when it is moved therein. In this respect, however, the gap causes vibrations and shocks of the missile within the canister when the missile is transported, handled and operated, and thus, resulting in a breakdown of the missile.
BRIEF DESCRIPTION OF THE INVENTION
Therefore, one object of the present invention is to provide a canister-launched missile capable of restraining a relative lateral movement of a missile within a canister when the canister-launched missile is being transported or handled and releasing the missile with negligible resistance force when it is launched.
To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, there is provided a lateral support device system for a canister-launched missile comprising: sabots separably formed on an outer circumferential surface of a missile; travel lock bar which is integrally fixed to the sabots; and travel lock bolt fixed at the canister and selectively pressing the upper end of the travel lock bar.
Herein, a groove is formed on the upper surface of the sabots in the direction of the missile launching, and the travel lock bar is fixed to the sabot so that the upper end of the travel lock bar is located below the upper surface of the sabots.
The lateral support device system further comprises: a position adjustment pin fixed at the bottom surface of the sabot so as to be inserted in a position adjustment recess formed on the outer circumferential surface of the missile, and a spring installed and compressed inside the sabot and allowing the position adjustment pin to be pressed and inserted in the position adjustment recess of the missile.
The lateral support device system further including a spring seat having a convex portion at one end for accommodating one end of the spring and having a portion at the other end for fixing the a position adjustment pin.
A load support plate is formed between the bottom surface of the sabot and the outer circumferential surface of the missile, so that when the travel lock bolt presses the sabot, the load support plate contacts with the outer circumferential surface of the missile.
A plurality of sabots and a plurality of travel lock bolts are formed at certain intervals on the outer circumferential surface of the missile.
On the other hand, the present invention provides a lateral support device system for a canister-launched missile comprising: sabots formed on an outer circumferential surface of a missile; travel lock bar which is integrally fixed to the sabots; and travel lock bolt fixed at the canister and selectively pressing the upper surface of the sabots.
The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
In the drawings:
FIG. 1 is a side perspective view of a canister-launched missile including a lateral support device system in accordance with the present invention;
FIG. 2 is a sectional view taken along line II-II of FIG. 1 ; and
FIG. 3 is a perspective view showing the shape that the construction of FIG. 2 is mounted in the missile.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described in detail with reference to the accompanying drawings.
In describing the present invention, detailed descriptions with respect to a known function or construction will be omitted to make the gist of the present invention clear. The construction of the lateral support device system 100 in accordance with the present invention will be described in detail.
The lateral support device system 100 includes sabots 110 protruded from the side of an outer circumference of the missile 10 ; a travel lock bar 120 formed inside the sabot 110 ; a load support plate 130 formed to cover the circumference of the bottom of the sabot 110 and contacting with the outer circumferential surface of the missile 10 when a certain load is applied to the sabot 110 ; a position adjustment pin 140 is fixed to the spring seat 150 and inserted in a position adjustment recess 10 a formed on an outer circumferential surface of the missile 10 ; a spring seat 150 for receiving a portion of the position adjustment pin 140 at one end thereof; a spring 160 installed to be compressed between a receiving portion formed at the other end of the spring seat 150 and an inner surface of the sabot 110 ; a travel lock bolt 170 installed to press the upper end of the travel lock bar 120 of the sabot 110 with a certain load; and a lock bolt fixture 180 for fixing the travel lock bolt 170 and helping transfer of the travel took bolt 170 .
The sabot 110 is formed as a sabot body 111 with a hollow portion formed therein, and installed not to be fixed on the outer circumferential surface of the missile 10 but to contact therewith.
When the travel lock bolt 170 is fixed at the lock bolt fixture 180 and transferred in the direction of the missile 10 to press the front end of the travel lock bar 120 of the sabot 110 , the load support plate 130 is pressed by the bottom of the circumference of the sabot body 111 and tightly attached with the outer circumferential surface of the missile 10 .
The position adjustment pin 140 has thread on one end and is fastened to the other end of the spring seat 150 . And the other end of the position adjustment pin 140 inserted in the position adjustment recess 10 a of the missile 10 , rather than being fastened in the recess. Therefore, although the depth of the recess is different from other one, as the position adjustment pin is fixed to the spring seat 150 , the position adjustment pin 140 can be inserted into the recess with the constant depth.
One end of the spring seat 150 includes a convex portion for accommodating the one end of the spring 160 and a receiving portion for fixing the position adjustment pin 140 .
A contact surface 190 of the travel lock bolt 170 pressed by a certain force contacts with a front end of the travel lock bar 120 of the sabot 110 , which is not fixed at the travel lock bar 120 . Accordingly, as the missile 10 is launched in the canister 20 , the frictional restriction condition between the travel lock bolt 170 and the travel lock bar 120 is smoothly released.
Accordingly, when the missile 10 is launched by force overcoming the frictional force between the travel lock bolt 170 and the travel lock bar 120 , the constraint according to the frictional force between the travel lock bolt 170 and the travel lock bar 120 is naturally released according to the launching thrust of the missile 10 .
The lock bolt fixture 180 includes a fixing portion 181 having a screw thread formed at the center thereof and fastened with the outer circumferential surface of the canister 20 with a fixing bolt 181 a , an adjusting portion 182 having a protrusion to be inserted into a polygonal recess formed on a front end of the travel lock bolt 170 , and a position fixing bolt 183 for rotating the travel lock bolt 170 by using the adjusting portion 182 and fastening the adjusting portion 182 and the fixing portion 181 .
As shown in FIG. 3 , the lateral support device system 100 is formed at four positions by 90° intervals on the outer circumferential surface of the missile 10 and protects the missile 10 such that when the missile 10 mounted within the canister 20 is moved (fluctuated) in the lateral direction when being handled, transported and operated, a relative movement between the canister 20 and the missile 10 may not occur.
Namely, in order not to allow formation of a gap between the outer circumferential surface of the sabot 110 and the inner surface of the canister 20 , the travel lock bolt 170 is installed at the lock bolt fixture 180 , which is fastened to strongly press the travel lock bar 120 provided at the center of the sabot 110 to make the load support plate 140 contact with the outer circumferential surface of the missile 10 .
The sabots 110 are supportedly installed at the outer circumferential surface of the missile 10 at 90° intervals not to allow formation of a gap between the canister 20 and the missile 10 before the missile is launched. When the missile 10 starts to be launched, the missile 10 caught by the sabots 110 by means of the position adjustment pin 140 proceeds together with the sabots 110 within the canister 20 , overcoming the frictional force generated by a load in an axial direction between the travel lock bolt 170 and the travel lock bar 120 . Then, the contact state between the travel lock bolt 170 and the travel lock bar 120 is released, and accordingly, the outer circumferential surface of the sabot body 111 is slid in a state of contacting with the inner surface of the canister 20 by virtue of the spring 160 and the spring seat 150 . At the moment the missile 10 blasts off after being highly accelerated within the canister 20 , the sabots 110 scatter in all directions by a restoration force of the compressed spring 160 .
As stated above, the scope of the present invention is not limited to the above-described specific embodiment of the present invention but can be modified suitably within the coverage of the claims. For example, without installing an travel lock bar 120 in the sabots, the travel lock bolt can contact directly with the upper surface of the sabot so as to remove the clearance between the missile and the canister.
As so far described, a lateral support device system of a canister-launched missile in accordance with the present invention has the following advantages.
That is, by installing sabots separably formed on the outer circumferential surface of the missile and the travel lock bolt fixed at the canister and selectively pressing a front end surface of the sabots so as to contact with the sabots, with the missile placed inside the canister before being launched, no gap is formed between the canister and the missile even without an additional protrusion or unit, so that an impact that may be applied to the missile can be restrained to the maximum and thus the missile can be stably fixed in the lateral direction.
Moreover, after the missile is launched from the canister, the sabots can be automatically separated from the missile without using an additional unit.
As the present invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its spirit and scope as defined in the appended claims, to and therefore all changes and modifications that fall within the metes and bounds of the claims, or equivalence of such metes and bounds are therefore intended to be embraced by the appended claims.
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A lateral support device system of a canister-launched missile of the present invention is provided for eliminating the clearances between missile and the canister in 4 places by 90 degrees interval, and therefore no relative movement occurs between the missile and the canister. Therefore, the missile and the detent is free from shocks and vibrations that occurs during the handling, transportation and operation. In addition, when the missile is fired, those lateral lock become free with a little energy loss.
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FIELD OF THE INVENTION
The present invention relates to a brake system as well as to a method for controlling and/or monitoring a brake system pump.
BACKGROUND INFORMATION
German Patent 195 48 248 A1 describes a method and a device for controlling a pump of an electrohydraulic brake system. In the brake system, a hydraulic fluid is conveyed from an accumulator via a valve means to the individual wheel brake cylinders, the hydraulic fluid being conveyed to the accumulator by a pump. In order that the loading of the accumulator by the pump be as noiseless as possible, the pump can be driven at a mark-to-space ratio that can be stipulated in accordance with need.
German Published Patent Application No. 196 38 196 describes a system for monitoring a brake system having a controllable hydraulic pump that is located in a hydraulic circuit, and having at least one solenoid valve whose operating state can be altered in accordance with a control signal. In this context, by altering the operating state of the solenoid valve, the resistance to flow in the hydraulic circuit is influenced. Monitoring elements are provided which, when predetermined operating conditions exist, actuate a display device to indicate a fault, as a function of a detected slowing of the hydraulic pump in varying operating states of the solenoid valve.
For safety reasons, the pressure supply, is monitored especially in electrohydraulic brake systems. For this purpose, the absolute system pressure is continually monitored with respect to threshold values, as is the pressure and the pressure change rate when the accumulator is loading. While the pressure is being regulated (for example, in the context of an anti-locking system or an anti-spin regulation system), the result is that the accumulator undergoes a volume drain, which is impossible or at best very difficult to measure. When there is a simultaneous reloading of the accumulator, it proves impossible in conventional systems to carry out a precise monitoring of the pump effectiveness. In conventional systems, conclusions about the operation or the effectiveness of the pump can only be formed on the basis of a pressure increase in the accumulator.
In order to avoid generating noise, a pump of this type is not driven at 100% during a loading operation, but is generally operated in a clocked manner. However, during travel, a noise generated by the clocked pump is noticeable and disturbing, in particular when rotational speeds change, whereas noise is significantly less noticeable at a constant rotational speed.
SUMMARY OF THE INVENTION
An object of the present invention is to create a brake system in which the pump operation can be reliably monitored in a simple manner. In addition, it is the goal to make available a brake system that produces noise at as low a level as possible.
According to the present invention, it is possible, in particular, to operate an electrohydraulic brake system such that the pump effectiveness, i.e., particularly the pump rotational speed and the pump performance, can be evaluated and monitored even during a simultaneous volume drain from the accumulator. In addition, by determining the pump rotational speed, which is made simple by the present invention, a phase-regulated driving of the pump is possible in order to minimize the disturbing noises by improving the pump clocking. During the operation of the pump, pressure pulsations are generated whose temporal curve mirrors the periodic opening of the discharge valve of the pump, i.e., in an electrohydraulic brake system, for example, the accumulator loading pump. In this context, the period duration of the pulsations or the corresponding measuring signal corresponds to the duration of one revolution of the pump. The maximum fluctuation level is a measure for the pump performance at a preselected elasticity on the pump outlet side and at a preselected temperature of the hydraulic fluid or of the pressure medium. In a typical brake system, e.g., an electrohydraulic one, the clocked pump operates, for example, at rotational speeds of roughly 1500-3000 rpm, which corresponds to a period duration of 20-40 ms.
According to one preferred embodiment of the brake system according to the present invention, the pressure sensor is arranged directly at the outlet of the pump. As a result of this arrangement, and despite the presence of elasticities which are caused, for example, by reservoirs provided in the brake system and/or by bore holes, pressure pulsations can be measured in a very precise and reliable manner.
According to one preferred embodiment of the method according to the present invention, a smoothing-out, as well as an offset compensation, is carried out on a measuring signal obtained as a result of detecting the pressure pulsations. At pump rotational speeds of 1500-3000 rpm, it is possible to smooth out the signal, for example, by reading in the pressure sensor signal sufficiently frequently, for example, every 2 ms. An offset compensation can be achieved as a result of the fact that this signal has subtracted from it a signal that is filtered over a long term, for example, the average value of the signal over the immediately preceding 40-80 ms. In this context, the time duration between two positive zero crossings is a measure for the period duration. The maximum value, or the amplitude of the signal obtained in this manner, depending on the temperature of the pressure medium, is a direct function of the pump performance. For example, by comparing the measured signal values with the stored table values, it can be evaluated as to whether the pump performance conforms with the specified values, and therefore whether the pump is functioning normally.
It has proven to be advantageous to operate the pump in a clocked manner and to drive it at a time point that can be stipulated, in accordance with a zero crossing and/or an extreme value of the smoothed-out or offset-compensated measuring signal. As result of this measure, it is possible to minimize structure-born sound generation from the point of view of noise intensity. The pump can be operated particularly quietly if it is driven in a phase-correct manner.
According to the present invention, it is possible, in a simple manner, to monitor the efficiency of the pump on the basis of the level of the detected pressure pulsations, or of the amplitude of the measuring signal that is generated from this source.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a block diagram to illustrate the elements of an electrohydraulic brake system according to the present invention.
FIG. 2 depicts a flowchart to illustrate the method according to the present invention.
DETAILED DESCRIPTION
In the depicted brake system, a brake pedal is designated as reference numeral 100 . Via the brake pedal, pressure can be built up in a master brake cylinder 110 . Using a pedal travel sensor 118 , the motion of the brake pedal can be detected. Master brake cylinder 110 is in contact with a reservoir 115 . Master brake cylinder 110 is connected to a safety valve 120 , which in the depicted position is located in its non-current-receiving state. A pedal travel simulator 125 is connected parallel to the safety valve.
In the connecting line between master brake cylinder 110 and safety valve 120 , or pedal travel simulator 125 , a pressure sensor 130 is arranged that makes available a signal which registers pressure PHZ in the master brake cylinder.
In the non-current-receiving state, safety valve 120 enables the connection between the master brake cylinder and discharge valves 141 and 142 . The discharge valves, also in their non-current-receiving state, are connected in the pass direction and they enable the connection to the wheel brake cylinders.
Discharge valve 141 is assigned to wheel brake cylinder VR of the right front wheel, and discharge valve 142 is assigned to wheel brake cylinder VL of the left front wheel. The pressure in the wheel brake cylinders can be measured by sensors 151 , 152 .
In addition, the wheel brake cylinders are in contact with an accumulator 185 , via intake valves 161 and 162 and a check valve 170 . The pressure in accumulator 185 can be measured using a pressure sensor 180 . Intake valve 161 is assigned to the right front wheel, and intake valve 162 is assigned to the left front wheel.
Accumulator 185 is also in contact, via intake valves 163 and 164 , with wheel brake cylinder HL of the left rear wheel and with wheel brake cylinder HR of the right rear wheel, respectively. The wheel brake cylinders of the left rear wheel and of the right rear wheel are in turn in contact with reservoir 115 via discharge valves 143 and 144 , respectively.
Discharge valves 141 and 142 , via safety valve 120 , can also be brought into contact with reservoir 115 .
A pump 190 , driven by a pump motor 195 , conveys the hydraulic fluid from reservoir 115 into accumulator 185 .
On the outlet side of pump 190 , i.e., between pump 190 and reservoir 185 , a further pressure sensor 200 is provided. Using this pressure sensor 200 , pressure pulsations in the hydraulic fluid caused by the operation of the pump can be detected. The temporal curve of the pressure pulsations mirrors the periodic opening of the discharge valve (undepicted in detail) of pump 190 . The determined pressure fluctuation signals can be fed to a control unit 300 , which carries out an appropriate signal processing. This control unit 300 is advantageously a control unit that controls and regulates the entire operation of the depicted electrohydraulic brake system, i.e., the driving of the pump, the other pressure sensors, and the valves. Input signal lines and output signal lines of control unit 300 are designated as 301 and 302 , respectively. For the sake of the clarity of the drawing, the signal lines that communicate with signal lines 301 , 302 and are connected to pressure sensor 200 or to the other elements of the depicted brake system are not depicted in detail.
The depicted electrohydraulic brake system operates as follows:
In normal operation, safety valve 120 receives current. Safety valve 120 enables the connection between reservoir 115 and the discharge valves and interrupts the connection between master brake cylinder 110 and discharge valves. When the driver actuates brake pedal 100 , then sensor 118 determines the signal that corresponds to the pedal travel of brake pedal 100 and/or sensor 130 delivers a pressure signal reflecting the pressure in the master brake cylinder.
On the basis of at least one of these signals, which reflect the input of the driver, as well as of any further operational variables, control unit 300 determines the driving signals for impacting on intake valves 161 , 162 , 163 , and 164 as well as on discharge valves 141 , 142 , 143 , and 144 .
When pump motor 195 receives current, pump 190 is driven, and it conveys hydraulic fluid from reservoir 115 into accumulator 185 . The consequence of this is that the pressure in accumulator 185 rises, as measured by pressure sensor 180 . By opening intake valves 161 through 164 and by closing discharge valves 141 through 144 , the pressure in the wheel brake cylinders is increased in accordance with the input of the driver. By opening the discharge valves and closing the intake valves, the pressure in the wheel brake cylinders can be decreased in accordance with the pedal actuation.
It is particularly advantageous to measure the pressure in the wheel brake cylinders using pressure sensors 151 through 154 . In this case, pressure regulation and/or fault monitoring is possible.
Pedal travel simulator 125 brings it about that the driver feels on brake pedal 100 an appropriate force, which would arise in a corresponding actuation of the brake pedal in a conventional brake system.
In the event of the failure of the device, safety valve 120 loses its current and enables the connection between master brake cylinder 110 and wheel brake cylinders of front wheels VL, VR. Thus the driver, via the brake pedal, has direct influence on the wheel brake cylinders of the front wheels.
To a sufficient extent pump, 190 conveys hydraulic fluid into the accumulator so that sufficient brake pressure is available. The monitoring of the pump operation can be carried out using pressure sensor 200 . It should be noted that it is possible to dispense with the aforementioned pressure sensor 180 because, on the basis of the signal, filtered over a long term, from pressure sensor 200 , information exists regarding the loading of the accumulator. In this context, the period duration of the measured pressure pulse signal corresponds to the pump revolution period. The maximum fluctuation level, i.e., the amplitude of the measuring signal, represents a measure for the pump performance at a preselected elasticity on the pump outlet side and at a preselected temperature of the pressure medium. Using appropriate signal processing procedures to be carried out in control unit 300 , continual monitoring of the pump performance is therefore possible, especially during a simultaneous volume drain from reservoir 185 . The temperature of the electrohydraulic brake system, i.e., especially the temperature of the hydraulic fluid, can be measured, for example, using a temperature measuring device provided in pressure sensor 200 . Temperature measuring devices of this type can also be provided in further pressure sensors used in the depicted brake system. A temperature signal measured in this manner can also be fed to the control unit so that the measured pressure pulse signal for a given temperature can be compared with table values stored in the control unit. Therefore, in a simple and inexpensive manner, it can be determined whether the pump performance conforms to the stored, i.e., specified, values. Providing pressure sensor 200 , as in the present invention, also permits a phase-regulated driving of pump 190 , as a result of which it is possible to minimize the noise generated by pump 190 . Due to the fact that the rotational speed of pump 190 can be measured in a simple and reliable manner by pressure sensor 200 , this rotational speed can be used as a reference variable in the pump regulation. In general, by arranging pressure sensor 200 on the outlet side of pump 190 , the efficiency of the pump can be continually monitored, and the pump can be operated in a low-noise manner at a substantially constant rotational speed and/or in phase-correct driving.
The method according to the present invention is once again depicted in the flowchart of FIG. 2 . In this context, in a step 101 , hydraulic fluid is conveyed into accumulator 185 by pump 190 . Immediately thereafter, in a step 102 , a determination is carried out using pressure sensor 200 of the pressure pulsations arising in the operation of the pump. In a further step 103 , on the basis of an evaluation of the detected pressure pulsations, a measuring signal for controlling and monitoring the pump performance is obtained. In a subsequent step 104 , a smoothing out and/or an offset compensation of the obtained measuring signal is carried out. On the basis of this smoothed-out or offset-compensated measuring signal, in a step 105 , the driving of the pump takes place at a time point that can be stipulated in accordance with a zero crossing and/or an extreme value of the measuring signal.
The device and the method are not limited to the electrohydraulic brake system employed in the exemplary embodiment. Rather, the present invention can be used in any brake systems in which, at the outlet of the element conveying the pressure medium, especially a pump, pressure pulsations can be measured, for example, in a sensory manner and thus evaluated.
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A brake system in which a hydraulic fluid can be conveyed from an accumulator via a valve into individual wheel brake cylinders, the hydraulic fluid being conveyed by a pump into the accumulator, having a pressure sensor arranged on the outlet side of the pump for detecting pressure pulsations in the hydraulic fluid arising in the operation of the pump and having an arrangement for evaluating the pressure pulsations in order to obtain a measuring signal for controlling and/or monitoring the pump.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This is a National Stage Entry into the U.S. Patent and Trademark Office from International PCT Patent Application No. PCT/IB2015/001210, having an international filing date of Jul. 20, 2015, which claims priority to French Patent Application No. FR 14/01849, filed Aug. 14, 2014, the entire contents of both of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a system and method for generating textures on an object from data other than colorimetric data.
RELATED ART
[0003] In the field of computer graphics, a wide variety of tools have been in use for many years for applying colors onto objects. Conventionally, a color is applied as a layer, in the manner of a layer of paint applied to a real physical substrate.
[0004] Applying a color layer conventionally produces a uniform result. To perform variations in color, strength or opacity, a user must proceed manually to set color parameters at each point, thereby generating an accurate and detailed colorimetric mapping. Different graphics tools such as virtual brushes or applicators are available to a user who performs such a “mapping”.
[0005] To change a previously established “mapping”, a user will use the same types of tool for applying the changed parameters point after point, thereby producing a modified colorimetric result. Even though a user may use an enclosing box to select several points to be changed in a similar way, the process must be carried out manually, for each image, thus requiring considerable time.
[0006] A variety of filters are also known, which may be applied to one or more colors in an image. Conventionally, such filters act in such a way that they modify colors as a function of intrinsic parameters of the colors themselves. Such filters thus make it possible to generate effects either by selecting an environment or a style imposed by a user, or as a function of the original parameters of the colors to be processed.
[0007] The process of generating or changing object colors thus does not allow object features or parameters to which the color is applied, nor the environment in which the objects are displayed, to be taken into account. Thus, to generate realistic effects, a user must proceed manually to determine the target points or areas, parameters to be changed, and the amount of change in the chosen parameters. If one or more objects of one or more scenes are to be processed, the required operations may involve considerable implementation time.
[0008] For example, to color an area of a wooden material in order to provide it with a realistic wood appearance, a user must perform the parameter adjustments in a careful and accurate way. Since the coloring tools do not take material properties, or interactions between the objects and the environment, into account, a user who wishes to produce a visual effect based on a reaction or a behavior of a material must first design or imagine the effect desired in a realistic way, and then perform colorimetric modifications based on the parameters of the involved colors. Thus, if a color is applied to an object, its coloring impact will be the same in all areas of this object. For example, if the object has a metal portion, a wooden portion and a plastic area, the applied color produces the same effect on all of these areas, whereas on a real object, the effects produced on each of the materials would show differences, or would even be very different according to the circumstances.
[0009] Document FR2681967 discloses a method for changing the colors of an image displayed on a display based on the determination of colorimetric values. The method comprises selecting at least one color representative of at least one pixel in the image comprised of a plurality of pixels, determining colorimetric values of said at least one color, selecting a second color and determining colorimetric values of the second color, and modifying the colorimetric values of a plurality of pixels of the image so that, for any given pixel of said plurality having colorimetric values which correspond to the colorimetric values of said at least one color, the colorimetric values of the given pixel are modified to correspond to the colorimetric values of the second color. The applied color is the same whatever the object's nature (plastic, wood, etc.) and does not take textures into account, but only changes in color of a user selected area.
[0010] Document EP0884694 discloses a method for adjusting colors in digital images, in particular “red eye” correction on photographs. The pixel color data is adjusted by identifying pixels in a digital image whose original color data correspond to the predetermined color. However, the applied color is automatic and is only based on colorimetric data, in particular colors of the iris.
[0011] Document WO2008066880 discloses a method for obtaining an original set of two or more original colors associated with a piece of art. In order to do so, an input set of one or more user selected colors is received. For each original color, a mapping of the original color onto the derived colors is performed. The plurality of derived colors are obtained based on one or more user selected colors.
[0012] Document WO2012154258 discloses a 3D colorimetric coloring tool. Each pixel in the image comprises a set of pixel values in a 3D color space. Although it allows a wide range of colors to be used, the applied color does not change depending on the material to which it is applied.
[0013] The document “flow and changes in appearance”, Dorsey J and al, computer graphics proceedings 1996 (siggraph), Aug. 4-9, 1996; New York, N.Y.: ACM, pages 411-420, discloses a phenomenological model based on particle systems and equations for modelling the absorption of water by the surface and sedimentation of deposits. The document describes a model with examples of flows over complex geometries. In particular, this document focuses on the explanation and parameterization of phenomena which involve water absorption by surfaces and sedimentation of deposits.
[0014] Also, application US2010045669 describes a system and method for simulating and visualizing a flow of fluid interacting with an object. An embodiment of the invention disclosed in this document provides for a simulation of the fall of a liquid along a 2D plane and generates a first and a second depth buffer for top and bottom surfaces of the object. The values of the first and second simulated textures correspond to the object's upper and lower surfaces. A mesh of the fluid is rendered along a 2D plane based on the simulation textures.
[0015] Application US20100156920 relates to an apparatus for time-coherence texture synthesis, including a texture preprocessor for receiving, as input information, a 2D texture image and a 3D triangular mesh. The 2D image is preprocessed in a form suitable for rapid searching. A vector field generator is provided for defining a vector field on a 3D surface of the 3D triangular mesh. A color search unit is provided for finding the respective colors of the edges of the triangle based on a previous phase. A texture synthesizer is provided for determining the texture coordinates of the triangle. The texture preprocessor further receives information regarding the size of a texture to be synthetized and an initial vector field orientation.
[0016] According to another aspect, the conventional process for generating or modifying object colors does not allow modifications to be performed on the object's shape in a given application in reaction to the physical, chemical, or mechanical parameters of the application itself, and on the inks applied. Finally, conventional processes using the relief-based geometries do not retain the data from the previous steps once the relief features have been modified. Thus, to go back to an previous geometry, it is necessary to manually reconstruct the corresponding architectural elements, which often requires significant implementation time. In case of a complex geometry, it may sometimes be difficult to recover certain previous parameters.
[0017] Thus, there is a need to overcome these various drawbacks.
SUMMARY OF THE INVENTION
[0018] An object of the invention is to provide a system and method for improving the efficiency and productivity of authoring tools.
[0019] Another object is to provide a graphical system and method for enhancing the graphical flexibility and capabilities when creating colors or renderings.
[0020] Another object of the invention is to provide a graphical system and method for increasing the realism of the represented elements.
[0021] Yet another object of the invention is to provide a system and a method for improving interactivity between the rendering of a represented object and its environment.
[0022] Yet another object of the invention is to provide a system and a method for creating a context-sensitive editing mode with environmental parameters taken into account.
[0023] Yet another object of the invention is to provide a system and method for performing modifications in the target object's shape based on physical, mechanical, chemical or intrinsic parameters.
[0024] Yet another object of the invention is to provide a system and method for going back to phases of geometric modifications of the target object.
[0025] For that purpose, the invention provides various technical means. For example, the invention first provides a system for generating procedural textures on an object from physical ink data and physical applicator data, comprising:
access to physical ink data, comprising a plurality of parameters among the following: color, viscosity, temperature, drying time, chemical composition, transparency; access to physical applicator data, comprising a plurality of parameters among the following: width, depth, thickness, profile, roughness, porosity, applicator flexibility, application force, pressure, application temperature; access to target object data, including initial mesh data of the target objects and initial relief data of the target objects; access to mixing rules and functions data; access to physical data of initial textures T; a microprocessor and control instructions; a pre-projection virtual rendering generation module, provided for combining the physical ink data with the physical applicator data; a pre-projection virtual rendering (PPVR) transformation module, provided for adapting this rendering's data to a given rendering projection mode; a tessellation module for tessellating the target object data in order to transform relief data of the target objects into a mesh; an integrator module for integrating the physical parameters, provided for generating a new set of textures T+1 for said one or more objects taking into account the object data, data from the set of textures T, tessellation module data and transformed pre-projection virtual rendering data.
[0036] With this system architecture, the resulting textures include all geometric and colorimetric details for realistic and accurate rendering of the applied parameters, using highly-reduced memory space due to the use of procedural parameters.
[0037] Advantageously, the system comprises a module for rendering textures from the previously obtained procedural parameters.
[0038] Also, advantageously, the system includes a time-based backup module provided for retaining the data needed to again generate a set of textures of an object for which one or more parameters are modified or to return to a previous step of a process, in a state in which the parametric architecture was in that previous step.
[0039] Since the modified procedural data includes parameters relating to the geometry of the object transformed as a function of time, it is possible to go back to a previous state. Such a time-based mode is provided for easily and rapidly carrying out tests or comparisons between various parametric architectures, without having to change all parameters of a process, or returning to a previous step, without having to parameterize all the data again.
[0040] Also, advantageously, the mixing rules and functions data include parameters related to the deformation of objects.
[0041] Parameters related to the deformation of objects are advantageously effective on the mesh and/or relief data.
[0042] According to an alternative embodiment, the system comprises an integrator module, provided for using combination rules and/or functions to define and/or adjust the modes of integration of the various physical parameters relative to one another.
[0043] Alternatively, the integrator module includes a rule selection sub-module and a rule implementation sub-module for, on the one hand, selecting at least one applicable rule and/or function, and on the other hand, determining the mode of application of the rule in order to generate the resulting data for textures T+1.
[0044] The system thereby offers great flexibility, for example by providing rules according to which a given parameter, such as, for example, corrosion, produces an effect on a metallic material, and no effect on a PVC material.
[0045] Advantageously, the system comprises access to any application rate and/or environment data.
[0046] The invention also provides a method for generating procedural textures on an object from physical ink data and physical applicator data, comprising the steps in which: one or more data sources provide access to:
[0047] physical applicator data, comprising a plurality of parameters among the following: width, depth, thickness, profile, roughness, porosity, applicator flexibility, application force, pressure, application temperature;
[0048] target object data, comprising initial mesh data of the target objects and initial relief data of the target objects;
[0049] mixing rules and functions data;
[0050] physical data of initial textures T;
a pre-projection virtual rendering generation module combines the physical ink data with the physical applicator data; a pre-projection virtual rendering transformation module receives the previously obtained pre-projection virtual rendering data, and adapts this data to a given rendering projection mode; a tessellation module performs a transformation of at least part of the (initial) relief data into (final) mesh data; an integrator module for integrating the physical parameters receives object data, data from the set of textures T, transformed pre-projection virtual rendering data, relief and mesh data of the object, and any corresponding application rate and environment data, and generates a new set of textures T+1 for said one or more objects, taking this data into account.
[0055] In an advantageous embodiment, the integrator module receives integration rules and/or functions to define and/or adjust the modes of action of the various physical parameters relative to one another.
[0056] According to yet another embodiment, a rule selection sub-module selects at least one applicable rule and/or function and a rule implementation sub-module to determine the mode of application of the rule in order to generate the resulting data for textures T+1.
[0057] Also, advantageously, a time-based backup module retains the data needed to again generate a set of textures (T+1) of an object for which one or more parameters are modified or to return to a previous step of a process, in the state in which the parametric architecture was in this previous step.
DESCRIPTION OF THE DRAWINGS
[0058] Other features and advantages of the invention will appear from the following description, which is provided by way of non-limiting example, with reference to the appended drawings, in which:
[0059] FIG. 1 is a schematic representation of an exemplary system for generating textures according to the invention; and
[0060] FIG. 2 is a block diagram showing the main steps of the texture generation method according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0061] In the following description, substantially identical or similar items will be referred to by identical reference numerals.
[0062] By physical “ink” or “paint”, is meant a solid, liquid, or gaseous element or a mixture of these phases, which, when applied to an object, causes a physical change at least in the surface of said object, in particular textures on this object, such that at least one of its physical parameters or features, in particular a visible feature, is modified.
[0063] By “physical parameter”, is meant any physical and/or chemical element, property, or feature, liable to be measured or detected observed or quantified, characterizing an object, ink, environment, applicator, etc.
[0064] By “parametric architecture”, is meant the set of parameters for defining the physical, chemical features (an object's constituents, properties, visual aspect, texture, ink, etc.) and behavioral features of an element (ink, texture, object, etc.).
[0065] By “physical applicator”, is meant an element, in particular a virtual element whether visible or not in a scene, allowing ink or paint to be applied to a physical object, such as a brush, roller, pencil, gun applicator, spray nozzle or vaporizer, plate, tool, etc.
[0066] By “application rate”, is meant the overall opacity of the brush/applicator stroke applied by a user, which is user adjustable and uncorrelated to other parameters, such as ink. For example, when a user starts the painting process on an object which is not or is slightly covered, the “application rate” can be set to a large value, so that each brush/applicator stroke strongly impacts the object's texture. When the user reaches a phase of refinement and small alterations, he/she can adjust this rate to a lower value, so as not to entirely change already painted locations, but to gently adjust some details.
[0067] Depending on the circumstances and embodiments, the application rate can be expressed in several ways. For example, the application rate τ can be expressed as a value ranging between 0 and 1. If there are two inputs A (the existing texture) and B (the texture to be applied), the output Y is equal to “A*(1−T)±B*T”. If τ=0, nothing is applied and the new texture is equal to the existing texture. If τ=1, the new texture is equal to the texture to be applied (i.e. points covered by the brushstroke) and the previous texture is entirely covered in the affected areas.
[0068] By mixing “rule” or “function” is meant a description of the process that determines how a material (and optionally one or more ‘inks’ already applied to the material at a given location) and an ink applied to this material will react. By way of illustration, some examples of rules are as follows:
[0069] a liquid applied to bare wood is absorbed by the wood. Alternatively, its effect is to darken the color of the wood;
[0070] a liquid applied to a varnish or plastic is not absorbed at all and produces a “drop” effect on the surface of the material;
[0071] heat applied to a painted material has the effect of flaking the paint and then burning it, depending on the temperature set by the user, and possibly calcining the material to which the paint is applied if it is combustible;
[0072] applying an acid or sandblasting to glossy plastic will gradually roughen it, reducing its brightness, and make it increasingly rough. With the method and system described in the following, the various steps of an evolutionary process can be determined and presented.
[0073] By “procedural texture”, is meant a texture defined algorithmically and/or mathematically and displayed by a rendering engine which allows the mathematical data to be transformed into a conventional image format such as bitmap.
[0074] FIG. 1 illustrates an exemplary system for generating procedural textures according to the invention. This system comprises at least one microprocessor 13 a, adapted for implementing instructions contained in an instruction memory 13 b. A plurality of modules are advantageously provided by the instructions implemented by the microprocessor.
[0075] An ink data item 1 stores the physical parameter data of the one or more inks available. For example, this data includes color, viscosity, temperature, drying time, chemical composition, transparency rate, etc.
[0076] A physical applicator data item 2 stores data that characterize physical applicators. This data may include a plurality of parameters such as width, depth or thickness, profile, roughness, porosity, applicator flexibility, application force, pressure, application temperature, etc. Typically, this will be any parameter that may influence the application characteristics of an ink onto a destination object. An index can be assigned to each of the parameters in order to weight their significance levels.
[0077] An application rate data item 3 stores the data of physical parameters related to the application rate for off-object rendering.
[0078] A target object data item 4 , which includes initial target object mesh data 401 and initial target object relief data 402 , stores the target object data liable to be modified by the applied physical parameters. This data comprises, for example, the physical characteristics of the target objects such as shapes, dimensions, weight, absorption coefficient, porosity, chemical composition and various characteristics relating to the surface and textures of objects.
[0079] A data item 6 of textures T of the object stores data for the initial textures of the target objects onto which one or more inks may be applied. Any data for newly obtained textures T+1 is contained in a memory element 7 . This data includes, for example, physical characteristics such as ink composition, color, thickness, brightness, relief, light reflection characteristics, etc.
[0080] An integration data item 5 stores rules and/or functions data to be applied by integrator 16 to generate the new set of textures T+1. These rules and/or functions allow one or more processes, which may influence the result, to be taken into account, such as color mixing (for example, a rule can allow calculation of the averages of the applied colors), chemical interactions between components, capillary diffusion, combustion or any thermodynamic process, drop effect, modification or alteration of the object's surface (such as corrosion or oxidation, mold, flaking, etc.).
[0081] Furthermore, for adequate management of the geometric characteristics, the mixing rules and functions data 5 includes parameters relating to object deformation. These parameters relating to object deformation are advantageously effective on the mesh and/or relief data of the target objects.
[0082] A Pre-Projection Virtual Rendering (PPVR) data item 8 stores data for the rendering obtained after combining the ink data and the physical applicator data. Any post-transformation rendering data obtained after the expected projection mode has been taken into account is contained in a memory element 9 . This data includes, for example, physical characteristics such as ink composition, color, thickness, brightness, relief, light reflection characteristics, etc.
[0083] An optional item of parameters related to environmental conditions 10 includes parameters that may affect several elements in the scene, such as temperature, pressure, humidity, physical force (magnetic, gravitational or the like) data, etc.
[0084] An optional time-based backup module 11 allows data related to a given time scale to be saved, in particular, user inputs such as trajectory, pressure, direction, opacity data, etc. For example, this module can rerun an animated simulation after modifying one or more parameters, by performing only the operations that are required by the modified data. Thus, it is possible to simply and rapidly perform consecutive simulations based on a previous one, or to recover a previously performed simulation.
[0085] The memory elements described above and/or the various modules can be combined into one or more elements and one or more modules without significantly affecting the operation of the system.
[0086] Through a user input 19 , data can be received from an external source, such as a user who provides a course of application of the physical parameters. This input can be used to receive several types of parameters such as pressure, direction, or opacity data, etc., so as to appropriately define, quantify and delimit the applied parametric elements.
[0087] A pre-projection virtual rendering (PPVR) generation module 14 is provided for generating a pre-projection virtual rendering onto the target object with physical pre-projection virtual rendering (PPVR) data being adapted for projection onto a target object independently from the projection mode. A pre-projection virtual rendering (PPVR) is obtained based on the physical ink and physical applicator data.
[0088] A pre-projection virtual rendering (PPVR) transformation module 15 is provided for setting the PPVR data to a given rendering projection mode (vector/unidirectional or normal/tangential).
[0089] A tessellation module 410 performs a transformation on at least one portion of the relief (initial) data into mesh (final) data.
[0090] A physical parameter integrating module 16 , provided for generating a new set of textures T+1. for said object, with object data, data for the set of textures T, transformed PPVR data, relief and mesh data of the object and any corresponding application rate and environment data.
[0091] Integrator module 16 includes a rule selection sub-module 17 and a rule implementation sub-module 18 for, on the one hand, selecting at least one applicable rule and/or function, and on the other hand, determining the mode of application of the rule to generate the resulting data for textures T+1.
[0092] A bus 12 enables data transfers among the various modules and memory elements described below.
[0093] FIG. 2 shows a flowchart of the main steps of the procedural texture generation method according to the invention. In step 20 , the system is initialized and the pre-projection virtual rendering (PPVR) generation module 14 receives data items 21 and 22 related to the ink parameters and physical applicator parameters, and user data 23 related to the course of application of the physical parameters. An off-object rendering is generated by the pre-projection virtual rendering (PPVR) generation module 14 .
[0094] In step 30 , the pre-projection virtual rendering (PPVR) transformation module 15 performs a transformation of the rendering into a format required by the applicable projection mode. Depending on this mode, step 31 will be involved in case it is a vector-based or unidirectional projection mode. Step 32 will be carried out in case it is a normal or tangential projection mode.
[0095] A tessellation step 424 transforms at least part of the relief data into mesh data.
[0096] Regardless of the type of projection, the next step 40 integrates the pre-projection virtual rendering (PPVR) by means of the integrator module. This step involves selecting applicable rules and/or functions and implementing the integration based on these applicable rules and/or functions. This phase involves integrating physical parameters such as the object's parameters, including the final mesh and final relief data, application rate, texture parameters T and environment parameters to generate and/or adapt a new set of textures T+1 for the one or more objects affected by events occurring in the scene. Finally, in step 50 , the data for texture T+1 is obtained.
Modifications and Other Embodiments
[0097] The system and method of the present invention have been disclosed above in a working environment suitable for an editing tool intended for a user wishing to create or modify the rendering of one or more objects.
[0098] Alternatively, the system and method of the present invention can be used in a standalone mode, for generating object renditions based on physical parameters that are pre-established or may be computed by the system itself, for example based on intermediate results. Such embodiments are advantageously employed in movies or video games, especially games or movies in which the renditions or textures are generated by a procedural texture generation engine. Document WO2012014057, which is incorporated herein by reference, discloses an example of such a rendering system and method.
[0099] The system and method of the invention can generate and/or modify renditions of objects based on technical (physical, chemical, thermodynamic, etc.) factors inherent to the objects themselves as well the scene's environment.
[0100] For example, to create a corrosive effect on an object, a user may use an ink or paint and objects whose parameters are related to corrosion. Among these physical parameters (other than color data), object behaviors that depend on the applied inks or paints, that is, interactions between the various physical elements, may for example imply that materials such as plastics do not react to corrosive effects, corroded areas develop on steel, copper becomes oxidized, etc.
[0101] In some embodiments, certain parameters can be assigned either to physical inks or paints, or to objects or the environment, or else to mixing rules or functions. The parametric distribution or architecture can also vary in order to produce comparable renditions.
[0102] In another exemplary use of the method and system according to the invention, the physical paint or ink to be applied onto objects only comprises non-colorimetric parameters, such as thermal energy or heat data, pressure data, etc. In one example where the physical applicator applies heat, the applicator can be a soldering iron for performing pyrography operations on a wooden plate. If a metal edge frames the wood area to be burned, parameters and rules allow physical phenomena to be managed so that the application of the soldering iron to the metal does not generate any “burned” effect. The data for the course of application is used to define the design or pattern produced by the burning operation. Depending on the case, the course data can be provided by a user who simulates a movement of the soldering iron, or of an application card used as input.
[0103] In another example, a paint remover is applied to a table-top by means of a spray gun. The initial painted wood textures are substituted to textures showing the same wood, but in its natural state, without paint. Depending on the course of application, one or more areas retaining leftover paint may still be present on the object.
[0104] Table 1 below illustrates examples of parameters and rules used to implement the aforementioned examples.
[0000]
TABLE 1
Example of physical parameters
Ink/
Mixing
Final
Paint
Applicator
Object
rule/function
Initial texture
texture
Corrosive
Brush or
Metallic
Mode and
New metal
Rusty
liquid
roll
body
intensity of
metal
metal
corrosion
Heat
Soldering
Wood
Effect and
Light-colored
Burned
gun
plate
intensity of
wood
wood
heat
Liquid
Spray
Table-top
Effect and
Painted wood
Natural
paint
(spray gun)
intensity of
wood
remover
chemical
attack
[0105] The time-based backup can advantageously be used to go back into a given process in order to select one of multiple previous states. It can also help to rebuild a process by modifying only one or a few parameters, without having to change other parameters, thus avoiding having to reconfigure the entire data. This allows, for example, results that can be achieved by modifying only certain parameters to be quickly and easily compared. For example, it is possible to change a characteristic of an ink (for example, color) for one or more brushstrokes previously applied during the process. In another example, ink viscosity is changed to reduce its impact on a prior layer.
[0106] The figures and their above descriptions illustrate rather than limit the invention. The reference numerals in the claims have no limiting character. The words “include” and “comprise” do not exclude the presence of elements other than those listed in the claims. The word “a” preceding an element does not exclude the presence of a plurality of such elements. In addition, the above described system and method advantageously operate in a multi-channel mode, that is, by processing several textures (diffuse, normal, etc.) at each step. Thus, the terms “texture T (or T+1)” and “textures T (or T+1)” refer to one or more textures depending on the particular cases or embodiments.
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The invention relates to a system and method for generating procedural textures on an object on the basis of physical ink data and physical applicator data. The system includes: access to target object data having data for initial meshing and initial contouring of the target objects; access to data pertaining to mixture rules and mixture functions; access to physical data for initial textures T; a module for generating a pre-projection virtual rendering provided to combine the physical ink data with the physical applicator data; a module for tessellating the data of the target objects so as to convert the contours of the target objects into meshing; and an integrating module for the physical parameters, the integrating module being provided to generate a new set of textures T+I for the object(s).
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to tools for working wet mortar such as concrete and pertains in particular to apparatus for imparting a groove to the mortar; i.e., to form an expansion crack.
2. Description of the Prior Art
Mortar such as concrete poured in a long strip as for a sidewalk requires the establishment of perforated points where stress fracture can occur. Typically, the stress fracture points are grooves cut in the surface of the wet mortar. Traditionally, floats having a rib on one side are used to impart the necessary groove as, for example, shown in U.S. Pat. Nos. 775,110 issued to O. M. Jumper and 1,916,887 issued to W. T. McClain on July 4, 1933. While these arrangements are generally satisfactory, simpler and more efficient arrangements will achieve economies and convenience heretofore not available.
Accordingly, an object of this invention is to achieve simple and convenient grooving of wet mortar.
SUMMARY OF THE INVENTION
In accordance with the preferred embodiment of the invention, simplicity and convenience in grooving is achieved by combining a float assembly and a guide assembly wherein the float assembly has track brackets and a grooving rib and the guide assembly includes a cable which restricts the track guides and, in turn, the grooving grip, to a predetermined path over the mortar to be grooved.
In accordance with one feature of this invention, a drum assembly in the guide assembly locates the cable a predetermined height above the mortar to facilate accurate grooving.
In accordance with another feature of this invention, a ratchet assembly in the guide assembly tensions a cable between itself and the drum assembly so as to form a convenient guide reference for the float assembly.
In accordance with another feature of this invention, the float assembly includes opposed track brackets adapted to engage the cable so as to simplify accurate movement of the float assembly.
A better understanding of these and other features and objects of the invention will be facilitated by reference to the following drawing and detailed description.
DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view illustrating a float assembly and guide assembly cooperating in accordance with this invention.
FIG. 2 is a side elevation view of the float assembly shown in FIG. 1.
FIG. 3 is an end elevation view of the float assembly shown in FIG. 1.
DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a float assembly 10 and a guide assembly 11 are shown. As shown in FIG. 2, the float assembly 10 comprises a pair of track brackets 20 and 21, a handle bracket 22, a float 23 and a rib 24. The float 23 is advantageously formed from a rigid material such as sheet steel and the rib 24 projects outwardly along the length thereof at a height of approximately three quarters of an inch. Typically, the float 23 is three to six inches wide and six to ten inches long.
The handle bracket 22 is rigidly attached to the float 23 as by welding and is adapted to accept a handle 26.
The track brackets 20 and 21 are also rigidly attached to the float 23 as by welding and can be individual units or made from a single unitary piece. In either case, they are typically made of a rigid material such as sheet steel and each includes a slot 25 which has a width of approximately one-eighth inch terminating in an opening adapted to accomodate a cable 13.
The cable 13 is advantageously 3/32 inch steel and is a part of the guide assembly 11 which also includes a drum assembly 14 and a ratchet assembly 15. As shown in FIG. 1, the drum and ratchet assemblies 14 and 15 are adapted to rest on forms 16 which contain wet mortar 17 such as concrete or the like and which are partially held in place by the stakes 18.
As best seen in FIG. 1, the drum assembly 14 comprises two flanges 19 and 20 separated by a center section or drum 21. One flange 20 rests on the form 16 and the drum 21 spaces the other flange 19 a predetermined height above the form 16. All of the components of the drum assembly 14 are advantageously made of sheet steel and the flange 19 is perforated to accept one end of the cable 13 while the drum 21 and the flange 20 are hollow and perforated respectively to accept a stabilizer stake 28.
Each stabilizer stake 28 is advantageously a five eighth inch circular rod made of iron. Moreover, each includes a skirt 29 adapted to assist in spacing and tensioning the cable 13.
The ratchet assembly 15 is a typical drum take-up and includes a suitable ratchet control drum (not shown), a handle 27 and a housing 30. The housing 30 holds the other components in place and includes a hollow portion adapted to accomodate the top of a stabilizing stake 28. As shown in FIG. 1, the housing 25 rests on the form 16 when mounted in place and, as a result, the cable 13 is located a predetermined height above the mortar 17.
In operation, a pair of stabilizer stakes 28 are oppositly installed in the ground in place of the pair of normal stakes 18 adjacent to the place in the mortar 17 where a groove is to be cut. Next, the drum and ratchet assemblies 14 and 15 are mounted on top of their respective stabilizer stakes 28. The cable 13 is then stretched between the two assemblies to form a guide wire and the handle 25 turned until the desired cable tension is reached; i.e., when the forms 16 start to pull slightly inward.
Next, the float assembly 10 is placed on the mortar 17 and the cable 13 is inserted in the slots 25. Thereafter, the float 23 is pushed with a steady motion across the mortar 17 by the handle 26. If desired, the float 23 can be pulled back to further define the groove or it can be merely lifted off and transported to the next groove location.
If desired, the float 23 can be made with a double set of parallel track brackets 20 and 21. In that case, the float 23 is made doubly wide. In either case, the slots 25 are opened so as to readily accept the cable 13.
When the float and guide assemblies 10 and 11 are used, bridging planks are not needed to span the fresh mortar. Moreover, the grooves are readily made by one man. As a result, significant economies are achieved in making grooves in fresh concrete.
In summary, a float and guide assembly have been disclosed which simplify and make more efficient the process of grooving wet mortar. While only one embodiment has been disclosed, that embodiment is illustrative of the principals of the invention and many others falling within the scope of the invention will readily occur to those skilled in the art.
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A float and guide assembly are disclosed for grooving wet mortar. The float assembly comprises a float, grooving rib, handle and two track brackets for guidably engaging a cable. The cable is part of the guide assembly which includes drum and ratchet assemblies which cooperate to hold the cable a predetermined height above the mortar and which impart tension to the cable so it can act as a guide.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to German Patent Application No. 10 2011 121 308.6, filed Dec. 15, 2011, which is incorporated herein by reference in its entirety.
[0002] 1. Technical Field
[0003] The present disclosure relates to a storage compartment arrangement for a motor vehicle, in particular an automobile, with a storage compartment cover displaceable by a drive, a motor vehicle with such a storage compartment arrangement and a method for displacing the storage compartment cover of such a storage compartment arrangement.
[0004] 2. Background
[0005] It is known to optionally cover a storage compartment of an automobile with a storage compartment cover which is displaceable by a drive. In particular, when the storage compartment cover in a preferred embodiment has a display, for example of a vehicle information, navigation, entertainment and/or telecommunication system (“articulating display”), advantageously a storage site, in particular for valuable objects, can be provided which, when the cover is closed, is not visible and is protected from access. However, this presupposes that the driver, on leaving the vehicle, closes the cover. If he has forgotten this, hitherto he has to laboriously open the vehicle again, get in and close the cover directly.
[0006] From DE 103 40 817 A1 it is known, in connection with a so-called comfort entry/go function, to unlock and lock a glove compartment lock by remote control.
[0007] Therefore, it may be desirable to improve the operating comfort of a motor vehicle. In addition, other objects, desirable features and characteristics will become apparent from the subsequent summary and detailed description, and the appended claims, taken in conjunction with the accompanying drawings and this background.
SUMMARY
[0008] According to various aspects of the present disclosure, a storage compartment arrangement has one or more storage compartments, wherein at least one, generally several storage compartments are optionally able to be covered completely or at least partially by a storage compartment cover which is displaceable by a drive. Two or more storage compartments can be covered by the same or different storage compartment covers. Likewise, two or more storage compartment covers can be provided for covering one storage compartment. A covering is understood here to mean in particular a partitioning, generally preventing access and/or opaque, with respect to an interior of the motor vehicle. In another exemplary embodiment, a storage compartment cover here can be able to be arrested in one or more positions in one example, by a drive and/or a closing device, generally at least one mechanical lock.
[0009] A drive for displacing one or more storage compartment covers can have in particular one or more electric motors, magnets, hydraulic and/or pneumatic actuators such as hydraulic or respectively pneumatic cylinders, and suchlike. Generally, at least one storage compartment cover is displaceable by motor, in one example, electric motor.
[0010] A storage compartment is generally arranged in the interior of a motor vehicle, in one example, it can be arranged, in particularly integrated, on an instrument panel and/or a center console.
[0011] According to another aspect of the present disclosure, a key and a control device are provided, which is configured to cooperate with the key. The key can be a mechanical key for the mechanical opening and/or closing at least of one mechanical lock of the motor vehicle. Additionally or alternatively, the key can be configured for the contactless actuation of the motor vehicle, in particular a locking system of the motor vehicle. In another exemplary embodiment, the control device can be connected with a central locking system of the motor vehicle or can be integrated therein, in particular can be formed by the latter.
[0012] The key and control device can cooperate by contact. In particular, a mechanical actuation of the key, for example the insertion into and/or the withdrawal from a lock and/or the opening and/or closing of a lock, can bring about an electrical signal to the control device, for example via a bus line of a central locking system. Additionally or alternatively, the key and control device can cooperate in a contactless manner, in particular wirelessly, generally via radio waves, microwaves, ultrasound, infrared light or suchlike. A cooperation is understood to mean here in a generalized manner in particular a communication or respectively the sending of a signal from one of the key and the control device and the receiving and processing from the other of the key and the control device. The communication can be one-sided, in particular only a sending of signals from the key to the control device can be provided. Likewise, a bidirectional communication can also be provided, in which the key and control device send and receive signals reciprocally.
[0013] According to an aspect of the present disclosure, the control device displaces one or more storage compartment covers on the basis of an actuation of the key. For this, the control device can actuate the drive accordingly, in particular can send control signals to the drive, supply the drive with energy or suchlike. In another exemplary embodiment, the control device can open and/or close the storage compartment cover(s) completely or partially. If several storage compartment covers are provided, these can be actuated jointly or respectively uniformly by the control device. In particular, the control devices can close all the storage compartment covers, substantially completely. Likewise, provision can be made to actuate various storage compartment covers differently, for example to only close selected storage compartment covers. In another exemplary embodiment, by various actuations of the key different storage compartment covers can be actuated. Additionally or alternatively it is possible, also in the case of only one storage compartment cover, to actuate this/these storage compartment cover(s) differently by various actuations of the key. For example, by a singular actuation of a button of the key, a closing of a storage compartment cover can be commanded. By multiple actuation of the same button and/or by actuation of a further button of the key, an opening of the same storage compartment cover, a closing of a further storage compartment cover etc. can be commanded. An actuation of the key is understood to mean here in a generalized manner in particular a handling of the key such that a signal is brought about to the control device. In an exemplary embodiment, the key has one or several input means, in particular buttons, switches, sensors or suchlike, on the actuation of which, for example touching, depressing or suchlike, a signal to the control device is brought about. Additionally or alternatively, the mechanical actuation of the key, for example the insertion into and/or the withdrawal from a lock and/or the opening and/or closing of a lock can also bring about a signal to the control device. Various actuations can then be constituted for example by actuating various input means, in the various actuating of an input means, for instance a different number and/or duration of button actuations, a turning of the key in a mechanical lock in various directions and/or about various angles, and suchlike.
[0014] In an exemplary embodiment, at least one storage compartment cover has a display and/or operating device, in particular for an information, entertainment, navigation and/or telecommunication device of the motor vehicle. A display for an information device of the motor vehicle can be, in particular, a speed, engine speed, temperature, fluid level, in particular fuel and/or oil display or suchlike. An entertainment device of the motor vehicle can be, in particular, an audio and/or video device, for instance a radio, a cassette, CD or DVD player. The device can be provided for displaying and/or operating and for this can have in particular at least one display, in particular an LCD display, a touchscreen and/or one or more input means, in particular buttons, switches, sensors or suchlike. In this way, the storage compartment cover combines a covering and a display and/or operating functionality, the space behind a display and/or operating device, which is in any case necessary, is utilized effectively, and can in addition be concealed so as to be inconspicuous when the cover is closed.
[0015] The control device can displace one or more storage compartment covers on the basis of a vehicle closure actuation. In particular, provision can be made that with a vehicle closure actuation, one or more, in particular all the storage compartment covers are automatically closed.
[0016] Additionally or alternatively, an individual cover displacement actuation of the key can be provided, which only brings about the displacement of one or more storage compartment covers. In particular, a distinct input means and/or a distinct actuation, in particular an actuation pattern with a predetermined number and/or duration of actuations, can be provided and associated with the displacement of the storage compartment cover(s). For example, a distinct key can be provided which only commands a closing of the storage compartment cover(s). Likewise, a button which closes a central locking system wirelessly on a singular actuation, can command a closing of the storage compartment cover(s) on multiple and/or longer actuation.
[0017] In another exemplary embodiment, an actuation and/or a state of the storage compartment cover(s), in particular a closed state, is indicated by a display device. This can be a display device of a storage compartment cover itself. Thus, for instance, a screen of a storage compartment cover can light up briefly when it is being closed or is closed. In another exemplary embodiment, the display device for displaying an actuation and/or a state of a storage compartment cover is a lighting- and/or blinker device of the motor vehicle. For example, headlamps, an interior lighting arrangement and/or one or more blinkers or respectively direction indicators of the vehicle can light up once or several times, in order to indicate that one or more storage compartment covers are being closed or are closed.
[0018] In another exemplary embodiment, at least one storage compartment has one or more electrical connections, generally in order to connect a mobile apparatus, such as for instance a cellphone, a handheld, a portable storage medium or suchlike with the vehicle. In particular, a storage compartment can have one or more USB connections or suchlike. In storage compartments with such connections in fact the risk exists that valuable apparatus which is connected there remains unprotected when the storage compartment cover is not closed.
[0019] A person skilled in the art can gather other characteristics and advantages of the disclosure from the following description of exemplary embodiments that refers to the attached drawings, wherein the described exemplary embodiments should not be interpreted in a restrictive sense.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The various embodiments will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:
[0021] FIG. 1 illustrates a storage compartment arrangement according to an exemplary embodiment of the present disclosure; and
[0022] FIG. 2 illustrates a method for displacing a storage compartment cover of the storage compartment arrangement of FIG. 1 according to an exemplary embodiment of the present disclosure.
DETAILED DESCRIPTION
[0023] The following detailed description is merely exemplary in nature and is not intended to limit the present disclosure or the application and uses of the present disclosure. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.
[0024] FIG. 1 shows a center console of an automobile which is not illustrated further. Integrated into this is a storage compartment 2 , which has a USB connection for a cellphone or suchlike (not illustrated).
[0025] The storage compartment 2 can be optionally closed by a storage compartment cover 1 , on which a touchscreen of a car navigation and/or entertainment device is arranged in a manner which is not illustrated in further detail. For this, a control device 4 is provided, indicated in dashed lines in FIG. 1 , behind the center console, which control device actuates an electric motor 5 which can displace the storage compartment cover 1 in the manner indicated by the movement arrow in FIG. 1 . The control device 4 can be commanded for example by touching the storage compartment cover 1 , in order to open or close the storage compartment cover 1 .
[0026] A key 3 is provided for the wireless opening and closing of a central locking system of the motor vehicle. For this, it has two input means in the form of buttons 3 . 1 , 3 . 2 . On a single short pressing of the one button 3 . 1 , a radio signal is sent to the central locking system, which thereupon locks all the external locks of the motor vehicle, in one example, its door locks. On a single short pressing of the other button 3 . 2 , another radio signal is sent to the central locking system, which thereupon unlocks all the external locks of the motor vehicle, in one example, its door locks.
[0027] By longer pressing of the one button 3 . 1 , a radio signal is sent to the control device 4 , which thereupon completely closes the storage compartment cover 1 by means of the electric motor 4 , in so far as it is not already closed. By longer pressing of the other button 3 . 2 , another radio signal is sent to the control device 4 , which thereupon completely opens the storage compartment cover 1 by means of the electric motor 4 , in so far as it is not already open. If, or respectively as soon as, the storage compartment cover 1 is completely closed, the control device 4 activates four blinkers of the motor vehicle, one blinker 6 of which is illustrated as a representative in FIG. 1 , so that these flash briefly several times and thus indicate that the storage compartment cover 1 is completely closed.
[0028] Likewise, a closing of the storage compartment cover 1 can also be commanded by simultaneous actuating of the button 3 . 1 and/or 3 . 2 or another actuation pattern. In another exemplary embodiment, which is not illustrated, a distinct button can also be provided, by the actuation of which a closing of the storage compartment cover 1 can be commanded. In another exemplary embodiment, a signal emitted by the key 3 can also be received by the central locking system and can be passed on to the control device 4 . In another exemplary embodiment, the control device 4 can be integrated into the central locking system; in one example, provision can be made that the central locking system also actuates the electric motor 5 .
[0029] FIG. 2 shows a method for the displacement of the storage compartment cover 1 : in S 10 the control device 4 checks, for example cyclically, whether an actuating signal has been received by the key 3 . If this is not the case (S 10 : “N”), the control device 4 remains passive. If it has received an actuating signal from the key 3 (S 10 : “Y”), it checks in S 20 whether the storage compartment cover 1 is already completely closed. If this is the case (S 20 : “N”), the control device 4 actuates the blinkers 6 and waits for further actuating signals. If, on the other hand, the storage compartment cover 1 is not yet completely closed (S 20 : “N”), as illustrated in FIG. 1 , the control device 4 actuates the electric motor 5 in S 30 such that it completely closes the storage compartment cover 1 , and the blinkers 6 , as soon as the storage compartment cover 1 is completely closed.
[0030] In another exemplary embodiment, the control device 4 does not check cyclically whether an actuating signal has been received by the key 3 , but rather is activated by such an actuating signal.
[0031] While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the present disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the present disclosure as set forth in the appended claims and their legal equivalents.
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A storage compartment arrangement for a motor vehicle, in particular an automobile, is provided. The arrangement can include a storage compartment, a storage compartment cover displaceable by a drive, a key and a control device, which is configured to co-operate with the key and to displace, in particular to close, the storage compartment cover on the basis of an actuation of the key.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of Chinese Patent Application No. 200810074226.0 filed Feb. 13, 2008, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
The embodiments described herein relate to a detector panel and an X-ray imaging apparatus, and more particularly to a portable detector panel having an X-ray detector assembly housed in a case, and an X-ray imaging apparatus using such detector panel.
As a type of X-ray imaging apparatuses, there are mobile imaging apparatuses. The X-ray imaging apparatus of this type is composed of a movable system console and a portable detector panel. The system console includes an X-ray irradiator and a control circuit, while the detector panel is composed of an X-ray detector assembly and an X-ray transmissive flat case.
The X-ray imaging apparatus is carried to a hospital room of a patient for carrying out radiography. The radiography is carried out in the hospital room in such a manner that the detector panel is put on a part of the patient to be imaged, and an X-ray is irradiated from the opposite side. The X-ray signal detected by the detector panel is transmitted to the system console with wire or wirelessly (see, for example, Japanese Unexamined Patent Publication No. 2002-336227 (paragraph numbers 0017 to 0020, FIG. 1)).
The X-ray detector assembly includes an X-ray detector including a two-dimensional array of X-ray detecting elements that convert the incident X-ray into an electrical signal, a support substrate, an interface circuit, and a flexible circuit board that connects the X-ray detector and the interface circuit.
The two-dimensional array of the X-ray detecting elements is mounted to the surface of the support substrate, the interface circuit is mounted to the back surface of the support substrate, and the flexible circuit is mounted from the surface of the support substrate to the back surface.
The X-ray detector described above is rigidly fixed to the inner bottom wall of the case via a spacer made of an appropriate hard material, or fixed through a cushion that is made of a soft material and arranged below the spacer for absorbing impact (see, for example, U.S. Pat. No. 6,700,126 (columns 3 to 5, FIG. 4)).
BRIEF DESCRIPTION OF THE INVENTION
When the X-ray detector assembly is fixed in the case through the spacer made of a hard material, a shock produced when the detector panel is dropped on the floor and hit against something is directly transmitted, so that the X-ray detector assembly is susceptible to breakdown. When the cushion is arranged below the spacer, the shock to the X-ray detector assembly is eased, but there is a problem in the reliability of the cushion material.
Since the cushion is interposed, the precise positioning of the X-ray detector assembly becomes difficult, which brings poor productivity. Further, the stability of the X-ray detector assembly to the external environment is poor due to the temperature characteristic of the cushion or the affect by the external vibration.
In view of this, a detector panel is provided having shock resistance and excellent stability to the external environment, and an X-ray imaging apparatus that uses the detector panel.
In a first aspect, a portable detector panel includes an X-ray detector assembly having an X-ray detecting surface on its surface; a box-like case that houses the X-ray detector assembly therein and whose at least upper part that is opposite to the X-ray detecting surface is X-ray transmissive; and a buffer member that is arranged between the inner side wall of the case and the X-ray detector assembly, is made of a hard material, and has a flexible shape with respect to the movement of the X-ray detector assembly in the direction generally parallel to the X-ray detecting surface.
In a second aspect, the X-ray detector assembly includes: a support substrate; an X-ray detector supported on the upper surface of the support substrate; an electric circuit board supported on the lower surface of the support substrate; and a flexible circuit board that electrically connects the X-ray detector with the electric circuit.
In a third aspect, the detector panel also includes a spacer that supports the X-ray detector assembly housed in the case so as to be apart from the inner bottom wall of the case.
In a fourth aspect, the spacer is movable with respect to the movement of the X-ray detector assembly in the direction generally parallel to the X-ray detecting surface.
In a fifth aspect, the buffer member includes a beam arranged on the inner side wall of the case the X-ray detector assembly and is flexible with respect to the pressing force to the X-ray detector assembly in the direction generally parallel to the X-ray detecting surface.
In a sixth aspect, the beam are provided at four corners of the inner side wall of the case or the X-ray detector.
In a seventh aspect, the beam is a cantilever beam one end of which is supported on the inner side wall of the case or the X-ray detector assembly.
In an eighth aspect, the beam is in a shape corresponding to the shape of a corner of the X-ray detector assembly.
In a ninth aspect, the buffer member includes a beam that is arranged between the inner side wall of the case and the X-ray detector assembly and is flexible with respect to the pressing force to the X-ray detector assembly in the direction generally parallel to the X-ray detecting surface.
In a tenth aspect, the buffer member includes a straddle mounted beam that is arranged on a side face of the supporting substrate and is flexible with respect to the pressing force by a projecting portion arranged on an inner side wall of the case in the direction generally parallel to the X-ray detecting surface.
In an eleventh aspect, an X-ray imaging apparatus includes a system console having an X-ray irradiator and a control circuit; and a portable detector panel that detects an X-ray generated from the X-ray irradiator, the detector panel including: an X-ray detector assembly having an X-ray detecting surface on its surface; a box-like case that houses the X-ray detector assembly therein and whose at least upper part that is opposite to the X-ray detecting surface is X-ray transmissive; and a buffer member that is arranged between the inner side wall of the case and the X-ray detector assembly, is made of a hard material, and has a flexible shape with respect to the movement of the X-ray detector assembly in the direction generally parallel to the X-ray detecting surface.
In a twelfth aspect, the X-ray detector assembly includes: a support substrate; an X-ray detector supported on the upper surface of the support substrate; an electric circuit board supported on the lower surface of the support substrate; and a flexible circuit board that electrically connects the X-ray detector with the electric circuit.
In a thirteenth aspect, the detector panel further includes a spacer that supports the X-ray detector assembly housed in the case so as to be apart from the inner bottom wall of the case.
In a fourteenth aspect, the spacer is movable with respect to the movement of the X-ray detector assembly in the direction generally parallel to the X-ray detecting surface.
In a fifteenth aspect, the buffer member includes a beam arranged on the inner side wall of the case the X-ray detector assembly and is flexible with respect to the pressing force to the X-ray detector assembly in the direction generally parallel to the X-ray detecting surface.
In a sixteenth aspect, the beam are provided at four corners of the inner side wall of the case or the X-ray detector assembly.
In a seventeenth aspect, the beam is a cantilever beam one end of which is supported on the inner side wall of the case or the X-ray detector assembly.
In an eighteenth aspect, the beam is in a shape corresponding to the shape of a corner of the X-ray detector assembly.
In a nineteenth aspect, the buffer member includes a beam that is arranged between the inner side wall of the case and the X-ray detector assembly and is flexible with respect to the pressing force to the X-ray detector assembly in the direction generally parallel to the X-ray detecting surface.
In a twentieth aspect, the buffer member includes a straddle mounted beam that is arranged on a side face of the supporting substrate and is flexible with respect to the pressing force by a projecting portion arranged on an inner wall of the case in the direction generally parallel to the X-ray detecting surface.
In some embodiments, the detector panel includes a buffer member that is arranged between the inner side wall of the case and the X-ray detector assembly, is made of a hard material, and has a flexible shape with respect to the movement of the X-ray detector assembly in the direction generally parallel to the X-ray detecting surface. Therefore, the detector panel facilitates shock resistance and excellent stability with respect to the external environment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing an appearance of an exemplary X-ray imaging apparatus.
FIG. 2 is a view showing the state in which the X-ray imaging apparatus shown in FIG. 1 is being moved.
FIG. 3 is a view showing the state in which a patient is imaged by the X-ray imaging apparatus shown in FIG. 1 .
FIG. 4 is a view showing a basic configuration of a detector panel that may be used with the X-ray imaging apparatus shown in FIG. 1 .
FIG. 5 is a view showing a basic internal configuration of the detector panel shown in FIG. 4 .
FIG. 6 is a horizontal sectional view showing a basic configuration of the detector panel shown in FIG. 4 .
FIG. 7 is a horizontal sectional view showing another basic configuration of the detector panel shown in FIG. 4 .
FIG. 8 is a horizontal sectional view showing another basic configuration of the detector panel shown in FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
Various embodiments of the present invention will be explained in detail with reference to the drawings. The present invention is not limited to the embodiments described herein. FIG. 1 schematically shows the appearance of an X-ray imaging apparatus. The configuration of this apparatus represents only one example of the X-ray imaging apparatus.
As shown in FIG. 1 , the present apparatus has a system console 100 . The system console 100 has a box-like structure of substantially a rectangular solid, and has an electric circuit for imaging control in its inside. The system console 100 has a caster 102 for movement at its lower part and a grip handle 104 at its upper part. Thus, the present apparatus becomes a movable X-ray imaging apparatus that can be freely moved as shown in FIG. 2 .
An operation panel 106 is provided to the upper surface of the system console 100 . The operation panel 106 includes a man-machine communication device such as, for example, a graphic display or a keyboard.
A vertical column 110 is provided to the back of the system console 100 . An X-ray irradiator 130 is mounted to a leading end of an arm 120 that extends horizontally from the column 110 . The X-ray irradiator 130 generates X-ray by a high voltage supplied from the system console 100 through a cable 132 .
The direction of the X-ray irradiator 130 is changeable at the leading end of the arm 120 . The arm 120 can be moved up and down along the column 110 . The column 110 is spinnable about the longitudinal shaft.
The present apparatus has a detector panel 200 . The detector panel 200 has a plate-like structure of substantially a rectangular shape. It is provided separate from the system console 100 , and is portable. The detector panel 200 is stored in a bin 108 at the front of the system console 100 when radiography is not carried out. When the radiography is carried out, the detector panel 200 is take out of the bin 108 for use. The detector panel 200 is one example of a best mode for carrying out the present invention. The configuration of the detector panel 200 illustrates one example of the best mode for carrying out the present invention relating to a detector panel.
FIG. 3 shows the scene when the present apparatus is used. As shown in FIG. 3 , the present apparatus is used in a hospital room. Radiography is carried out in such a manner that the detector panel 200 is put on the back of a patient, and X-ray is irradiated from the front side by the X-ray irradiator 130 of the system console 100 . The X-ray signal detected by the detector panel 200 is transmitted wirelessly or by a cable (not shown) to the system console 100 .
FIG. 4 shows a basic configuration of the detector panel 200 . As shown in FIG. 4 , the detector panel 200 has a box-like case 55 and a rectangular plate-like X-ray detector assembly 51 housed in the case 55 . The upper part of the case 55 that is opposite to an X-ray detecting surface 52 a ′ of the X-ray detector assembly 51 is made of an X-ray transmissive material. The case 55 has a grip 552 at its one end.
FIG. 5 shows one example of an internal configuration of the detector panel 200 . FIG. 5 is a vertical sectional view of the detector panel 200 . As shown in FIG. 5 , the X-ray detector assembly 51 is composed of an X-ray detector 52 , a support substrate 53 , and an electronic circuit board 54 . The X-ray detector 52 is mounted to the surface of the support substrate 53 , and the electronic circuit board 54 is mounted to the back surface of the support substrate 53 , wherein both are electrically connected by a flexible circuit board 56 .
The X-ray detector 52 is constructed by laminating a scintillator layer 52 a and a photoelectric conversion layer 52 b over a glass substrate 52 c . The scintillator layer 52 a converts X-rays into light, and the photoelectric conversion layer 52 b converts this light into an electrical signal. The photoelectric conversion layer 52 b is constructed of a two-dimensional array of such photoelectric conversion elements as photodiodes. The electrical signal obtained as the result of conversion is inputted to the electric circuit board 54 through the flexible circuit board 56 .
An electric circuit is mounted to the electric circuit board 54 . The electric circuit is an interface to the system console 100 . It converts the inputted signal into digital data and transmits the resultant to the system console 100 wirelessly or by a cable (not shown).
The rear face of the support member 53 is provided with a plurality of spacers 57 . The support member 53 is kept at a distance from the inner bottom wall of the case 55 by the spacers 57 . The end faces 58 of the spacers 57 are not fixed on the inner bottom wall of the case 55 . That is, the end faces 58 of the spacers 57 are moving ends. The spacers 57 may be provided on the case 55 side. In this case, the end faces on the support member 53 side are moving ends.
FIG. 6 illustrates an example of the internal configuration of the detector panel 200 in the form of horizontal sectional view. As illustrated in FIG. 6 , the case 55 has a buffer member 59 at each of the four corners of its inner circumferential surface. The buffer members 59 are each constructed of a pair of cantilever beams having a flexible structure in the direction of bending. Each pair of cantilever beams has an opening angle of 90 degrees at a cantilever portion.
The flexible shape here means the shape that functions as a rigid body with respect to a shock or vibration produced upon a normal use, and that functions as an elastic body so as to absorb energy with respect to an extreme shock or vibration applied when dropped on a floor or hit against something. The buffer members described above can be realized by appropriately designing the material, shape and size. The buffer members 59 are constructed integrally with the case 55 . These buffer members 59 are constructed, for example, by molding the case 55 integrally with the buffer members 59 .
The support member 53 has a projecting portion 53 a at each of its four corners in correspondence with these buffer members 59 . The four projecting portions 53 a are respectively abutted against the four buffer members 59 . Each portion constructed of a buffer member 59 and a protruded portion 53 a is an example of a supporting mechanism of the invention.
When excessive impact or vibration is horizontally applied, the buffer members 59 perform buffering action by flexing their beams. Impact or vibration is horizontally applied when a corner or an edge of the detector panel 200 hits the floor or a foreign object or on any other like occasion. Impact and like on the X-ray detector assembly 51 is lessened by the buffer members, and the X-ray detector assembly 51 becomes less prone to fail. In addition, a cushion material or the like is not used for buffering, and high reliability is obtained.
FIG. 7 illustrates another example of the internal configuration of the detector panel 200 in the form of horizontal sectional view. As illustrated in FIG. 7 , the case 55 has four projecting portions 60 on its inner circumferential surface on four sides. The support member 53 has a buffer member 61 on its four side in correspondence with these protruded portions 60 . The four buffer members 61 are abutted against the four respective protruded portions 60 . The buffer members 61 are each constructed of a straddle mounted beam flexible when horizontally pressed by the X-ray detector assembly 51 . The buffer members 61 are constructed integrally with the support member 53 . These buffer members 61 are constructed, for example, by molding the support member 53 integrally with the buffer members 61 .
When excessive impact or vibration is horizontally applied, the buffer members 61 perform buffering action by flexing their beams. This lessens impact or the like on the X-ray detector assembly 51 , and the X-ray detector assembly 51 becomes less prone to fail. In addition, a cushion material or the like is not used for buffering, and high reliability is obtained.
FIG. 8 illustrates another example of the internal configuration of the detector panel 200 in the form of horizontal sectional view. As illustrated in FIG. 8 , the support member 53 has buffer members 62 respectively formed at its four corners. The buffer members 62 are diagonally extended from the four corners. Their ends are each constructed of a beam abutted against the corresponding one of the four corners on the inner circumference of the case 55 . The beams are in such a shape that they are flexible under pressing force horizontally applied to the X-ray assembly 51 .
The buffer members 62 are constructed integrally with the support member 53 . These buffer members 62 are constructed, for example, by molding the support member 53 integrally with the buffer members 62 . When excessive impact or vibration is horizontally applied, the buffer members 62 perform buffering action by flexing their beams. This lessens impact or the like on the X-ray detector assembly 51 , and the X-ray detector assembly 51 becomes less prone to fail. In addition, a cushion material or the like is not used for buffering, and high reliability is obtained.
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A portable detector panel includes an X-ray detector assembly having an X-ray detecting surface on its surface, a box-like case that houses the X-ray detector assembly therein and whose upper part that is opposite to the X-ray detecting surface is X-ray transmissive, and a buffer member that is arranged between the inner side wall of the case and the X-ray detector assembly, is made of a hard material, and has a flexible shape with respect to the movement of the X-ray detector assembly in the direction generally parallel to the X-ray detecting surface.
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[0001] The present invention is a continuation of PCT/CH2004/000194 filed 31 Mar. 2004.
BACKGROUND OF THE INVENTION
[0002] Caterpillars for ski-run vehicles consist of several parallel belts which are connected together with lateral carriers. Conventional belts of this kind consist of an elastomer which is reinforced by a textile carcass. These known carcasses consist of several bands layed one over another of polyamide webs. The useful life of such belts is approximately one fifth of the useful life of the ski-run track vehicle.
[0003] The present invention aims at increasing the life-span of such belts. This task is solved by the combination of features of the claims.
BRIEF DESCRIPTION OF THE INVENTION
[0004] In accordance with the foregoing, the present invention comprises a crawlertrack belt of an elastomer reinforced by a textile carcass. The belt has at least one row of cylindrical holes extending in a longitudinal direction. Laterally-extending carriers are fastened to the belt through the holes. The carcass comprises at least one web with bearing warps arranged parallel to each other and are shaped and parallel with respect to the outside surfaces of the belt. The warps are of an aramid construction.
[0005] Because aramid has a much higher tension strength than polyamide, the carcass can be much thinner. This improves the alternating bending stability significantly. Thus, the useful life of the belts is considerably improved. By the considerably higher stiffness of aramid compared with polyamide, the danger of injury when a belt tears is considerably reduced and the load distribution on the various belts of the caterpillar is improved.
[0006] Preferably the bearing warp yarns consist of several twines and are twisted in a sense contrary to twist the twines. The twines are twisted in the same sense as the threads or yarns from which they are found. At an equal number of windings per meter the result is that the yarn filaments in the center of the twines are approximately parallel to the length direction of the twines. This results in the highest possible strength and stiffness of the twines.
[0007] A particularly high life duration is achieved when all of the bearing aramid-yarns are arranged in a single plane, i.e. in a single layer of the web. This results in an even distribution of the load on all bearing yarns, as well over guide rollers or drive rollers. The elastomer layer on the outside of the belt is preferably thicker than on the inside for wear considerations.
[0008] For manufacturing of the belt, the carcass is soaked with liquid epoxy resin and thereafter used such that a thin epoxy layer of about 1% of the weight of the carcass surrounds the carcass. A latex solution adapted to the elastomer to be applied is then applied to the carcass. After curing, the latex layer surrounds the carcass with a level of at least 10% of the weight of the carcass. Onto this latex layer the elastomer is vulcanised on both sides at about 160° C. by calendering.
[0009] The manufacturing method described above results in a particularly durable connection between the carcass and the elastomer. The through holes of the at least one row of holes are preferably cut by a high pressure water jet. Conventionally these holes are punched, which results in frayed hole edges and irregular hole walls. These disadvantages can be avoided by water jet cutting. The load transfer between the belt and the lateral carriers is thereby improved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] An exemplary embodiment of the invention is hereinafter described with reference to the drawings, in which
[0011] FIG. 1 shows a perspective view of caterpillar belt of a ski-run track vehicle;
[0012] FIG. 2 shows a longitudinal section through a caterpillar belt;
[0013] FIG. 3 shows a partial view of a carcass; F.
[0014] FIG. 4 shows the structure of the twines;
[0015] FIG. 5 shows the structure of a cord yarn;
[0016] FIG. 6 shows a further embodiment of the belt in a lateral section; and
[0017] FIGS. 7 and 8 show two variants of the connection of two belt ends to form an endless belt in longitudinal section.
DETAILED DESCRIPTION OF THE INVENTION
[0018] FIG. 1 shows schematically the structure of a caterpillar 10 of a ski-track vehicle. The caterpillar 10 is guided over two rollers 11 spaced from one another, of which one is connected to a drive unit. The caterpillar 10 comprises several parallel belts 12 each having at least one row of throughgoing holes or orifices 13 . Lateral carriers 14 of aluminium are screwed to each of the belts 12 through the holes. The longitudinal extension of the carriers 14 extends parallel to the axis of the rollers 11 .
[0019] Each belt 12 consists of an elastomer 15 in which a textile carcass 16 is embedded. In the embodiment shown in FIGS. 2 and 3 , the carcass 16 consists of a single web layer in which bearing warps 17 are unwaved and lie parallel to the outside surfaces 18 of the belt 12 and consist of an aramid. In the embodiment of FIG. 3 , the warps 17 are connected together by wefts 19 of a polyamide. In the example of FIG. 2 , the carcass has linearly throughgoing wefts 20 on both sides of the warps 17 . On one side of the warps 17 these linearly extending wefts could also consist of an aramid. This results in a particularly high resistance to piercing of the carcass 16 . The wefts 20 are connected together by further warps 21 of a polyamide. These waved warps 21 contribute practically nothing to the longitudinal strength but serve to hold the carcass 16 together. As shown in FIG. 2 , the orifices 13 may be reinforced by tubular rivets 22 .
[0020] FIGS. 4 and 5 show the structure of the bearing warps 17 . The warp 17 of FIG. 5 is a cord which is wound in the opposite sense than the twines 28 of FIG. 4 from which it is formed. In the represented embodiment the cord is wound clockwise or Z, whereas the twines 28 are wound counter clockwise or S. The three yarns 29 of a twine 28 are wound in the same sense as the twine 28 , in the example shown counter clockwise or S. Each yarn 29 consists of several hundred, e.g. about one thousand aramid filaments 30 . The winding number of the filaments 30 per meter in the yarn 29 is approximately equal to the number of windings per meter of the yarn 29 in the twine 28 , and (at least for the middle belts 12 a of the caterpillar 10 ) approximately equal to the windings per meter of the twines 28 . This results in the highest possible strength and stiffness of the bearing warps 17 . The number of windings is exaggerated in the drawing. 60 windings per meter have shown to be optimal. For the outermost belt 12 b of the caterpillar 10 of the ski-track vehicle the winding number of the twines 28 in the warps 17 is preferably somewhat higher. Thereby the stiffness of these belts is lower than those of the middle belts 12 a . This can be of advantage in turns.
[0021] A further embodiment is shown in FIG. 6 in lateral section. The carcass 16 consists in this case of a web according to FIG. 3 in which the wefts 19 are considerably thinner than the warps 17 , and additionally with a covering web 34 on each side of first web of a polyamide, aramid, or polyester. The covering web 34 is coated with an elastomer on both sides. Instead of the covering web, an elastomer foil can be used, e.g. one with short fibers of an aramid.
[0022] As depicted in FIGS. 7 and 8 , for manufacturing of the endless belts, the ends 35 , 36 of the belt of e.g. 10 m length with the structure described are ground down on opposite sides over a length L of e.g. 30 cm parallel to the outside surfaces 18 to the bearing warps 17 . The two ends 35 , 36 are then vulcanised together over the length L such that the warps 17 of the two ends 35 , 36 touch. Thereby, a tensile strength of over 70% of the one of the belts is achieved.
[0023] With conventional belts with several layers of reinforcing webs the above described method of connection is not possible. In conventional belts the belt ends are either connected by hinges or by finger splicing. All these connections do not reach the strength of the described overlapping splicing.
[0024] With the described overlapping splicing there results a step 37 on both outer surfaces 18 of the height of the diameter d of the bearing warps 17 . In the application of caterpillars for ski-track vehicles, these steps hardly disturb operation. In other applications it may be advantageous to grind off these steps 17 , which is shown schematically in FIG. 7 in phantom.
[0025] An even stronger connection results when the grinding surfaces 38 are tilted by a small angle d/L against the outer surfaces 18 , as shown in FIG. 8 . Thereby the steps 37 are avoided. The bending strength of the belts is constant even over the connecting region. The angle d/L is preferably approximately 0.05°, and in any case smaller than 0.5°. The grinding surfaces 38 are still approximately parallel to the outside surfaces, in contrast to conventional tilted splicings.
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A crawlertrack for a ski trail grooming machine comprises a number of parallel belts joined to one another by cross members. Each belt is made of an elastomer reinforced by a textile carcass. The belt has a row of holes for attaching the cross member. The supporting warp threads of the carcass are made of aramid and flatly extend parallel to the outer sides of the belt.
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BACKGROUND OF THE INVENTION
The present application is a division of our pending application, filed Apr. 10, 1974, application Ser. No. 459,655, entitled "PHOTOCOPY MACHINE" and now U.S. Pat. No. 3,989,238.
The present invention relates to the art of photocopy machines and, more particularly, so-called desk-top copiers.
Until relatively recently, it has been necessary in performing copying operations with such copiers to manually feed each document to be copied into the machine. To eliminate this drawback, some desk-top copiers have been equipped in recent years with various automatic feed devices capable of successfully feeding individual documents from a document stack into the copier without need for the presence of an operator once document feed has been initiated. Although copiers equipped with automatic original document feed devices have been well received, such copiers have heretofore been subject to a number of drawbacks.
With some copiers equipped for automatic feed of original documents, it is necessary to employ the automatic feed mechanism although only a single document is to be copied. Forced usage of the automatic feed mechanism is disadvantageous for at least two reasons. First, it often requires bothersome adjustment of the feed device so far as to accomodate the single document to be copied. This usually involves adjustment of the document side guides and can involve adjustment for document thickness. Second, the feed mechanism subjects the original document to the rigors of a power feed tire or set of tires and a document reversing transport path. Where the original document is brittle with age, or where the original document is worn and frayed, but valuable, there is a natural reluctance for good reason on the part of users in subjecting the document to the rigors of the power feed mechanism. Other copiers equipped for automatic feed afford the possibility of making copies without usage of the automatic feed device. However, with such copiers the power feed unit must be removed from the copier in order to permit access to the entryway of the original document feed or transport system.
It is necessary to afford ready access to the original document transport path or paths of desk-top copiers so that original documents can be retrieved from the sheet handling apparatus in cases of document jam or machine stoppage. Heretofore, access to the original document path has been obstructed by any automatic feed device employed and has required removal thereof or substantial disassembly of the apparatus before the entire sheet handling apparatus could be rendered accessible.
As alluded to hereinabove, it has heretofore been necessary to adjust automatic original document feed devices in accordance with the thickness of the documents to be fed. With existing feed devices, such adjustment involves considerable guesswork on the part of the operator. Often, proper adjustment can be made only after having aborted several copying runs due to improper feeding.
Although desk-top copiers are available which can make copies of original documents not in sheet form, such as a book page, such versatility has heretofore been absent with copiers equipped with automatic document feed devices.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a photocopy machine having the capabilities, without any apparatus adjustment or equipment removal, of automatic original document feed and manual document feed.
Another object of the invention is to provide a photocopy machine of the above character wherein access to the original document transport path can be readily had so as to facilitate retrieval of original documents therefrom and to enable copying of original documents of non-sheet form.
A more particular, but important, object of the invention is to provide improved original document feed apparatus such that the necessity for critical adjustment thereof in accordance with document thickness is eliminated.
A photocopy machine in accordance with the present invention comprises a copier unit having a document feed deck and a mating feed module mounted to open from, and close upon, the copier unit. The copier unit and module each include sheet feeding and guiding elements which, when the module is closed upon the copier unit, are disposed in opposed relationship to define a straight line original document feed path having an entryway aligned with the feed deck of the copier unit. The feed module includes apparatus for automatically separating stacked documents and facility for transporting the same to the above entryway, whereupon the separated documents are transported along the straight line document feed path in the same fashion as manually fed documents. When the feed module is opened from the copier unit, the opposed feeding and guiding elements are separated and, hence, the document feed path is exposed to facilitate retrievel of jammed or stranded documents and to enable copying of original documents of non-sheet form.
Improved apparatus for successively separating the top document from a stack of documents includes, in accordance with the present invention, a document feed tire, a pair of friction pads arranged in flanking relationship to the feed tire with the upper surfaces of the pads defining a plane that slightly intercepts the outer periphery of the tire, and a document support that defines a plane that is slightly inclined with respect to the plane of the pads and which intercepts such plane.
A better understanding of the present invention, the objects and advantages thereof, will be had with reference to the following detailed description of the presently preferred embodiment when considered in conjunction with the accompanying drawings in which:
FIG. 1 is a side view with portions of the front wall structure cut away of a copier unit with the feed module in its opened position;
FIG. 2 is a side sectional view of the feed module in its closed position upon the copier unit;
FIG. 3 is a sectional view taken, as indicated, along the line 3--3 of FIG. 2.
FIG. 4 is a sectional view taken, as indicated, along the line 4--4 of FIG. 2;
FIG. 5 is a fragmentary perspective view showing the arrangement of the feed tire, retarder bars, and hopper;
FIG. 6 is a side elevational view of the copier with the feed module in its closed position and showing details of the mechanical drive; and
FIG. 7 is a schematic circuit diagram of the copier drive system.
DETAILED DESCRIPTION
Referring now to the drawings, a copying machine incorporating the present invention is shown to comprise a copier unit 10 and a feed module 12 mounted upon the copier unit for movement between the closed position (FIGS. 2 and 6) and an open position (FIG. 1). For purposes of illustrative disclosure, the copier unit 10 is of the electrostatic type wherein an original document is illuminated and an image of any indicia thereon is projected through an optical system to light sensitive copy paper, the resultant latent electrostatic image then being developed by the application of toner particles to the paper in a manner well known in the art.
More particularly, the copier unit 10 illustrated herein (see FIG. 1) includes a substantially rectangular housing including side walls 14, 16. A copy paper transport system 18 is provided to transport a length of copy paper along a pathway from a copy paper input 20 to a copy paper output 22, the copy paper being stored in a roll 24 supported on a spindle. The copy paper transport system 18 is further defined by cooperating pairs of feed rollers 26, 28, 30, 32 and 34 spaced apart along the pathway and which serve to convey the copy paper past a corona discharge station 36, an image receiving station 38, a developing station 40, and, finally, to an output conveyor 42 leading to the copy paper output 22. A knife 44 is positioned in the copy paper pathway between feed roller pairs 26 and 28 to sever the copy paper to a length corresponding to that of the original document.
The top face of the copier unit 10 is constituted by a feed deck 45 and by a set of transversely extending guide plates 46, 48 and 50 and feed rollers 52, 54, 56 and 58. This guide plate and feed roller set in cooperation with a corresponding set of guide plates and feed rollers of the module 12 to be described hereinafter forms an original document transport system for transporting original documents along a straight line document path to and past an illuminating station, defined by scanning window 60. As will be described hereinafter, travel of the original document along the straight line original document path is synchronized with that of the copy paper along the copy paper path. Briefly, the timed relationship is such that at the time the original document reaches the scanning window 60, a corresponding length of copy paper (severed by knife 44) has travelled past the corona discharge station 36 so as to be charged thereby and has reached the image receiving station 38. When the original document reaches the scanning window 60, it is illuminated by a high intensity exposure lamp 62. Light reflected from the original document is transmitted through an optical system, including mirror 64 and lens 66, onto the sensitized copy paper passing across the image receiving station 38. The developer station 40 includes a receptacle 68 containing toner solution 70. Feed roller pair 34 squeeze the toner back into the receptacle and transfer the copy paper on to the output conveyor 42.
The feed module 12 basically comprises a pair of complementary shaped side frame walls 72, 74 interconnected by a pair of the bars 76 and 78, a tie rod 80 and a horizontal base plate 82. Supported between the side frame walls 72, 74 and below the base plate 82 is a set of transversely extending guide plates 84, 86 and 88 and feed rollers 90, 92, 94 and 96. As stated hereinabove this guide plate and feed roller set cooperates with the guide plate and feed roller set of the copier unit 10 to define the original document transport system. As will be discussed below, the feed module 12 further includes facility for receiving a feed table or chute for supporting a stack of original documents, and a feed system, including a document separator mechanism and a transport guide system, for automatically feeding original documents successively from the feed table to the original document transport system.
With reference to FIGS. 2 and 3 the feed table or chute 98 is shown in its normal inserted position within the module 12. The chute 98 comprises a unitary, generally channel shaped, downwardly extending side walls 100, 102 and a top wall 104 which serves as a bottom support table for stacked original documents. The chute 98 is supported between the side frame walls 72, 74 of the module 12 by locating pins 106, 108 extending inwardly from the side frame walls and by tie bar 78, the leading edge regions of the side walls 100, 102 having arcuate cut out portions S to receive and seat upon the locating pin 106, 108 and the bottom rear edge regions of the side walls 100, 102 being shaped to seat upon tie bar 78. Elongated angle shaped guides 110, 112 attached to the inner faces of side frame walls 72, 74 facilitate insertion of the chute therebetween.
A pair of document side guides 114, 116 are mounted upon the top wall 104 of the chute. The side guides 114, 116 are generally angle-shaped in configuration, each comprising an upstanding wall 118 having an inwardly turned leading edge region 120 and an inwardly extending bottom wall 122. Provision is made for adjustable transverse movement of the side guides 114, 116 so that documents of various widths can be accommodated by the chute. To this end a transverse slot is formed in the top wall 104 of the chute through which extend sliders 124, one for each of the document side guides, which are fixed to the underside of the bottom walls 122 of the document side guides. Downwardly turned portions 126, 128 of the top wall 104 of the chute both define the above mentioned slot and define runners of the sliders. Each slider is provided a thumb screw 129 which extends through a transverse slit in wall portion 126 to enable sidewise adjustment of the document side guides.
The document separating arrangement of the document feed system includes a feed tire 130 of relatively soft, high friction rubber, supported on a wheel 132 that is fixed on rotatable shaft 134 extending between journals (not shown) supported by the side frame walls 72, 74. Completing the document separating arrangement, a mount 136 carries a pair of friction bars 138, 140 in flanking relationship with respect to the feed tire 130. Proper spacing, to be discussed hereinbelow, between the friction bars is maintained by virtue of a spacer plate 142 affixed to mount 136. A channel shaped bracket 144 and cooperating thumb screw 146 maintain the friction bars positionally upon the mount and permit adjustable movement thereof along the direction of feed (i.e. to the left or right in FIG. 2). The friction bars are disposed, as best shown in FIG. 2, such that the plane defined by the upper surfaces thereof slightly intercepts the outer periphery of the feed tire. To permit adjustment in the amount of such intercept, screws 148 and 150 extend through slots in the mount so that the entire mount can be shifted in the direction of feed. Such adjustment need only be made once.
With reference to FIGS. 3, 4 and 6, it will be noted that the plane of the support table 104 of chute 98 is slightly inclined with respect to the plane defined by the flat top surfaces of bars 138 and 140 and is substantially tangent to the tire 130. It will also be noted that the forward region of the support table is cut out to define an opening 104A such that, when the chute is in place, the bars 138 and 140 can freely extend through the cut out region and above the plane of the support table 104. A tongue 104b of the support table 104 extends into the cut out region between the bars 138 and 140 to the point where the plane defined by the upper surfaces of bars 138 and 140 intercepts the plane defined by the upper surface of support table 104. This point is slightly short of the region of pinch P (See FIG. 5) between the bars 138 and 140 and feed tire 130 (i.e. the length region along bars 138 and 140 below the top surface of which the feed tire dips).
In the presently referred form illustrated herein, the feed tire 130 and wheel assembly is a conventional assembly commonly used in various feeding applications, the tire being of pure gum rubber and having a width of 1/2 inch and the wheel-tire assembly having a diameter of 1-9/16 inches. With particular reference to FIG. 4, a sectional view through the axis of the tire 130 and along a line normal to the plane of support table 104, the bars 138 and 140 are positioned in the illustrated embodiment to afford a penetration of the tire 130 below the upper surfaces thereof of approximately 1/32 inch and a clearance between the feed tire and each of the bars of approximately 1/16 inch. In the embodiment disclosed herein the bars are formed of aluminum with an approximately 1/16 inch thick top layer of rubber bonded thereto. The rubber constituting the upper surface of bars 138 and 140 in the embodiment illustrated herein is 70 durometer neoprene exhibiting a surface friction greater than that of paper. (It has been found that the surface friction of such rubber purchased in strip form from suppliers can vary. Whether the neoprene is suitable can quickly be determined upon pushing one's finger with gentle pressure over the surface. If the finger slides along smoothly, the rubber will not be satisfactory. If the finger bumps along the surface, the rubber will be satisfactory).
The above described feed tire and friction bar arrangement enables, as stated hereinabove, proper feeding of a stack of documents and requires no adjustment to maintain such proper feeding even though the thicknesses of documents being fed vary from that of vellum to that of relatively heavy cardstock such as punch cards and the like. The reason for this attribute can be best understood with reference to FIGS. 2 and 4. As is conventional, any stack of documents to be fed is first fanned (i.e. slanting the stack so that the leading edge of the upper of any two adjacent sheets of the stack slightly overhangs the leading edge of the lower of such adjacent sheets) and then slid into the supply chute 98. Because the stack has been fanned, the leading edges of the upper documents will be urged downwardly by the pressure of the feed tire on the upper leading edge region of the topmost sheet. Depending upon considerations such as the height of the stack and the extent to which the stack has been fanned, the leading edge of the topmost document may or may not initially be located at or near the pinch area P (see FIG. 5). Likewise, if the stack has not been perfectly fanned, the leading edge of the topmost document may not overhand or lead the leading edge of the sheet immediately therebelow. In any case, upon rotation of the feed tire 130 (clockwise direction in FIG. 2) the topmost document will be drawn in the feed direction. If the leading edge of the topmost document initially was at the pinch area P, immediately upon being drawn the upper surfaces of friction bars 138 and 140, and particularly the upper edges thereof adjacent the tire 130, will engage spaced apart localized underside regions of the sheet being drawn to maintain such regions in a plane that slightly intercepts the perimeter of the tire. Such results in a slight bending of the sheet between such spaced apart regions by the pressure of the feed tire upon the top-side of the sheet, as well as pinching forces acting between the inner edge regions of the bars and the underside of the sheet and acting between the tire and topside of the sheet. The rolling coefficient of friction of the tire, being greater than that of the sliding coefficient of friction of the rubber, forming the top inner edge region of the bars 138 and 140, the sheet will continue to be drawn by rotation of the tire. If the leading edges of two sheets simultaneously reach the area of pinch P, rotation of the feed tire will draw only the upper of the two documents because the pinching forces and higher coefficient of friction of the rubber of bars 138 and 140, as compared with that of paper, almost immediately causes a condition of slide between the sheets.
It has been found that the document separating and feeding mechansim illustrated herein results in no damage to the sheets being fed. In this connection it should be noted that the feed tire, being of resilient material (pure gum rubber in the illustrated embodiment) will tend to flatten against a relatively stiff document rather than bend it enough to cause any creasing. Testing has shown that the amount of bending inflicted upon sheets of thin, flexible material is sufficient to cause permanent creasing or other damage.
Document separating and feeding mechanisms, such as that disclosed herein, have been found to be capable of several thousand successive operations on documents of variable thickness prior to a misfeed. The mechanism will begin to occassionally misfeed after the top inner edges (i.e. the neoprene) of the bars 138 and 140 wear down to the extent that insufficient pinching action is available. With the arrangement illustrated herein, when such wear has occurred, the thumb screw 146 can be loosened and the position of the bars 138 and 140 adjusted so as to present unworn top inner edge regions in the pinch area P. In this connection the disposition of the elongated bars illustrated herein need only be such as to afford edge regions in the pinch area. The choice of neoprene to serve as the edge regions was made after determining that such material exhibited excellent wear characteristics as well as suitable frictional characteristics. In similar vein the configuration of the bars 138 and 140 was selected in order to afford the ability to easily replace worn edges in the pinch area P. Fine abrasive stone would be a suitable alternative to the neoprene except that it exhibits less desirable wear characteristics.
The transport guide system of the document feed system includes a pair of receiving guides 152, 154; a pair of direction reversing guides 156, 158; and feed roller pair 160, 161, all of which extend between the side frame walls 72, 74 of the feed module 12. In order to afford access to the document reversing path, reversing guide 156 is removably secured in spaced relation to guide 158 by a pair of thumb screws 159 which are in threaded engagement with annular seats 159a fixed to guide 158. The seats 159a are located near the side frame walls 72, 74 so as not to impede the document path.
Completing the document feed system, a switch 162 mounted upon the base plate 82 of the feed module, has a wire trip arm 164 extending through aligned slits 166, 168 of reversing guides 156, 158 so as to be deflected upon passage of a document therebetween. As will be explained hereinbelow, when trip arm 164 is deflected, switch 162 acts to prevent feed tire 130 from operating to further separate documents from the document stack.
Referring now particularly to FIG. 6 and 7, the mechanical drive means for the original document transport system and the copy paper transport system will be described. A motor (not shown) drives a main sprocket 182, which in turn drives a continuous revolving drive chain 184. The rollers 52, 54, 56 and 58 of the copier unit 10 are linked to the chain 184 respectively by sprockets 186, 188, 190 and 192. Operating driving force is imparted to the document feed system of the feed module through the engagement of driven feed roller 52 of the copier unit 10 with feed roller 90 of the feed module 12. The rotary motion, imparted to roller 90, is transmitted via a gear train comprising input gear 170 (which is fixed to rotate with roller 90), idler gears 172, 174, driven gear 176 (which is fixed to rotate guide roller 161) and driven gear 178. Gear 178 is connected through an electrically operated clutch 180 such that it is connected to drivingly rotate shaft 134 when clutch 180 is engaged. One roller each of roller pairs 26, 28, 30, 32 and 34 of the copy paper transport system are similarly linked to the chain 184 respectively by sprockets 194, 196, 198, 200 and 202. The other roller of each cooperating pair is an idler roller. A copy paper clutch, indicated generally by the reference numeral 204 (FIG. 7) couples and decouples sprocket 194 from the shaft of the input drive roller of roller pair 26. When the clutch energizes, the input roller pair 26 pulls the copy paper from the roll 24 into the copy paper pathway and past the knife 44 toward the roller pair 28.
A document-switch 206 (FIG. 2) is centrally positioned between sidewalls 14, 16 of the copier unit adjacent to the input driver roller 52. Switch 206 includes a trip arm 208 and stationary terminals 210 and 212. Arm 208 is depressed by the leading edge of an original document from an original-position in contact with terminal 210 to a copy-position in contact with terminal 212. When switch 206 initially switches into a copy-position, clutch 204, a knife relay 214 and a first solenoid stop means 216 energize.
The knife relay 214 controls switches 218 and 220. Switch 218 includes a switch arm 221 and contacts 222 and 224; and switch 220 includes switch arm 226 and contacts 228 and 230. Switch arm 221 is connected to terminal 232 of a knife solenoid 234. The energizing or de-energizing of the solenoid 234 causes knife switch 236 to open and close. The other terminal 238 of knife solenoid 234 is connected to line 1 of the AC power. Contact 222 is connected to contact 210 of switch 206, and contact 224 is unconnected. Switch arm 226 is connected to line 2 of the AC power. Contact 228 is connected to contact 212 of document-switch 206, to input power terminal 240 of the first solenoid stop means 216 and a terminal 242 of knife switch 236. The other input power terminal 244 of the stop means 216 is connected to AC line 1. Contact 230 is connected to input power terminal 246 of a second solenoid stop means 248. Input power terminal 250 of knife relay 214 is connected to AC line 1 and input terminal 252 is connected to switch arm 254 of knife switch 236 and terminal 256 of copy clutch 204.
A light relay 258 includes a switch 260 having a switch arm 262 moving between contacts 264 and 268. Switch arm 262 is connected to AC line 1; contact 264 is connected to input power terminal 270 of the second solenoid stop means 248, to the corona power supply 36' and to the high intensity exposure lamp 62; and contact 268 is connected to a heater unit 272. Input power terminals 274 and 276 of relay 258 are connected respectively to AC line 2 and contact 278 of a copy-switch 280.
Contact 282 of copy-switch 280 is connected to terminal 284 of clutch 204; and switch arm 286 of copy-switch 280 is connected to AC line 1. The corona power supply 36' and exposure lamp 62 are turned "on" when switch arm 286 connects with contact 278.
A cam-switch control cooperates with the copy-switch 280 to primarily control the "on-off" of the corona and the exposure lamp. The switch control means comprises a cam 290 comprising an outward extending neck portion 292 having an arcuate outer edge. The leading side edge 294 of the cam abutte fingers 296, 298 (See FIG. 6) respectively of the first and second solenoid stop means 216 and 248 at different times of the copy cycle. The outer edge of neck portion 292 depresses the switch arm 286 of the copy-switch 280. The fingers 296, 298 respectively of solenoid stop means 216 and 218 block the cam 290 when in a de-energized condition and release the cam in an energized condition.
A gear train indicated generally by reference numeral 300 links cam 290 with the chain drive 184 (FIG. 6). Gear train 300 comprises an input gear 302, output gear 304, and intermediate gears 306 and 308. Input gear 302 meshes with chain coupling gear 310 which is fixed to the shaft of the driven roller of roller pair 30. Sprocket 198 linked with main chain 184 is also mounted on such shaft. Output gear 304 and cam 290 are mounted on a stub shaft 312. Intermediate gear 308 is linked with intermediate gear 306 and the output gear 304.
The rotational speed of cam 290 is the same as the rotational speed of the output gear 304. The speed of the output gear with respect to the speed of the chain 184 or a gear directly linked with the chain is determined by the size of the coupling gear 310, the input gear 302, the intermediate gear 306 and the output gear 304. Gear 308 functions primarily as a transmission gear.
The feed tire clutch 180 has one of its terminals 314 directly connected to a terminal 316 of a male plug 318 that is fixed to project through the underside of the feed module 12 and engage with a female socket 320 fixed to the topside of the copier unit 10. The other terminal 322 of clutch 180 is connected to switch arm 164 of switch 162. Terminal 324 of switch 162 is connected to the other terminal 326 of plug 318. Terminal 328 of female socket 320 is normally connected to AC line 1 while its other terminal 330 is connected through a low paper switch 332 to terminal 210 of switch 208. Switch arm 334 of low paper switch 332 is operable to break the connection between terminals 210 and 330 when the supply of copy paper on roll 24 is nearly exhausted. A low paper by-pass switch 336 can be used to override low paper switch 332.
Operation of the sequential switching of the machine will be first described for the manual mode of operation. All switches in FIG. 7 are shown in their respective positions prior to inserting an original document into the machine for reproduction. When the original document is inserted, its leading edge depresses arm 208 of document-switch 206 from the original-position of the copy-position, causing the clutch 204, the knife relay 214 and the first solenoid stop means 216 to energize. The energized clutch 204 enables input roller pair 26 to pull the copy paper into the copy paper transport system.
In the energized or "on" state for knife relay 214, switch 218 provides a pathway from AC line 2 to terminal 232 of the knife solenoid 234, which becomes the sole pathway to line 2 for the knife solenoid after the document-switch 206 is switched back to its original position; and switch 220 provides a pathway from AC line 2 to terminal 252 of the knife relay 214 via knife switch 236, to maintain the knife relay 214 energized for the time interval after the document-switch 206 has returned to its original position and prior to the operation of the knife solenoid 234 of knife 44.
Prior to the release of the first solenoid stop means 216 from contact with the cam 290, the outer edge of neck portion 292 of the cam maintains switch arm 286 in connection with contact 282 of the copy-switch 280, which is its initial-position. When the first solenoid stop means 216 is energized, finger 296 is moved out of contact with cam 290. The cam now free of contact with finger 296 rotates clockwise until the leading edge 294 of neck portion 292 abuts the second finger 298 of the second solenoid stop means 248. During the cam movement between the first and second stop means 216 and 248, the neck portion 292 moves out of contact with the copy-switch 286. When this occurs, the copy-switch 280 switches into its operational-position, thereby severing the path between AC line 2 and clutch 204 and energizing the light relay 258. When the clutch is de-energized, the driven roller of roller pair 26 is decoupled from chain 184 and the copy paper is primarily pulled along the guide path by roller pair 28.
When light relay 258 is energized, relay switch 260 severs the path between the heater means 272 and AC line 2 and connects AC line 2 with the corona high voltage power supply 36', the exposure lamp 62, and terminal 270 of the second solenoid stop means 248.
When the trailing edge of the original document has moved past the document-switch 206, switch arm 208 returns to to its original position; thereby providing a current path between AC line 2 and terminal 232 of knife solenoid 234 via switch 218 of knife relay 214. This energizes the knife solenoid 234, causing a length of copy paper to be severed from the roll and the solenoid switch 236 to "break open."
When solenoid switch 236 is open, the path between terminal 252 of the knife relay 214 and AC line 2 is severed, causing the knife relay 214 to de-energize. Switch 220, in its de-energized or "off" state, servers the AC link with the first solenoid stop means 216 and provides a link between AC line 2 and terminal 246 of the second solenoid stop means 248, causing respectively the first stop means 216 to deenergize and the second stop means 248 to energize.
When the second stop means 248 is energized, finger 298 is moved out of contact with cam 290. The cam, now free of contact with finger 298, continues its clockwise rotation until contacting finger 296 of the first stop means 216. Prior to reaching finger 296, the cam switches the copy-switch 280 from the operational-position to the initial position.
When the copy-switch 280 switches back to the initial-position, light relay 258 is de-energized, thereby turning off the corona power supply 36' and the exposure lamp 62. Now the machine is in stand by awaiting another original document.
Operation for the power feed or automatic feed mode is the same as the manual mode except that the sequence is initiated by the feed tire 130 drawing the uppermost from a stack of documents located in the chute into the nip of roller pair 160, 161. When the leading edge of such document reaches the trip arm 164 of feed roller switch 162, the trip arm is depressed by the document which breaks the connection between terminal 314 of the feed tire clutch 180 and AC line 1 thereby deactivating the feed tire and preventing it from drawing another document. Travel of the previously drawn document continues under the influence of roller pair 160, 161 until such document is guided into the original document transport path and into the nip of roller pair 52, 90. The leading edge of the document depresses trip arm 208 which breaks the connection between terminal 322 of the feed tire clutch 180 and AC line 2 thereby preventing feed tire 130 from further drawing another document. When the trailing edge of the document passes trip arm 208, terminals 314 and 322 are both connected with their respective AC lines and feed tire 130 is operable to draw a subsequent document from the stack. The distance between trip arms 164 and 208 is preferably slightly less than the minimum length of original document recommended for use in order to insure that trip arm 164 is not released until trip arm 208 is depressed. This distance is 51/4 inches in the illustrated embodiment.
With reference to FIGS. 1 and 2 it will be noted that when the feed module 12 is swung to its open condition the set of guide plates 46, 48 and 50 and feed rollers 52, 54, 56 and 58 are completely free so as to permit their utilization for the purpose of making copies of documents which are not in sheet form. To make a copy of a book page, for example, the operator need only rest the book upon the feed deck with the leading edge of the book page to be copied atop roller 52 and initiate the copy sequence. The operator, by maintaining light downward pressure on the book, allows the rollers 52 to move the book toward roller 54 and ultimately to rollers 56 and 58 past the illuminating window 60 in proper timed relationship with the copy paper.
It will now be apparent that there has been provided a photocopy machine which avoids the disadvantages of prior constructions and which achieves the foregoing objects. In this connection it should be understood that, while a specific preferred embodiment has been disclosed herein, various changes and variations may readily be made without departing from the spirit and scope of the appended claims.
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Photocopy machine having a feed module for successively feeding individual original documents from a stack thereof. Cooperating portions of the feed module and of the photocopying machine form a straight line original document feed path having an entryway that is accessible for conventional insertion of original documents. The feed module includes apparatus for successively feeding original documents from a stack along a direction reversing path that leads to the above entryway of the straight line feed path. The feed module can be pivoted to afford access to the straight line original document path and to permit copying of original documents which cannot be sheet fed. The feed module includes an original document separating arrangement wherein a feed tire and flanking retarder bars are cooperatively disposed so as to obviate need for any adjustment of the arrangement to afford proper feeding of documents of variable thickness.
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RELATED APPLICATION
This application is a non-provisional application claiming priority on U.S. Provisional Patent Application Ser. No. 61/237,447 filed Aug. 27, 2009, which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
The invention relates to protective substrates applied to batteries and methods for making and applying same.
BACKGROUND
Battery packs are used in many environments including medical equipment, environmental monitoring equipment and power tools, to name a few. Each battery pack can include, for example, one or more battery cells, connectors that are welded to the cells to electrically connect the cells, one or more sheets of vulcanized paper adhered to a top and/or bottom of the cells, and shrink wrap that encloses the cells, connectors and vulcanized paper.
The vulcanized paper, which is also known as “fish paper”, can serve to serve to insulate the cells and otherwise protect the cells from damage, such as damage that may result from an impact to the battery pack. Vulcanized paper can be adhered to the top or bottom of the cells in various manners. In one example, a worker can bond vulcanized paper to the cells by applying a layer of adhesive to the vulcanized paper and then quickly pressing the vulcanized paper against the cells and allowing the adhesive to set. In another example, the vulcanized paper can be manufactured to include an adhesive layer on one of its sides, and the adhesive layer can be covered with backing paper to protect the adhesive layer until the vulcanized paper is ready to be applied to the cells. At the time of applying the vulcanized paper to the cells, a worker can peel the backing paper from the vulcanized paper and then press the vulcanized paper against the cells to bond the vulcanized paper to the cells.
Bonding vulcanized paper to battery cells is problematic. Having a worker bond vulcanized paper to the cells by applying a layer of adhesive to the vulcanized paper and then quickly pressing the vulcanized paper against the cells and allowing the adhesive to set is an inefficient and time consuming operation. For example, the worker must manually apply the layer of adhesive to each piece of vulcanized paper and evenly distribute the adhesive on a surface of the vulcanized paper before bonding the vulcanized paper to the cells. Additionally, manufacturing vulcanized paper to include an adhesive layer on one of its sides and covering the adhesive layer with backing paper until the vulcanized paper is ready to be applied to the cells is also inefficient. Workers often struggle to remove the backing paper from the vulcanized paper. Since different patterns of vulcanized paper are often cut from stock sheets of adhesive-backed vulcanized paper using an automated die, laser or water cutting tool, it is impractical to use backing paper that is pre-scored (i.e., scored prior to cutting patterns into the stock sheet) because the scores may not line up with the cut patterns of vulcanized paper.
SUMMARY
Examples of a protective layer for positioning on adjacent battery cells in a battery pack are shown. In one such example, the protective layer includes a substrate including a main section having a shape substantially corresponding to at least one surface of the battery cells and having a tab extending from an edge of the main section. The tab is frangibly coupled to the main section. A backing material overlays the substrate in a region corresponding to at least a portion of the main section and the tab. A layer of adhesive material between the backing material and the substrate to releasably bond the backing material to the substrate. The backing material is selectively removable in response to breaking the tab from the main section and peeling the backing material from the main section to expose the layer of adhesive on the main section.
BRIEF DESCRIPTION OF THE DRAWINGS
The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
FIG. 1 is an exploded perspective view of a plurality of battery cells and a protective layer;
FIG. 2 is a perspective view of a stock sheet of vulcanized paper having an adhesive layer and backing paper that is partially peeled away from the vulcanized paper;
FIG. 3 is a top elevation of the stock sheet of vulcanized paper having the adhesive layer and backing paper illustrating a cutting template for forming a plurality of protective layers, the stock sheet oriented such that the vulcanized paper side faces upward;
FIG. 4 is a cross section view along line A-A in FIG. 3 at a junction between a main section and a tab of one of the protective layers;
FIG. 5 is another example of a cross section view along the junction between the main section and the tab of one of the protective layers;
FIG. 6 is a perspective view of one of the protective layers oriented such that its backing paper faces upward; and
FIG. 7 is a perspective view of the protective layer of FIG. 6 with the tab separated from the main section and the backing paper partially peeled from the main section.
DETAILED DESCRIPTION
A protective layer for positioning adjacent at least one of a first end and a second end of one or more battery cells in a battery back is disclosed and the protective layer can be easily applied to the battery cells. In one embodiment, the protective layer includes a brittle substrate having a main section having a shape substantially corresponding to a perimeter of the first or second end of the one or more battery cells and having a tab extending from an edge of the main section. The substrate defines one or more perforations along a junction between the main section and the tab. A layer of adhesive overlays a surface of the substrate, and backing paper having a shape corresponding to the main section and the tab of the substrate is attached to the layer of adhesive. The backing paper is selectively removable in response to breaking the tab from the main section and peeling the backing paper from the main section to expose the layer of adhesive on the main section.
As shown in FIG. 1 , an example of a battery pack 10 can include one or more battery cells 12 , with the illustrated battery pack 10 including three cells 12 . Alternatively, a different number of cells 12 can be included. The cells 12 can be lead-acid cells, lithium-ion cells, nickel-cadmium cells or another type of cells. Each cell 12 can have a top or first end 12 a and a second or bottom end 12 b opposite the top end 12 a . Each end 12 a and 12 b can be electrically conductive. For example, the top end 12 a can define a positive terminal and the bottom end 12 b can define a negative terminal. The cells 12 can be oriented in alternating fashion with a first cell having its top end 12 a oriented upward, a second cell having its bottom end 12 b oriented upward, a third cell having its top end 12 a oriented upward, etc.
The cells 12 can be electrically connected to one another using connectors 14 . The connectors 14 can be formed of a highly electrically conductive material, such as nickel, brass or silver. Each connector 14 can extend between respective terminals of a pair of adjacent cells 12 and can be electrically connected thereto. For example, a first end of one of the connectors 14 can be connected to a positive terminal of one cell 12 and an opposing end of the connector 14 can be connected to a negative terminal of an adjacent cell 12 for electrical communication between the two cells 12 . Each connector 14 can be connected to cells 12 by, as an example, soldering the connector 14 to the cells 12 . While the cells 12 are shown as being serially connected, some or all of the cells 12 can alternatively be connected in parallel.
Still referring to FIG. 1 , a protective substrate 16 can be positioned against an end 10 a of the battery pack 10 . While not shown, another substrate can be positioned against an opposing end 10 b of the battery pack 10 . The substrate 16 can have shape substantially corresponding to a perimeter of the group of cells 12 . For example, the substrate 16 can be shaped to overlay the conductive portions at the ends 12 a and 12 b of the cells 12 on the end 10 a of the battery pack 10 . As another example, the substrate 16 can be shaped to corresponding to a perimeter shape defined by the ends 12 a and 12 b of the cells 12 in aggregate. As yet another example, the substrate 16 can be shaped to overlay the terminals of the cells 12 a and 12 b without extending to the perimeters of the ends 12 a and 12 b of the cells 12 .
The substrate 16 can be formed of a brittle material such as vulcanized paper, also known as “fish paper”, of the type available from S & S Electronics of Oceanside, Calif. or Composite Components of Carlsbad, Calif., among others. When made of vulcanized paper, the substrate 16 can have a thickness of 0.010 inches to 0.062 inches, though the substrate 16 can have a thickness outside that range. Instead of being constructed from vulcanized paper, the substrate 16 can be formed of another material such as cardboard, PVC, thermoplastic such as sold under the trademark Plexiglas or another material. The substrate 16 can be highly electrically insulating, and the substrate 16 can additionally have other properties such as a high impact resistance and/or an aversion to chemical reactions. The substrate 16 can protect the battery 10 from damage if the battery 10 is impacted, and the substrate 16 can also provide insulation to avoid unintended paths of electrical flow. Alternatively, the substrate need not be brittle.
Referring now to FIG. 2 , a stock sheet of material 18 , e.g., vulcanized paper, from which the substrate 16 is formed is shown. The stock sheet of material 18 can have a standard size, such as 18″ by 24″, or the material 18 can come in rolled form. The material 18 can have a first side 18 a and a second side 18 b . A layer of adhesive 20 can be applied to the second side 18 b of the material 18 , and backing paper 22 can overlay the layer of adhesive 20 to form a composite as best seen in FIGS. 4 and 5 . The backing paper 22 can be peelable from the adhesive 20 . For example, the backing paper 22 can be made of a material that is not strongly bonded to the adhesive 20 .
As shown in FIG. 3 , a plurality of patterns 24 , each corresponding to one of the substrates 16 and a tab 26 conjoined therewith (see FIG. 6 ) once cut from the material 18 , can be arranged on the material 18 to maximize the number of substrates 16 produced from the material 18 . The patterns 24 can be programmed in an automated cutting machine and need not actually be transcribed onto the material 18 . The substrates 16 and tabs 26 can be die cut, laser cut, water cut, or otherwise cut from the material 18 . Cuts can extend through the material 18 and the backing paper 22 in order to separate each substrate 16 and its tab 26 from the remainder of the material 18 .
In addition to cutting the substrates 16 from the material 18 , perforations 28 can be formed between the substrate 16 (also referred to as a main section) and its tab 26 as shown in FIG. 4 . The perforations 28 can be at a junction between each substrate 16 and its tab 26 , such as along an edge or perimeter of the substrate 16 . In the example shown in FIG. 4 , the perforations include alternating through perforations 28 a that extend from one side of the substrate 16 to the other side of the substrate 16 without penetrating the backing paper 22 and shallow perforations 28 b that do not extend all the way to the backing paper 22 . The perforations 28 thus result in the tab 26 being frangibly connected to the substrate 16 by only spaced apart portions of the tab 26 having a thickness less than the thickness of the substrate 16 , while the backing paper 22 covering the tab 26 is fully intact with the remainder of the backing paper 22 . The perforations 28 can be formed by configuring the power of a cutting tool and/or timing during which the cutting tool performs a cutting operations between the substrate 16 and tab 26 to achieve a desired perforation 28 depth, such as operating the cutting tool for a longer time and/or at a higher power while forming perforations 28 a compared to perforations 28 b.
The perforations 28 can have an alternative form than shown in FIG. 4 . For example, FIG. 5 shows another example of perforations that include only perforations 28 a , which extend from one side of the substrate 16 to the other side of the substrate 16 without penetrating the backing paper 22 . The perforations 28 shown in FIG. 5 may be necessary, for example, when variable cutting tool power is not available.
After cutting each substrate 16 and its tab 26 from the material 18 and forming perforations 28 that facilitate separation of the tab 26 from the substrate 16 , the substrate 16 , tab 26 and backing paper 22 assembly shown in FIG. 6 is ready to be distributed to a worker for applying the substrate 16 to cells 12 . The backing paper 22 can easily be separated from the substrate 16 , thereby exposing the adhesive layer 20 , by breaking the tab 26 from the substrate 16 along the perforations 28 and then peeling the backing paper 22 from the substrate 16 . The tab 26 thus facilitates removal of the backing paper 22 from the substrate 16 by allowing a worker to grasp the tab 26 and backing paper 22 while peeling the paper 22 from the substrate 16 . After removing the backing paper 22 from the substrate 16 , the worker can apply the substrate 16 to the cells. At the time of applying the substrate 16 to the cells, the worker can press the substrate 16 against the cells so that the adhesive layer 20 bonds the substrate 16 to the cells.
The above-described examples have been described in order to allow easy understanding of the protective layer and do not limit the protective layer. On the contrary, the attached claim is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structure as is permitted under the law.
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Disclosed herein an adhesive substrate having a peelable backing for use with battery packs. The adhesive substrate can include an integral tab, and perforations can be formed between a main body of the substrate and the tab. To peel the backing from the main body, the tab can be detached from the main body while remaining bonded to the peelable backing. The tab can be pulled to peel the backing from the main body of the substrate. The substrate is then applied to the battery pack.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application does not have any related US patent applications at the time of filing.
TECHNICAL FIELD
The presently claimed invention has applicability with consumer electronics implementations where device interoperability is desired. More specifically, the claimed invention relates to processing a concurrent IGRS-UPnP architecture for both IGRS and UPnP standards conformance.
BACKGROUND OF THE INVENTION
Consumer electronics standards often promise far more than at times are actually delivered. Often additional device standards result in a reduction in device interoperability rather than enhanced functionality. U.S. Pat. No. 7,218,243 entitled “System and method for automatically setting up a universal remote control” is one example of a system and method that describes configuring a remote control device automatically. The disclosed system and method has an aspect in common with the other references addressed in that an additional server and database is needed to upload required interface information. As a result of the external server connection, security issues and device inefficiency can arise.
U.S. Pat. No. 7,206,853 entitled “Content abstraction layer for use in home network applications” similarly defines a network architecture for a network of electronic devices including a device layer having a plurality of electronic devices interconnected using a network backbone. In the disclosed network architecture, many of the electronic devices each operate using a device native communication protocol. To control the electronic device through the defined abstraction layer, the disclosed Control Point needs to be implemented using a proprietary API.
The published Chinese patent application number 200610021946.1 details the architecture of middleware that transfers user inputted WSDL document to an IGRS service and generates source code.
The published Chinese patent number 00808405.X describes a gateway that connects devices on the UPnP network and HAVi network and translates two protocols, so devices can discover and control other different protocol devices through a dedicated gateway device.
SUMMARY OF THE INVENTION
Problems with the aforementioned references include the fact that none support concurrent IGRS and UPnP protocols. Most of the references require an external gateway to translate UPnP protocol to other protocols and concentrate on designing a Control Point in order to control devices with different protocols. According to the claimed device and related method the remote control built using the claimed invention stack can control both IGRS and UPnP devices and as a result no additional setup is required. Devices using the claimed invention can be controlled by any IGRS or UPnP standard Control Point. According to the claimed invention a defined stack provides API for developers to register their callback and transfer to service that conforms both IGRS and UPnP standards. As a result, the claimed invention enables one device to support two protocols and no external device is needed. Additionally, some of the disclosed devices need additional modification to the existing device in order to implement additional standard capability. The devices disclosed in the references need to connect to an additional server and database to upload required interface that can cause security issues as well as device inefficiency. The remote control built using the stack related to the claimed invention can control both IGRS and UPnP devices and no additional setup is required.
By circumventing the need for an external gateway, the claimed devices are able to use a single Control Point to support both IGRS and UPnP appliances. Devices with a concurrent UPnP/IGRS stack can be controlled by either IGRS or UPnP compliant Control Point and no modification is required for existing IGRS/UPnP devices. IGRS and UPnP both have the same goal in that both wish to deliver an industry standard to complete cross-industry device convergence. Both standards focus on the same consumer electronics products including intelligent appliances and mobile devices in home and corporate environments. Both standards have adopted similar distributed, open networking architecture. In addition, both have adopted the same TCP/IP, XML and HTTP standards. The primary intention is coexistence where device instructions and commands can be presented in the same network without interference.
Owing to different message formats, security technologies and protocol headers IGRS and UPnP messages often result in message conflict and device error. Under the claimed invention, a Single Control Point is used to support both IGRS and UPnP Appliances. Devices with concurrent UPnP/IGRS stack can be controlled by either IGRS or UPnP compliant Control Point with no modification is required for existing IGRS/UPnP devices and no external gateway is required.
Table 2 gives an overall comparison of IGRS and UPnP protocols
TABLE 2
IGRS
UPnP
Transport
TCP/IP (IPv4)
TCP/IP (IPv4/IPv6)
and
HTTP 1.1
HTTP 1.0/1.1
Network
Protocol
Discovery
Adopts SSDP
Adopts SSDP
Package Length: verbose
Package length: short
Discovery multicast through
Discovery multicast
address: 239.255.255.250:1900
through address:
Response unicast through port
239.255.255.250:1900
3880
Response unicast through
Support Device Group Search
the IP add/port the
Support Device/Service Search
request message come
through Proxy
from
Advertise-
Adopts SSDP & GENA
Adopts SSDP & GENA
ment
Multicast address:
Multicast address:
239.255.255.250:1900
239.255.255.250:1900
Support online/offline
Send out 3 + 2d + k
eventing
advertisements each time
Notify service online/offline
status to group master device
Description
Retrieve description document
Retrieve description
from secure pipe or non-secure
document from service
URL
SCPD URL
Device description conform to
Description document
IGRS device description
base on UPnP description
template
document standard
Service description base on
WSDL1.1 with extension of
IGRS portType
Service
Control through service session
Control through service
Control
Base on SOAP standard
control URL
Base on SOAP standard
Use GENA for service
eventing
Security
Incorporate in to the
Defined Device Security
underlying message structure
and Security Console
Support secure pipe and secure
profile
session
Online Notification
When a device joins the network, it advertises the availability of itself and all services that it provides. This lets control points know about all of the device functionality and all of the various ways the device can be found. The notification is multicasted through the network
TABLE 3
IGRS Online Notification Message
Header
Required
Type
Description
Host
Required
Multicast
Must be 239:255:255:250:1900
address and
host
Cache-Control
Required
Must have
Specifies the number of seconds
max-age
that the
directive
advertisement is valid. Should
be larger than 3 seconds
Location
Required
Single URL
This URL points to the location
of the IGRS
device description document if
device supports
non-secure pipe. Otherwise the
value should be
http://www.igrs.org/device
NT
Required
Notification
May take one of the following
Type
forms:
uuid:deviceURN
serviceTypeURN
NTS
Required
Single URI
Must be ssdp:alive
Server
Required
String
Concatenation of OS name, OS
version,
IGRS/1.0, product name, and
product version
USN
Required
Single URI
May take one of the following
forms:
uuid:deviceURN
uuid:deviceURN::serviceTypeURN
Man
Required
String
Must be
“http://www.igrs.org/spec1.0”;ns=01
01-IGRS Version
Required
String
Must be IGRS/1.0
01-
Required
String
Must be one of the following
IGRSMessageType
values:
DeviceOnlineAdvertisement
ServiceOnlineAdvertisement
01-SourceDeviceId
Required
Single URI
Device URN
01-DeviceType
Required
Single URI
Device Type URN
if it is
IGRS
device
online
message
01-DeviceName
Required
String
Device name
if it is
IGRS
device
online
message
01-ServiceName
Required
String
Service name
if it is
IGRS
service
online
message
01-ServiceType
Required
Single URI
Service Type URN
if it is
IGRS
service
online
message
01-ServiceId
Required
32 bit
Service Id
if it is
unsigned
IGRS
integer (0
service
reserved)
online
message
01-ConfigId
Required
32 bit
The value shall be increased by
if it is
unsigned
1 whenever
IGRS
integer (0
there is a configuration change.
device
reserved)
And the value
online
will return to 1 when upper limit
message
is reached.
01-BootId
Required
32 bit
The value shall be increased by
if it is
unsigned
1 when the
IGRS
integer (0
device is rebooted. And the
device
reserved)
value will return to
online
1 when upper limit is reached.
message
01-
Required
String
Device group ID list, spaced by
DeviceGroupIdList
if it is
”;”.
IGRS
device
online
message
01-
Required
String
Device Security ID list, spaced
DeviceSecurityId List
if it is
by ”;”.
IGRS
device
online
message
01-
Required
String
Service Security ID list, spaced
ServiceSecurityId List
if it is
by ”;”.
IGRS
service
online
message
01-
Optional
String
Secure listener list, format of
SecureListenerList
each listener is
“IP address:port” and spaced by
“;” in the list
string.
01-ListenerList
Required
String
Listener list, format of each
listener is “IP
address:port” and spaced by “;”
in the list
string.
TABLE 4
UPnP Online Notification Message
Header
Required
Type
Description
Host
Required
Multicast
Must be 239.255.255.250:1900
address and
host
Cache-
Required
Must have
Specifies the number of seconds
Control
max-age
that the
directive
advertisement is valid. Should
be larger than
1800 seconds
Location
Required
Single URL
This URL points to the location
of the UPnP
device description document of
the root
device.
NT
Required
Notification
May take one of the following
Type
forms:
upnp:rootdevice
uuid:deviceURN
deviceTypeURN
serviceTypeURN
NTS
Required
Single URI
Must be ssdp:alive
Server
Required
String
Concatenation of OS name, OS
version,
UPnP/1.0, product name, and
product version
USN
Required
Single URI
May take one of the following
forms:
uuid:deviceURN::upnp:rootdevice
uuid:deviceURN
uuid:deviceURN::deviceTypeURN
uuid:deviceURN::serviceTypeURN
TABLE 5
Concurrent IGRS-UPnP Online Notification Message
Header
Required
Type
Description
Host
Required
Multicast
Must be 239:255:255:250:1900
address and
host
Cache-Control
Required
Must have
Specifies the number of seconds
max-age
that the
directive
advertisement is valid. Should
be larger than
1800 seconds
Location
Required
Single URL
This URL points to the location
of the
Concurrent IGRS-UPnP device
description
document if device supports
non-secure pipe.
NT
Required
Notification
May take one of the following
Type
forms:
upnp:rootdevice
uuid:deviceURN
deviceTypeURN
serviceTypeURN
NTS
Required
Single URI
Must be ssdp:alive
Server
Required
String
Concatenation of OS name, OS
version,
protocol/1.0, product name, and
product
version
USN
Required
Single URI
May take one of the following
forms:
uuid:deviceURN::upnp:rootdevice
uuid:deviceURN
uuid:deviceURN::deviceTypeURN
uuid:device-
URN::serviceTypeURN
Man
Required
String
Must be
“http://www.igrs.org/spec1.0”;ns=01
01-IGRSVersion
Required
String
Must be IGRS/1.0
01-
Required
String
Must be one of the following
IGRSMessageType
values:
DeviceOnlineAdvertisement
ServiceOnlineAdvertisement
01-SourceDeviceId
Required
Single URI
Device URN
01-DeviceType
Required
Single URI
Device Type URN
if it is
IGRS
device
online
message
01-DeviceName
Required
String
Device name
if it is
IGRS
device
online
message
01-ServiceName
Required
String
Service name
if it is
IGRS
service
online
message
01-ServiceType
Required
Single URI
Service Type URN
if it is
IGRS
service
online
message
01-ServiceId
Required
32 bit
Service identifier
if it is
unsigned
IGRS
integer (0
service
reserved)
online
message
01-ConfigId
Required
32 bit
The value shall be increased by
if it is
unsigned
1 whenever
IGRS
integer (0
there is a configuration change.
device
reserved)
And the value
online
will return to 1 when upper limit
message
is reached.
01-BootId
Required
32 bit
The value shall be increased by
if it is
unsigned
1 when the
IGRS
integer (0
device is rebooted. And the
device
reserved)
value will return to
online
1 when upper limit is reached.
message
01-
Required
String
Device group ID list, spaced by
DeviceGroupIdList
if it is
“;”.
IGRS
device
online
message
01-
Required
String
Device Security ID list, spaced
DeviceSecurityIdList
if it is
by “;”.
IGRS
device
online
message
01-
Required
String
Service Security ID list, spaced
ServiceSecurityIdList
if it is
by ”;”.
IGRS
service
online
message
01-
Optional
String
Secure listener list, format of
SecureListenerList
each listener is
“IP address:port” and spaced by
“;” in the list
string.
01-ListenerList
Required
String
Listener list, format of each
listener is “IP
address:port” and spaced by “;”
in the list
string.
Offline Notification: When a device is removed from the network, it notifies control points that it is going away by sending Offline Notification message corresponding to each of the Online Notification it has previously sent out. This notifies the control points that the device and its services are no longer available. The notification is multicasted through the network.
TABLE 6
IGRS Offline Notification Message
Header
Required
Type
Description
Host
Required
Multicast
Must be 239.255.255.250:1900
address and
host
NT
Required
Notification
Same as NT header value in
Type
corresponding
online notification message.
NTS
Required
Single URI
Must be ssdp:bye-bye
USN
Required
Single URI
Same as USN header value in
corresponding
online notification message
Man
Required
String
Must be
“http://www.igrs.org/spec1.0”;ns=01
01-IGRSVersion
Required
String
Must be IGRS/1.0
01-IGRSMessageType
Required
String
Must be one of the following
values:
DeviceOfflineAdvertisement
ServiceOfflineAdvertisement
01-SourceDeviceId
Required
Single URI
Same as 01-SourceDeviceId
header value in
corresponding online
notification message
01-ServiceId
Required
32 bit
Same as 01-ServiceId header
if it is
unsigned
value in
IGRS
integer (0
corresponding online
service
reserved)
notification message
offline
message
TABLE 7
UPnP Offline Notification Message
Header
Required
Type
Description
Host
Required
Multicast
Must be 239.255.255.250:1900
address and
host
NT
Required
Notification
Same as NT header value in
Type
corresponding
online notification message.
NTS
Required
Single URI
Must be ssdp:bye-bye
USN
Required
Single URI
Same as USN header value in
corresponding
online notification message
TABLE 8
Concurrent IGRS-UPnP Offline Notification Message
Header
Required
Type
Description
Host
Required
Multicast
Must be 239.255.255.250:1900
address and
host
NT
Required
Notification
Same as NT header value in
Type
corresponding
online notification message.
NTS
Required
Single URI
Must be ssdp:bye-bye
USN
Required
Single URI
Same as USN header value in
corresponding
online notification message
Man
Required
String
Must be
“http://www.igrs.org/spec1.0”;ns=01
01-IGRSVersion
Required
String
Must be IGRS/1.0
01-IGRSMessageType
Required
String
Must be one of the following
values:
DeviceOfflineAdvertisement
ServiceOfflineAdvertisement
01-SourceDeviceId
Required
Single URI
Same as 01-SourceDeviceId
header value in
corresponding online
notification message
01-ServiceId
Required
32 bit
Same as 01-ServiceId header
if it is
unsigned
value in
IGRS
integer (0
corresponding online
service
reserved)
notification message
offline
message
Discovery occurs when Control Point sends out the discovery message to search for devices and services on the network and find ones that meet its search criteria.
TABLE 9
IGRS Discovery Request Message:
Header
Required
Type
Description
Host
Required
Multicast
Must be 239.255.255.250:1900
address and
host
Man
Required
String
Must be ssdp:discover
MX
Required
Integer
Maximum number of seconds in
which to
respond. The maximum value is
120 seconds
ST
Required
Single URI
Must be one of values:
urn:schemas-IGRS-
org:device:IGRSdevice:1
urn:schemas-IGRS-
org:service:IGRSservice:1
Man
Required
String
Must be
“http://www.igrs.org/spec1.0”;ns=01
01-IGRSVersion
Required
String
Must be IGRS/1.0
01-
Required
String
Must be one of following
IGRSMessageType
values:
SearchDeviceRequest
SearchServiceRequest
01-SourceDeviceId
Required
Single URI
Device URN
01-SequenceId
Required
32 bit
Sequence Id of search request
unsigned
message
integer (0
reserved)
01-ClientId
Required
32 bit
Client ID
unsigned
integer (0
reserved)
01-SearchAll
Optional
String
Must be TRUE
01-
Optional
String
Device Name
SearchByDeviceName
01-
Optional
Single URI
Device Type URN
SearchByDeviceType
01-
Optional
Single URI
Device URN
SearchByDeviceId
01-
Optional
Single URI
Device Group URN
SearchByDeviceGroupId
01-
Optional
Single URI
Service Type URN
SearchByServiceType
01-
Optional
String
Service Name
SearchByServiceName
TABLE 10
UPnP Discovery Request Message:
Header
Required
Type
Description
Host
Required
Multicast
Must be 239.255.255.250:1900
address and
host
Man
Required
String
Must be ssdp:discover
MX
Required
Integer
Maximum number of seconds in
which to
respond.
ST
Required
Single URI
May take one of the following
forms:
ssdp:all
upnp:rootdevice
uuid:deviceURN
deviceTypeURN
serviceTypeURN
TABLE 11
Concurrent IGRS-UPnP Discovery Request Message:
Header
Required
Type
Description
Host
Required
Multicast
Must be 239.255.255.250:1900
address and
host
Man
Required
String
Must be ssdp:discover
MX
Required
Integer
Maximum number of seconds in
which to
respond. The maximum value is
120 seconds
ST
Required
Single URI
Value must take form:
ssdp:all
upnp:rootdevice
uuid:deviceURN
deviceTypeURN
serviceTypeURN
urn:schemas-IGRS-
org:device:IGRSdevice:1
urn:schemas-IGRS-
org:service:IGRSservice:1
Man
Required
String
Must be
“http://www.igrs.org/spec1.0”;ns=01
01-IGRSVersion
Required
String
Must be IGRS/1.0
01-
Required
String
Must be one of following
IGRSMessageType
values:
SearchDeviceRequest
SearchServiceRequest
01-SourceDeviceId
Required
Single URI
Device URN
01-SequenceId
Required
32 bit
Sequence Id of search request
unsigned
message
integer (0
reserved)
01-ClientId
Required
32 bit
Client ID
unsigned
integer (0
reserved)
01-SearchAll
Optional
String
Must be TRUE
01-
Optional
String
Device Name
SearchByDeviceName
01-
Optional
Single URI
Device Type URN
SearchByDeviceType
01-
Optional
Single URI
Device URN
SearchByDeviceId
01-
Optional
Single URI
Device Group URN
SearchByDeviceGroupId
01-
Optional
Single URI
Service Type URN
SearchByServiceType
01-
Optional
String
Service Name
SearchByServiceName
TABLE 12
IGRS Discovery Response Message:
Header
Required
Type
Description
Cache-Control
Required
Must
Specifies the number of seconds that the
have
advertisement is valid. Should be larger than 3
max-age
seconds
directive
Ext
Required
No value
Location
Required
Single
This URL points to the location of the IGRS
URL
device description document if device
supports
non-secure pipe. Otherwise the value should
be
http://www.igrs.org/device
Server
Required
String
Concatenation of OS name, OS version,
IGRS/1.0, product name, and product
version
ST
Required
Single
Same as ST header value in corresponding
URI
request message
USN
Required
Single
May take one of the following forms:
URI
uuid:deviceURN::DeviceTypeURN
uuid:deviceURN::ServiceTypeURN
Man
Required
String
Must be “http://www.igrs.org/spec1.0”;ns=01
01-IGRSVersion
Required
String
Must be IGRS/1.0
01-
Required
String
Must be one of following values:
IGRSMessageType
SearchDeviceResponse
SearchServiceResponse
01-SourceDeviceId
Required
Single
Source Device URN
URI
01-TargetDeviceId
Required
Single
Target Device URN
URI
01-
Optional
String
Secure listener list, format of each listener is
SecureListenerList
“IP address:port” and spaced by ”;” in the list
string.
01-ListenerList
Required
String
Listener list, format of each listener is “IP
address:port” and spaced by “;” in the list
string.
01-
Required
String
Device security id list, spaced by ”;” in the
DeviceSecurityIdList
list
string
TABLE 13
Header
Required
Type
Description
UPnP Discovery Response Message:
Cache-Control
Required
Must have
Specifies the number of seconds that the
max-age
advertisement is valid. Should be larger than
directive
1800 seconds
Date
Required
RFC 1123
When the response was generated
date
Ext
Required
No value
Location
Required
Single
This URL points to the location of the UPnP
URL
device description document of the root
device.
Server
Required
String
Concatenation of OS name, OS version,
UPnP/1.0, product name, and product version
ST
Required
Single
Same as ST header value in corresponding
URI
request message
USN
Required
Single
May take one of the following forms:
URI
uuid:deviceURN:upnp-rootdevice
uuid:deviceURN
uuid:deviceURN::deviceTypeURN
uuid:deviceURN::serviceTypeURN
Concurrent IGRS-UPnP Discovery Response Message:
Cache-Control
Required
Must
Specifies the number of seconds that the
have
advertisement is valid. Should be larger than
max-age
1800 seconds
directive
Ext
Required
No value
Location
Required
Single
This URL points to the location of the
URL
Concurrent IGRS-UPnP device description
document if device supports non-secure pipe.
Server
Required
String
Concatenation of OS name, OS version,
protocol/1.0, product name, and product
version
ST
Required
Single
Same as ST header value in corresponding
URI
request message
USN
Required
Single
May take one of the following forms:
URI
uuid:deviceURN:upnp-rootdevice
uuid:deviceURN
uuid:deviceURN::deviceTypeURN
uuid:deviceURN::serviceTypeURN
Man
Required
String
Must be “http://www.igrs.org/spec1.0”;ns=01
01-IGRSVersion
Required
String
Must be IGRS/1.0
01-
Required
String
Must be one of following values:
IGRSMessageType
SearchDeviceResponse
SearchServiceResponse
01-SourceDeviceId
Required
Single
Source Device URN
URI
01-TargetDeviceId
Required
Single
Target Device URN
URI
01-
Optional
String
Secure listener list, format of each listener is
SecureListenerList
“IP address:port” and spaced by “;” in the list
string.
01-ListenerList
Required
String
Listener list, format of each listener is “IP
address:port” and spaced by “;” in the list
string.
01-
Required
String
Device security id list, spaced by “;” in the list
DeviceSecurityIdList
string
By implementing the disclosed concurrent UPnP-IGRS stack, network traffic is reduced as a result of message merging and reduced memory usage is attained through module reuse. As a direct and intended consequence, support is not needed from the respective standards bodies since the stack is completely standard compliant.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a block diagram of the primary embodiment of the claimed invention.
FIG. 2 depicts a block diagram of the architecture of the primary embodiment of the claimed invention as applied to IGRS, UPnP and Concurrent IGRS-UPnP Devices.
FIG. 3 depicts a schematic diagram of electronic devices in operation according to the claimed invention.
FIG. 4 depicts a flow diagram of concurrent IGRS-UPnP device operation according to the claimed invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 depicts a block diagram of the primary embodiment of the claimed invention. According to FIG. 1 , device 101 , 103 , 105 interaction is governed by four phases of operation starting with discovery (Online) 121 , description 131 , control 141 and discovery (Offline) 151 . With the IGRS and Concurrent IGRS-UPnP Device, discovery (Online) 121 begins with Alive Notification 123 in which the device notifies other devices on the network that the device is active. After Alive Notification, the description phase 131 is entered where pipe setup 133 is followed by IGRS Device Description 135 and IGRS Service Description 137 . After the description phase 131 is complete, control phase 141 begins with session setup 143 , action control 145 , session termination 147 and pipe disconnection 19 . Discovery (offline) 151 concludes with offline notification 153 . According to one embodiment of the claimed invention, the Concurrent IGRS-UPnP Devices is a control point and controls the actions of IGRS devices in the network through action control 145 .
FIG. 1 additionally depicts a block diagram of the primary embodiment of the claimed invention as applied to UPnP and Concurrent IGRS-UPnP Devices. With UPnP capable devices, device 101 , 103 , 105 interaction is similarly governed by four phases of operation starting with discovery (Online) 121 , description 131 , control 141 and discovery (Offline) 151 . With the UPnP and Concurrent IGRS-UPnP Devices, discovery (Online) 121 begins with Alive Notification 122 in which the device notifies other devices on the network that the device is active. After Alive Notification, the description phase 131 is entered where UPnP device description 134 is followed by UPnP Service Description 136 . After the description phase 131 is complete, control phase 141 begins with action control 144 . Discovery (offline) 151 concludes with offline notification 154 . According to one embodiment of the claimed invention, the Concurrent IGRS-UPnP Devices is a control point and controls the actions of UPnP devices in the network through action control 144 . According to another embodiment of the claimed invention, the Concurrent IGRS-UPnP Devices acts as a control point and controls the actions of IGRS devices and UPnP devices in the network through action control 145 and action control 144 respectively.
FIG. 2 depicts a block diagram of the architecture of the primary embodiment of the claimed invention as applied to IGRS, UPnP and Concurrent IGRS-UPnP Devices. FIG. 2 architecture summary 201 details port layer 210 with first port 211 connected to mini-server 214 and second port 221 connected to multicast listener 224 . Application (or API) layer 220 including mini-server 214 and multicast listener 224 also includes HTTP sender 228 . Under application layer 220 is the profile handler session layer 230 where UPnP Profile Handler 231 and IGRS Profile Handler 233 support mini-server 214 , multicast listener 224 and HTTP sender 228 . Below profile handler session layer 230 is device handler session layer 240 . Device handler session layer 240 includes Advertisement Handler 242 , Event Handler 244 , Description Handler 246 , Discovery Handler 247 and IGRS Pipe/Session Manager 248 . Transport layer 250 includes Core Library 252 which handles protocols such as HTTP, XML, SSDP, GENA, SOAP, WSDL and Security. Architecture summary 201 also depicts Abstract Layer 260 and Hardware Platform layer 270 .
FIG. 3 depicts a schematic diagram of electronic devices in operation according to the claimed invention. Device community 301 includes wireless IGRS display 303 , wireless UPnP audio content device 307 , UPnP display 309 , wired and wireless gateway 312 connected to concurrent IGRS-UPnP media player 315 , control point 318 and PC 321 with IGRS and UPnP software installed to allow for joint IGRS and UPnP control capabilities.
FIG. 4 depicts a flow diagram 400 of concurrent IGRS-UPnP device operation according to the claimed invention. In online step 401 , according to one embodiment of the claimed invention, the concurrent IGRS-UPnP device discovers other online devices in a network having IGRS devices and UPnP devices; according to another embodiment of the claimed invention, the concurrent IGRS-UPnP device notifies some or all of the online devices in the network that the concurrent IGRS-UPnP device is going online.
According to one embodiment of the claimed invention, the online step 401 includes composing interoperable messages that contains a portion of content compatible only with the IGRS protocol, a portion of content compatible only with the UPnP protocol, and a portion of content compatible with both the IGRS and the UPnP protocols such that the whole message is interoperable among the network of IGRS device and UPnP device. The concurrent IGRS-UPnP device may then either broadcast or transmit such message to other devices in the network.
According to an embodiment of the claimed invention, the concurrent IGRS-UPnP device takes initiative to broadcast interoperable messages for discovering other devices in the network. According to another embodiment of the claimed invention, the concurrent IGRS-UPnP device composes and broadcasts interoperable messages for notifying other devices in the network about going online.
In describing step 402 , the concurrent IGRS-UPnP device describes those online devices that were found in discovering step 401 . In controlling step 403 , the concurrent IGRS-UPnP device controls some or all of the online devices. According to an embodiment of the claimed invention, the concurrent IGRS-UPnP device composes and transmits the interoperable messages as described above in a one-to-one manner in the controlling step 403 .
In notifying step 404 , the concurrent IGRS-UPnP device notify some or all of the online devices in the network that the concurrent IGRS-UPnP device is going offline. According to an embodiment of the claimed invention, the concurrent IGRS-UPnP device composes and broadcasts the interoperable messages as described above in the notifying step 404 .
The above disclosure is related to the detailed technical contents and inventive features thereof. People skilled in this field may proceed with a variety of modifications and replacements based on the disclosures and suggestions of the invention as described without departing from the characteristics thereof. Nevertheless, although such modifications and replacements are not fully disclosed in the above descriptions, they have substantially been covered in the following claims as appended.
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Systems, apparatuses and methods for processing a concurrent IGRS-UPnP architecture for both IGRS and UPnP standards conformance, and to be used for consumer electronics device interoperability.
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FIELD
[0001] The present invention relates to a server in a visiting service management support system, a control method thereof, and a control program thereof.
BACKGROUND
[0002] The average life span of the Japanese has lengthened and the ratio of the aged to the population is also increasing. As the population in need of care is also increasing because of aging of the society, the Public Nursing Care Insurance Law (also referred to as the Long-Term Care Insurance Act (Law)) was put in force in April 2000, and the entry of the private sector into the care service-related business has expanded.
[0003] As described above, although the number of care service providers has increased as result of the enforcement of the Public Nursing Care Insurance Law, there are a variety of problems with regard to the business operating environment. Although an attempt to improve the system was made by the revised Public Nursing Care Insurance Law in 2006 and 2012, both the service users (e.g., persons requiring care, persons requiring assistance, etc.) and the service providers (e.g., nurses, care workers, care attendants, etc.) still feel discontented.
[0004] Specifically, there are the following problems.
[0005] (1) It is necessary to exchange a large number of documents among a person who desires to use a service by the time to use a care service, a care manager, a service provider, etc. A care manager is a person who receives a request for advice from a service user, clarifies problems and objectives when the service user uses the Public Nursing Care Insurance services, creates a plan (care plan) that summarizes the contents and schedules of the services that the service user uses, and establishes contact and arranges adjustment with the service provider whose service the service user needs.
[0006] (2) When the service provision is started actually, for the reports of medical treatment and care, a large number of documents need to be prepared, recorded, and presented, and therefore nearly half the time required to deal with one visit is spent by the clerical work other than the actual service.
[0007] (3) Further, these documents are also confidential, and therefore they are forced to be basically carried by hand-holding, and much time is required to move from the visit to back to the office.
[0008] Thus, the cost of the care service business as a whole rises, resulting in an increase in the burden of the service user. Further, the total hours spent at work are long, and therefore even the qualified service provider of caliber will lose the chance to work. In other words, since the total hours spent at work are long, the number of full-time staff tends to run short. Even if an attempt to cover the shortage by part-time staff, the time restriction of the part-time staff is severe, and therefore it is difficult to sufficiently cover the shortage. Further, although there are providers that perform part of the clerical work in place of the staff in order to reduce the burden of the clerical work, this will lead to the cost of outsourcing, and therefore it is not possible for a small-scale care service provider to resolve the problem of a reduction in burden on the management side. Thus, despite the fact that the demand for the care service has expanded, the number of staff actually engaged in the service provision is insufficient and the care service provider spends much time creating a visiting schedule of the service provider. Further, there has occurred a state where it is not possible for a small-scale care service provider to efficiently provide services. The state such as above has similarly occurred in the visiting nursing service or the like, not limited to the visiting care service.
[0009] A variety of solutions have been proposed for the problem such as this. For example, Patent Document 1 has disclosed matching between a person who desires to use a service and a service provider. In particular, matching has been disclosed in which the desired conditions of both are posted up on a dedicated bulletin board and those whose conditions match with each other are matched and managed on the system.
RELATED DOCUMENT
[0010] [Patent Document 1] Japanese Laid Open Patent No. 2002-074058
SUMMARY
[0011] However, even with the solution such as this, it is not possible to resolve the problem to improve the chance to work of the qualified service provider of caliber as described above.
[0012] The present invention has been made in view of the circumstance such as this, and an object of the present invention is to provide a server in a visiting service management support system that may improve the chance to work of the service provider by devising scheduling of the service provider, as well as improving the service provision efficiency by reducing the burden of task of the service provider, the person in charge of clerical work, the manager, etc., to secure flexibility in scheduling when the care service provider provides services, and thereby improving the chance to use a service of the service user, a control method of the server, and a control program of the server.
[0013] A server according to the present invention is a server in a visiting service management support system including a first terminal relating to a first service provider who provides a visiting service in a first type working pattern in which the first service provider works for a long time and continuously, a second terminal relating to a second service provider who provides a visiting service in a second type working pattern that is different from the first type working pattern and in which the second service provider works for a shorter time and less continuously than the first type working pattern, and a server capable of communicating with the first terminal and the second terminal, respectively, the server including: a communication unit configured to communicate with the first terminal and the second terminal, respectively; a storage unit configured to store first service provider's desired date and time information indicating a first service provider's desired date and time of service provision, second service provider's desired date and time information indicating a second service provider's desired date and time of service provision, and service user's desired date and time information indicating a service user's desired date and time of service use; a service scheduling information creation unit configured to assign each date and time indicated by the second service provider's desired date and time information to each date and time indicated by the service user's desired date and time information, to further assign each date and time indicated by the first service provider's desired date and time information to each date and time to which each date and time indicated by the second service provider's desired date and time information is not assigned among each date and time indicated by the service user's desired date and time information, to create service scheduling information including a service user, a first service provider or a second service provider, and a service provision date and time based on the assignment results, and to store the service scheduling information in the storage unit; and a service scheduling information reference unit configured to transmit the service scheduling information to the first terminal or the second terminal via the communication unit.
[0014] A server according to the present invention is a server in a visiting service management support system including a first terminal relating to a first service provider who provides a visiting service in a first type working pattern in which the first service provider works for a long time and continuously, a second terminal relating to a second service provider who provides a visiting service in a second type working pattern that is different from the first type working pattern and in which the second service provider works for a shorter time and less continuously than the first type working pattern, and a server capable of communicating with the first terminal and the second terminal, respectively, the server including: a communication unit configured to communicate with the first terminal and the second terminal, respectively; a storage unit configured to store first service provider's desired date and time information indicating a first service provider's desired date and time of service provision, second service provider's desired date and time information indicating a second service provider's desired date and time of service provision, and service user's desired date and time information indicating a service user's desired date and time of service use; a service scheduling information creation unit configured to simultaneously assign each date and time indicated by the first service provider's desired date and time information and each date and time indicated by the second service provider's desired date and time information to each date and time indicated by the service user's desired date and time information in accordance with a restriction condition that gives priority to each date and time indicated by the second service provider's desired date and time information over each date and time indicated by the first service provider's desired date and time information, to create service scheduling information including a service user, a first service provider or a second service provider, and a service provision date and time based on the assignment results, and to store the service scheduling information in the storage unit; and a service scheduling information reference unit configured to transmit the service scheduling information to the first terminal or the second terminal via the communication unit.
[0015] In the server according to the present invention, if the assignment results are modified, it is preferable for the service scheduling information creation unit to perform the assignment processing again so that the modification is reflected in the assignment results.
[0016] In the server according to the present invention, it is preferable for the service scheduling information creation unit to perform the assignment processing based on the service user's desired date and time information relating to a service user belonging to a predetermined group of a plurality of groups, and the first service provider's desired date and time information relating to a first service provider belonging to a predetermined group of a plurality of groups having a system different from that of the plurality of groups and the second service provider's desired date and time information relating to a second service provider.
[0017] In the server according to the present invention, it is preferable for the storage unit to further store service user management information including service user attribute information and a service provision record relating to the service user for each service user, and for the server to further include a service user management information reference unit configured to transmit the service user management information to the first terminal or the second terminal via the communication unit.
[0018] In the server according to the present invention, it is preferable to further include a service user management information updating unit configured to transmit a service provision record input form relating to a service user to the first terminal or the second terminal via the communication unit and to store the service provision record received from the first terminal or the second terminal via the communication unit in the storage unit as a service provision record relating to the service user.
[0019] A control method of a server according to the present invention is a control method of a server in a visiting service management support system including a first terminal relating to a first service provider who provides a visiting service in a first type working pattern in which the first service provider works for a long time and continuously, a second terminal relating to a second service provider who provides a visiting service in a second type working pattern that is different from the first type working pattern and in which the second service provider works for a shorter time and less continuously than the first type working pattern, and a server capable of communicating with the first terminal and the second terminal, respectively, the server including a storage unit configured to store first service provider's desired date and time information indicating a first service provider's desired date and time of service provision, second service provider's desired date and time information indicating a second service provider's desired date and time of service provision, and service user's desired date and time information indicating a service user's desired date and time of service use, the control method including, by the server: assigning each date and time indicated by the second service provider's desired date and time information to each date and time indicated by the service user's desired date and time information; assigning each date and time indicated by the first service provider's desired date and time information to each date and time to which each date and time indicated by the second service provider's desired date and time information is not assigned among each date and time indicated by the service user's desired date and time information; creating service scheduling information including a service user, a first service provider or a second service provider, and a service provision date and time based on the assignment results; storing the service scheduling information in the storage unit; and transmitting the service scheduling information to the first terminal or the second terminal.
[0020] A control method of a server according to the present invention is a control method of a server in a visiting service management support system including a first terminal relating to a first service provider who provides a visiting service in a first type working pattern in which the first service provider works for a long time and continuously, a second terminal relating to a second service provider who provides a visiting service in a second type working pattern that is different from the first type working pattern and in which the second service provider works for a shorter time and less continuously than the first type working pattern, and a server capable of communicating with the first terminal and the second terminal, respectively, the server including a storage unit configured to store first service provider's desired date and time information indicating a first service provider's desired date and time of service provision, second service provider's desired date and time information indicating a second service provider's desired date and time of service provision, and service user's desired date and time information indicating a service user's desired date and time of service use, the control method including, by the server: simultaneously assigning each date and time indicated by the first service provider's desired date and time information and each date and time indicated by the second service provider's desired date and time information to each date and time indicated by the service user's desired date and time information in accordance with a restriction condition that gives priority to each date and time indicated by the second service provider's desired date and time information over each date and time indicated by the first service provider's desired date and time information; creating service scheduling information including a service user, a first service provider or a second service provider, and a service provision date and time based on the assignment results; storing the service scheduling information in the storage unit; and transmitting the service scheduling information to the first terminal or the second terminal.
[0021] A control program of a server according to the present invention is a control program of a server in a visiting service management support system including a first terminal relating to a first service provider who provides a visiting service in a first type working pattern in which the first service provider works for a long time and continuously, a second terminal relating to a second service provider who provides a visiting service in a second type working pattern that is different from the first type working pattern and in which the second service provider works for a shorter time and less continuously than the first type working pattern, and a server capable of communicating with the first terminal and the second terminal, respectively, the server including a storage unit configured to store first service provider's desired date and time information indicating a first service provider's desired date and time of service provision, second service provider's desired date and time information indicating a second service provider's desired date and time of service provision, and service user's desired date and time information indicating a service user's desired date and time of service use, the control program causing the server to; assign each date and time indicated by the second service provider's desired date and time information to each date and time indicated by the service user's desired date and time information; assign each date and time indicated by the first service provider's desired date and time information to each date and time to which each date and time indicated by the second service provider's desired date and time information is not assigned among each date and time indicated by the service user's desired date and time information; create service scheduling information including a service user, a first service provider or a second service provider, and a service provision date and time based on the assignment results; store the service scheduling information in the storage unit; and transmit the service scheduling information to the first terminal or the second terminal.
[0022] A control program of a server according to the present invention is a control program of a server in a visiting service management support system including a first terminal relating to a first service provider who provides a visiting service in a first type working pattern in which the first service provider works for a long time and continuously, a second terminal relating to a second service provider who provides a visiting service in a second type working pattern that is different from the first type working pattern and in which the second service provider works for a shorter time and less continuously than the first type working pattern, and a server capable of communicating with the first terminal and the second terminal, respectively, the server including a storage unit configured to store first service provider's desired date and time information indicating a first service provider's desired date and time of service provision, second service provider's desired date and time information indicating a second service provider's desired date and time of service provision, and service user's desired date and time information indicating a service user's desired date and time of service use, the control program causing the server to: simultaneously assign each date and time indicated by the first service provider's desired date and time information and each date and time indicated by the second service provider's desired date and time information to each date and time indicated by the service user's desired date and time information in accordance with a restriction condition that gives priority to each date and time indicated by the second service provider's desired date and time information over each date and time indicated by the first service provider's desired date and time information; create service scheduling information including a service user, a first service provider or a second service provider, and a service provision date and time based on the assignment results; store the service scheduling information in the storage unit; and transmit the service scheduling information to the first terminal or the second terminal.
[0023] The server, the control method thereof, and the control program thereof may improve the chance to work of the service provider, and thereby, improving the chance to use a service of the service user by preferentially assigning the part-time staff over the full-time staff in scheduling the service provider, since it is easier for the part-time staff to perform the service provision task in the time period desired by the part-time staff him/herself.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a diagram illustrating an example of an outline configuration of a visiting service management support system;
[0025] FIG. 2 is a diagram illustrating an example of an outline configuration of a mobile terminal;
[0026] FIG. 3 is a diagram illustrating an example of an outline configuration of a server;
[0027] FIGS. 4A to 4F are each a diagram illustrating an example of a data structure of each of various management tables;
[0028] FIGS. 5A to 5C are each a diagram illustrating another example of a data structure of each of various management tables;
[0029] FIGS. 6A to 6D are each a diagram illustrating an example of a display screen of the mobile terminal;
[0030] FIGS. 7A to 7D are each a diagram illustrating another example of a display screen of the mobile terminal;
[0031] FIG. 8 is a diagram illustrating an example of an operation flow of the server;
[0032] FIGS. 9A and 9B are each a diagram illustrating another example of the operation flow of the server; and
[0033] FIGS. 10A and 10B are each a diagram illustrating still another example of the operation flow of the server.
DESCRIPTION OF EMBODIMENTS
[0034] Hereinafter, with reference to the drawings, a variety of embodiments of the present invention are explained. However, it should be noted that the technical scope of the present invention is not limited to those embodiments, but encompasses the inventions described in the claims and equivalents thereof.
[0035] (1) Outline of the Present Embodiment
[0036] In the present embodiment, a manager (including a service provider) creates service scheduling indicating which service provider provides which service user with which service. It is assumed that the service provider includes a full-time staff who provides a service in a working pattern in which the full-time staff works for a long time and continuously and a part-time staff who provides a service in a working pattern in which the part-time staff works for a shorter time and less continuously than the full-time staff, and the manager creates the service scheduling by giving priority to the part-time staff over the full-time staff. The service provider provides a service by appropriately referring to the service scheduling. Then, after providing a service, the service provider creates a service provision record.
[0037] In the present embodiment, although the visiting care service is supposed as the service provided by the service provider, the present invention is not limited to this. The service only needs to be one to which the present invention can be applied, and for example, the service may be the visiting nursing service or the visiting medical treatment service, or the care service, the nursing service, the medical treatment service, etc., in facilities, such as hospitals. The visiting medical treatment service is the service provided by a doctor periodically visiting a service user's home and performing medical treatment, remedy, and prescription of drug, receiving a request for advice, giving instructions, etc.
[0038] The manager or the service provider gives a mobile terminal instructions to create or refer to service scheduling, to create a service provision record, etc., (hereinafter, referred to as “creation of service scheduling or the like”). The mobile terminal makes a request to the server for creation of service scheduling or the like in accordance with instructions from a user. In response to the request from the mobile terminal, the server performs creation of service scheduling or the like.
[0039] (2) Configuration of Visiting Service Management Support System 1
[0040] FIG. 1 is a diagram illustrating an example of an outline configuration of a visiting service management support system 1 .
[0041] The visiting service management support system 1 includes at least one mobile terminal 2 and a server 3 . The mobile terminal 2 and the server 3 are connected to each other via a communication network, for example, via a base station 4 , a mobile communication network 5 , a gateway 6 , and the Internet 7 . A program (e.g., a browsing program) that is executed in the mobile terminal 2 and a program (e.g., a visiting service management support program) that is executed in the server 3 perform communication by using a communication protocol, such as the hypertext transfer protocol (HTTP).
[0042] (2.1) Configuration of Mobile Terminal 2
[0043] FIG. 2 is a diagram illustrating an example of an outline configuration of the mobile terminal 2 .
[0044] The mobile terminal 2 connects to the server 3 via the base station 4 , the mobile communication network 5 , the gateway 6 , and the Internet 7 and communicates with the server 3 . The mobile terminal 2 makes a request to the server 3 for creation of service scheduling or the like in accordance with an operation by a user through an operation unit 23 (button or the like). Further, the mobile terminal 2 receives display data relating to creation of service scheduling or the like from the server 3 and displays the data. To this end, the mobile terminal 2 includes a terminal communication unit 21 , a terminal storage unit 22 , the operation unit 23 , a display unit 24 , and a terminal processing unit 25 .
[0045] In the present embodiment, although a tablet terminal is supposed as the mobile terminal 2 , the present invention is not limited to this. The mobile terminal 2 only needs to be one to which the present invention can be applied and, for example, the mobile terminal 2 may be a tablet PC, a note PC, a multifunction mobile telephone (so-called “smart phone”), a mobile telephone (so-called “feature phone”), a personal digital assistant (PDA), etc.
[0046] The terminal communication unit 21 includes a communication interface circuit including an antenna whose reception band is a predetermined frequency band, and connects the mobile terminal 2 to a wireless communication network. The terminal communication unit 21 establishes a wireless signal circuit line by the CDMA (Code Division Multiple Access) system or the like with the base station 4 via a channel assigned by the base station 4 and performs communication with the base station 4 . Then, the terminal communication unit 21 transmits data supplied from the terminal processing unit 25 to the server 3 or the like. Further, the terminal communication unit 21 supplies data received from the server 3 or the like to the terminal processing unit 25 .
[0047] The terminal storage unit 22 includes at least one of, for example, a semiconductor memory device, a magnetic disk device, and an optical disk device. The terminal storage unit 22 stores an operating system program, a driver program, an application program, data, etc., which are used in the processing by the terminal processing unit 25 . For example, the terminal storage unit 22 stores an input device driver program that controls the operation unit 23 , an output device driver program that controls the display unit 24 , etc., as the driver programs. Further, the terminal storage unit 22 stores a browsing program or the like that acquires and displays display data relating to creation of service scheduling or the like as the application program. Furthermore, the terminal storage unit 22 stores display data, video data, image data, etc., relating to creation of service scheduling or the like as the data. Furthermore, the terminal storage unit 22 may temporarily store data relating to predetermined processing.
[0048] The operation unit 23 may be any device as long as the device is capable of operating the mobile terminal 2 and is, for example, a touch pad, a keyboard, etc. A user may input characters, figures, etc., by using the operation unit 23 . When operated by a user, the operation unit 23 generates a signal corresponding to the operation. Then, the generated signal is supplied to the terminal processing unit 25 as user's instructions.
[0049] The display unit 24 may also be any device as long as the device is capable of displaying videos, images, etc., and is, for example, a liquid crystal display, an organic EL (Electro-Luminescence) display, etc. The display unit 24 displays a video in accordance with video data supplied from the terminal processing unit 25 , an image in accordance with image data or the like.
[0050] The terminal processing unit 25 includes one or a plurality of processors and peripheral circuits thereof. The terminal processing unit 25 centralizedly controls the entire operation of the mobile terminal 2 and is, for example, a CPU (Central Processing Unit). The terminal processing unit 25 controls the operation of the terminal communication unit 21 , the display unit 24 , etc., so that various kinds of processing of the mobile terminal 2 are performed by an appropriate procedure in accordance with programs stored in the terminal storage unit 22 , the operations of the operation unit 23 , etc. The terminal processing unit 25 performs processing based on the programs (operating system program, driver program, application program, etc.) stored in the terminal storage unit 22 . Further, the terminal processing unit 25 may execute a plurality of programs (application program or the like) in parallel.
[0051] (2.1.1) Configuration of Terminal Processing Unit 25
[0052] The terminal processing unit 25 includes at least a browsing execution unit 251 . Each of these units is a function module that is implemented by a program executed by a processor included in the terminal processing unit 25 . Alternatively, each of these units may be mounted on the mobile terminal 2 as firmware.
[0053] The browsing execution unit 251 acquires and displays display data relating to creation of service scheduling or the like. In other words, the browsing execution unit 251 transmits a request to acquire display data relating to creation of service scheduling or the like to the server 3 via the terminal communication unit 21 in accordance with instructions from a user. Further, the browsing execution unit 251 receives corresponding display data from the server 3 via the terminal communication unit 21 . The browsing execution unit 251 creates drawing data based on the received display data. In other words, the browsing execution unit 251 specifies control data and contents data by analyzing the received display data and creates drawing data by laying out the specified contents data in accordance with the similarly specified control data. Then, the browsing execution unit 251 outputs the created drawing data to the display unit 24 .
[0054] (2.2) Configuration of Server 3
[0055] FIG. 3 is a diagram illustrating an example of an outline configuration of the server 3 .
[0056] The server 3 performs creation of service scheduling or the like in accordance with a request from the mobile terminal 2 . Further, the server 3 creates display data relating to creation of service scheduling or the like and transmits the display data to the mobile terminal 2 . To this end, the server 3 includes a server communication unit 31 , a server storage unit 32 , and a server processing unit 33 .
[0057] The server communication unit 31 includes a communication interface circuit for connecting the server 3 to the Internet 7 and performs communication with the Internet 7 . Then, the server communication unit 31 supplies data received from the mobile terminal 2 or the like to the server processing unit 33 . Further, the server communication unit 31 transmits data supplied from the server processing unit 33 to the mobile terminal 2 or the like.
[0058] The server storage unit 32 includes at least one of, for example, a magnetic tape device, a magnetic disk device, and an optical disk device. The server storage unit 32 stores an operating system program, a driver program, an application program, data, etc., which are used in the processing by the server processing unit 33 . For example, the server storage unit 32 performs creation of service scheduling or the like as the application program and stores a visiting service management support program or the like for creating display data relating to the results. Further, the server storage unit 32 stores, as data, a full-time staff attribute information management table ( FIG. 4A ) for managing full-time staff attribute information, a part-time staff attribute information management table ( FIG. 4B ) for managing part-time staff attribute information, a service user attribute information management table ( FIG. 4C ) for managing service user attribute information, a full-time staff's desired date and time management table ( FIG. 4D ) for managing the full-time staff's desired date and time of service provision, a part-time staff's desired date and time management table ( FIG. 4E ) for managing the part-time staff's desired date and time of service provision, a service user's desired date and time management table ( FIG. 4F ) for managing the service user's desired date and time of service use, a service scheduling management table ( FIG. 5A ) for managing restriction condition data when creating service scheduling and the service scheduling, a work procedure management table ( FIG. 5B ) for managing a service action work procedure, a service provision record management table ( FIG. 5C ) for managing service provision record input form data and a service provision record, etc. Furthermore, the server storage unit 32 may temporarily store temporary data relating to predetermined processing.
[0059] FIGS. 4A to 4F and FIGS. 5A to 5C are diagrams illustrating examples of data structures of various management tables.
[0060] In FIG. 4A , a full-time staff attribute information management table for managing full-time staff attribute information is illustrated. In the full-time staff attribute information management table, the identification number (ID), name, sex, qualification (e.g., care worker, care attendant, etc.), etc., of a full-time staff are stored for each full-time staff.
[0061] In the present embodiment, although “care worker” is displayed in the qualification field as an example of a visiting care service, for example, in the case of a visiting nursing service, “nurse” or the like is displayed in the qualification field.
[0062] In FIG. 4B , a part-time staff attribute information management table for managing part-time staff attribute information is illustrated. In the part-time staff attribute information management table, the ID, name, sex, qualification (e.g., care worker, care attendant, etc.), etc., of a part-time staff are stored for each part-time staff.
[0063] In FIG. 4C , a service user attribute information management table for managing service user attribute information is illustrated. In the service user attribute information management table, the ID, name, date of birth, sex, address, degree of required care (e.g., requiring assistance, required care level of 1 to 5, etc.), desire (e.g., desire regarding a staff or the like), etc., of a service user are stored for each service user.
[0064] In FIG. 4D , a full-time staff's desired date and time management table for managing the full-time staff's desired date and time of service provision is illustrated. In the full-time staff's desired date and time management table, the ID, date on which a full-time staff desires to take a holiday, etc., of a full-time staff are stored for each full-time staff.
[0065] In FIG. 4E , a part-time staff's desired date and time management table for managing the part-time staff's desired date and time of service provision is illustrated. In the part-time staff's desired date and time management table, the ID, desired date and time of service provision, etc., of a part-time staff are stored for each part-time staff.
[0066] In FIG. 4F , a service user's desired date and time management table for managing the service user's desired date and time of service use is illustrated. In the service user's desired date and time management table, the ID and desired date and time of service use, the ID of a service action to be used (e.g., assistance with using the toilet, assistance with meals, bed bath, etc.), etc., of a service user are stored for each service user.
[0067] In FIG. 5A , a service scheduling management table for managing service scheduling is illustrated. In the service scheduling management table, the ID of individual service scheduling, the ID of a service user relating to the individual service scheduling, the ID of a service provider, the service provision date and time, the ID of a service action to be provided, the service provision situation (“not yet” or “done”), the ID of a service provision record, etc., are stored for each individual service scheduling.
[0068] Although these pieces of information mainly relate to the schedule of the service user and the service provider, the present invention is not limited to those. Besides these pieces of information, for example, information relating to various plans, such as a flow of the entire business, may be included.
[0069] In FIG. 5B , a work procedure management table for managing the service action work procedure is illustrated. In the work procedure management table, the ID, name, and work procedure of a service action, the ID of a service provision record input form, etc., are stored for each service action.
[0070] In FIG. 5C , a service provision record management table for managing the service provision record is illustrated. In the service provision record management table, the ID of a service provision record, the ID of an input form, the service provision situation, etc., are stored for each service provision record.
[0071] The server processing unit 33 includes one or a plurality of processors and peripheral circuits thereof. The server processing unit 33 centralizedly controls the entire operation of the server 3 and is, for example, a CPU. The server processing unit 33 controls the operation of the server communication unit 31 or the like so that the various kinds of processing of the server 3 are performed by an appropriate procedure in accordance with programs stored in the server storage unit 32 , requests from the mobile terminal 2 , etc. The server processing unit 33 performs processing based on the programs (operating system program, driver program, application program, etc.) stored in the server storage unit 32 . Further, the server processing unit 33 may execute a plurality of programs (application program or the like) in parallel.
[0072] (2.2.1) Function of Server Processing Unit 33
[0073] FIGS. 6A to 6D and FIGS. 7A to 7D are diagrams illustrating examples of the display screen of the mobile terminal 2 based on the display data created by the server 3 .
[0074] In FIG. 6A , a home screen 600 that is displayed when a visiting service management support service is started is illustrated. The home screen 600 is displayed based on home screen display data received from the server 3 .
[0075] At the center of the screen, buttons 601 and 602 are displayed. The server 3 is requested via the terminal communication unit 21 to create service scheduling when the “Create service scheduling” button 601 is pressed down, and to refer to service scheduling when the “Refer to service scheduling” button 602 is pressed down.
[0076] In FIG. 6B , a Service scheduling editing screen 610 that is displayed when a request to create service scheduling is made on the home screen 600 illustrated in FIG. 6A is illustrated. The Service scheduling editing screen 610 is displayed based on service scheduling editing screen display data received from the server 3 .
[0077] At the center of the screen, service scheduling 611 for one day is displayed in the form of a table in which the horizontal axis represents the service provider and the vertical axis represents the service provision time, and within the table, icons 612 to 614 each indicating the individual service scheduling for a service user are displayed. When one of the icons 612 to 614 is pressed down, the server 3 is requested via the terminal communication unit 21 to refer to service user attribute information using the ID of the service user relating to the corresponding individual service scheduling as a parameter. The service user relating to the corresponding individual service scheduling may be changed, by moving among the icons 612 to 614 .
[0078] Further, buttons 615 and 616 are displayed at the top of the screen. The server 3 is requested via the terminal communication unit 21 to refer to the service scheduling 611 for the previous day when the “Previous day” button 615 is pressed down, and to refer to the service scheduling 611 for the next day when the “Next day” button 616 is pressed down, respectively, using the corresponding date as a parameter.
[0079] Furthermore, a “Check” button 617 is displayed at the bottom of the screen, and when this button is pressed down, the server 3 is requested via the terminal communication unit 21 to store the service scheduling in the server storage unit 32 .
[0080] In FIG. 6C , an Attribute information display screen 620 that is displayed when a request to refer to the service user attribute information is made on the Service scheduling editing screen 610 illustrated in FIG. 6B is illustrated. The Attribute information display screen 620 is displayed based on attribute information display screen display data received from the server 3 .
[0081] At the center of the screen, service user attribute information 621 is displayed for each item.
[0082] In FIG. 6D , a Service scheduling editing screen 630 that is displayed when the service scheduling 611 is edited on the Service scheduling editing screen 610 illustrated in FIG. 6B is illustrated. The service provider relating to the individual service scheduling for service user 1 is changed from staff 1 to staff 3 . Further, triggered by this change, the “Check” button 617 is changed to a “Modify” button 631 .
[0083] When the “Modify” button 631 is pressed down, the server 3 is requested via the terminal communication unit 21 to modify the service scheduling using the ID of the individual service scheduling relating to the change and the ID of the service provider as parameters.
[0084] Although the screens for the manager who creates the service scheduling are illustrated in FIGS. 6A to 6D , for example, if the login is performed using the ID of a service provider, only the service scheduling of which the service provider him/herself is in charge may be displayed on the screen, without displaying the service scheduling of the other service providers. This also applies in the following explanation.
[0085] In FIG. 7A , a Service scheduling (total) display screen 700 that is displayed when a request to refer to the service scheduling is made on the home screen 600 illustrated in FIG. 6A is illustrated. The Service scheduling (total) display screen 700 is displayed based on service scheduling display screen display data received from the server 3 .
[0086] At the center of the screen, service scheduling 701 for one day is displayed in the form of a table in which the horizontal axis represents the service provider and the vertical axis represents the service provision time, and within the table, icons 702 to 704 each indicating the individual service scheduling for a service user are displayed. When one of the icons 702 to 704 is pressed down, the server 3 is requested via the terminal communication unit 21 to refer to the individual service scheduling using the ID of the corresponding individual service scheduling as a parameter.
[0087] Further, buttons 705 and 706 are displayed at the top of the screen. The server 3 is requested via the terminal communication unit 21 to refer to the service scheduling 701 for the previous day when the “Previous day” button 705 is pressed down, and to refer to the service scheduling 701 for the next day when the “Next day” button 706 is pressed down, respectively, using the corresponding date as a parameter.
[0088] In FIG. 7B , a Service scheduling (individual) display screen 710 that is displayed when a request to refer to the individual service scheduling is made on the Service scheduling (total) display screen 700 illustrated in FIG. 7A is illustrated. The Service scheduling (individual) display screen 710 is displayed based on individual service scheduling display screen display data received from the server 3 .
[0089] At the center of the screen, individual service scheduling 711 is displayed for each item and for some of the items, buttons 712 to 715 are displayed. When the “Refer to” button 712 is pressed down, the server 3 is requested via the terminal communication unit 21 to refer to the service user attribute information using the ID of the corresponding service user as a parameter. When the “Assistance with meals” button 713 is pressed down, the server 3 is requested via the terminal communication unit 21 to refer to the service action work procedure using the ID of the corresponding service action as a parameter. When the “Change” button 714 is pressed down, the server 3 is requested via the terminal communication unit 21 to change the service provision situation from “not yet” to “done” using the ID of the individual service scheduling 711 as a parameter. Further, when the “Input” button 715 is pressed down, the server 3 is requested via the terminal communication unit 21 to transmit the service provision record input form using the ID of the individual service scheduling 711 as a parameter.
[0090] At the bottom of the screen, another individual service scheduling 716 for the service user relating to the individual service scheduling 711 is listed for each item and for some of the items, a “Refer to” button 717 is displayed. When the “Refer to” button 717 is pressed down, the server 3 is requested via the terminal communication unit 21 to refer to the service provision record using the ID of the corresponding individual service scheduling as a parameter.
[0091] In FIG. 7C , a Work procedure display screen 720 that is displayed when a request to refer to the service action work procedure is made on the Service scheduling (individual) display screen 710 illustrated in FIG. 7B is illustrated. The Work procedure display screen 720 is displayed based on work procedure display screen display data received from the server 3 .
[0092] At the center of the screen, a service action work procedure 721 is displayed in order.
[0093] In FIG. 7D , a Service provision record input screen 730 that is displayed when a request to transmit the service provision record input form is made on the Service scheduling (individual) display screen 710 illustrated in FIG. 7B is illustrated. The Service provision record input screen 730 is displayed based on service provision record input screen display data received from the server 3 .
[0094] At the top of the screen, individual service scheduling 731 is displayed for each item.
[0095] Further, a plurality of input boxes 732 , such as a checkbox, a radio button, and a text area, is displayed at the center of the screen, for each service action and, a server provision record may be input, by checking the relevant input box.
[0096] Furthermore, a “Transmit” button 733 is displayed at the bottom of the screen, and when this button is pressed down, the server 3 is requested via the terminal communication unit 21 to store the service provision record in the server storage unit 32 using the ID of the individual service scheduling 731 , the data input to the input box 732 , and the ID of the corresponding input form as parameters.
[0097] (2.2.2) Configuration of Server Processing Unit 33
[0098] In order to implement the above functions, the server processing unit 33 includes a service scheduling information creation unit 331 , a service scheduling information reference unit 332 , a service scheduling information updating unit 333 , a service user management information reference unit 334 , and a service user management information updating unit 335 . Each of these units is a function module that is implemented by a program executed by the processor included in the server processing unit 33 . Alternatively, each of these units may be mounted on the server 3 as firmware.
[0099] Hereinafter, the processing by the service scheduling information creation unit 331 is explained. The service scheduling information creation unit 331 creates and presents service scheduling to the manager. If the service scheduling is modified by the manager, the service scheduling information creation unit 331 creates service scheduling again so that the modification is reflected and presents the service scheduling to the manager. Then, after the service scheduling is checked by the manager, the service scheduling information creation unit 331 stores the service scheduling in the server storage unit 32 .
[0100] Specifically, if the service scheduling information creation unit 331 receives a request to create service scheduling from the mobile terminal 2 via the server communication unit 31 , extracts the service user's desired date and time of service use. For example, if service scheduling for the next one week is created, the service scheduling information creation unit 331 extracts information on the desired date and time of service use for one week. The period of time for which service scheduling is created may be based on a value determined in advance, or the period may be specified each time service scheduling is created.
[0101] In other words, the service scheduling information creation unit 331 refers to the service user's desired date and time management table stored in the server storage unit 32 and extracts the service user's desired date and time of service use for a predetermined period of time.
[0102] The service scheduling information creation unit 331 extracts the part-time staff's desired date and time of service provision.
[0103] In other words, the service scheduling information creation unit 331 refers to the part-time staff's desired date and time management table stored in the server storage unit 32 and extracts the part-time staff's desired date and time of service provision the predetermined period of time of which is the same as that of the service user's each desired date and time of service use for each part-time staff.
[0104] The service scheduling information creation unit 331 creates part-time staff service scheduling based on the extracted service user's desired date and time of service user and the extracted part-time staff's desired date and time of service provision.
[0105] In other words, the service scheduling information creation unit 331 compares the extracted service user's each desired date and time of service use with the similarly extracted part-time staff's each desired date and time of service provision, and then, assigns the time period where both the desired date and times coincide with each other, and temporarily stores the results (combination of the ID of the service user, the ID of the part-time staff, and the date and time of service provision) in the server storage unit 32 after giving an individual service scheduling ID newly adopted.
[0106] The assignment of the service provider to the service user is generally known as a nurse scheduling problem and a variety of solutions have been proposed. For example, if the service provider is replaced with a production machine and the service user with a lot, which is the minimum unit of production, the nurse scheduling may be regarded as parallel machine scheduling, and the solutions using the optimization method, such as the branch and bound method, the neutral network, and the genetic algorithm, have been proposed (e.g., “Genetic Algorithm Approach to an Operation Assignment Problem”, Taima Junji and two other authors, Transactions of the Institute of Systems, Control and Information Engineers, the Institute of Systems, Control and Information Engineers, Oct. 15, 1994, Vol. 7, No. 10, pp. 433-435). Consequently, explanation of details of the processing to assign the service provider to the service user is omitted.
[0107] The service scheduling information creation unit 331 creates the service scheduling editing screen display data based on the created part-time staff service scheduling.
[0108] In other words, the service scheduling information creation unit 331 refers to the part-time staff service scheduling stored in the server storage unit 32 using a predetermined date as a key and specifies the corresponding individual service scheduling. Further, the service scheduling information creation unit 331 refers to the service user attribute information management table stored in the server storage unit 32 using the ID of the service user relating to the specified individual service scheduling as a key and extracts the name of the corresponding service user. Furthermore, the service scheduling information creation unit 331 refers to the part-time staff attribute information management table stored in the server storage unit 32 using the ID of the part-time staff relating to the specified individual service scheduling as a key and extracts the name of the corresponding part-time staff. Then, the service scheduling information creation unit 331 creates the service scheduling editing screen display data for the specified individual service scheduling, including the ID of the individual service scheduling, the ID of the service user relating to the individual service scheduling, the ID of the part-time staff, etc., and for displaying the extracted name of the service user, the extracted name of the part-time staff, the service provision time relating to the individual service scheduling, icons and buttons for receiving various instructions, etc., in a predetermined layout.
[0109] The service scheduling information creation unit 331 transmits the created service scheduling editing screen display data to the mobile terminal 2 via the server communication unit 31 .
[0110] If the service scheduling information creation unit 331 receives a request to refer to the service scheduling of the specified date from the mobile terminal 2 via the server communication unit 31 , the service scheduling information creation unit 331 creates the service scheduling editing screen display data based on the created part-time staff service scheduling.
[0111] In other words, the service scheduling information creation unit 331 refers to the part-time staff service scheduling stored in the server storage unit 32 using the date given as a parameter as a key and specifies the corresponding individual service scheduling. Then, the service scheduling information creation unit 331 creates the service scheduling editing screen display data based on the specified individual service scheduling by the same procedure as that described above.
[0112] On the other hand, if the service scheduling information creation unit 331 receives a request to modify the service scheduling, the service scheduling information creation unit 331 creates the part-time staff service scheduling again based on the extracted service user's desired date and time of service use and the extracted part-time staff's desired date and time of service provision so that the modification is reflected.
[0113] In other words, the service scheduling information creation unit 331 sets a combination of the service user and the date and time of service provision (desired date and time of service use) relating to the individual service scheduling corresponding to the ID given as a parameter and the service provider corresponding to the ID given similarly as a parameter as a restriction condition, and assigns the extracted part-time staff's each desired date and time of service provision to the similarly extracted service user's each desired date and time of service use so that the restriction condition is met.
[0114] On the other hand, if the service scheduling information creation unit 331 receives a request to store the service scheduling, the service scheduling information creation unit 331 stores the created part-time staff service scheduling in the server storage unit 32 .
[0115] In other words, the service scheduling information creation unit 331 refers to the part-time staff service scheduling stored in the server storage unit 32 and specifies the individual service scheduling. Further, the service scheduling information creation unit 331 refers to the service user's desired date and time management table stored in the server storage unit 32 using the ID of the service user and the date and time of service provision relating to the specified individual service scheduling and extracts the ID of the corresponding service action to be used. Then, the service scheduling information creation unit 331 stores the ID of the specified individual service scheduling, the ID of the service user relating to the individual service scheduling, the ID of the service provider, the date and time of service provision, the extracted ID of the service action to be used, the service provision situation (“not yet”), the ID of the service provision record (“none”), etc., in the service scheduling management table stored in the server storage unit 32 .
[0116] Subsequently, the service scheduling information creation unit 331 specifies the date and time of service provision that is not the date and time of service provision relating to the created part-time staff service scheduling (hereinafter, referred to as “service user's unassigned desired date and time of service use”) among the extracted service user's desired date and times of service use.
[0117] The service scheduling information creation unit 331 extracts the full-time staff's desired date and time of service provision.
[0118] In other words, the service scheduling information creation unit 331 refers to the full-time staff's desired date and time management table stored in the server storage unit 32 and extracts the full-time staff's desired date and time of service provision the predetermined period of time of which is the same as that of the service user's each desired date and time of service use, or during the period of time in which the unassigned desired date and time of service use is included.
[0119] The service scheduling information creation unit 331 creates the full-time staff service scheduling based on the specified service user's unassigned desired date and time of service use and the extracted full-time staff's desired date and time of service provision.
[0120] In other words, the service scheduling information creation unit 331 compares the specified service user's each unassigned desired date and times of service use with the extracted full-time staff's each desired date and time of service provision, and assigns the time period where both the desired date and times coincide with each other, and temporarily stores the results in the server storage unit 32 after giving an individual service scheduling ID newly adopted.
[0121] The service scheduling information creation unit 331 creates the service scheduling editing screen display data based on the created full-time staff service scheduling.
[0122] In other words, the service scheduling information creation unit 331 refers to the full-time staff service scheduling stored in the server storage unit 32 using a predetermined date as a key and specifies the corresponding individual service scheduling. Then, the service scheduling information creation unit 331 creates the service scheduling editing screen display data based on the specified individual service scheduling by the same procedure as that described above.
[0123] The service scheduling information creation unit 331 transmits the created service scheduling editing screen display data to the mobile terminal 2 via the server communication unit 31 .
[0124] If the service scheduling information creation unit 331 receives a request to refer to the service scheduling of the specified date from the mobile terminal 2 via the server communication unit 31 , the service scheduling information creation unit 331 creates the service scheduling editing screen display data based on the created full-time staff service scheduling.
[0125] In other words, the service scheduling information creation unit 331 refers to the full-time staff service scheduling stored in the server storage unit 32 using the date given as a parameter as a key and specifies the corresponding individual service scheduling. Then, the service scheduling information creation unit 331 creates the service scheduling editing screen display data based on the specified individual service scheduling by the same procedure as that described above.
[0126] On the other hand, if the service scheduling information creation unit 331 receives a request to modify the service scheduling, the service scheduling information creation unit 331 creates the full-time staff service scheduling again based on the specified service user's unassigned desired date and time of service use and the extracted full-time staff's desired date and time of service provision so that the modification is reflected.
[0127] In other words, the service scheduling information creation unit 331 sets the contents of the modification as a restriction condition and assigns the extracted full-time staff's each desired date and time of service provision to the specified service user's each unassigned desired date and time of service use so that the restriction condition is met.
[0128] On the other hand, if the service scheduling information creation unit 331 receives a request to store the service scheduling, the service scheduling information creation unit 331 stores the created full-time staff service scheduling in the server storage unit 32 .
[0129] In other words, the service scheduling information creation unit 331 refers to the full-time staff service scheduling stored in the server storage unit 32 and specifies the individual service scheduling. Then, the service scheduling information creation unit 331 stores the specified individual service scheduling or the like in the service scheduling management table stored in the server storage unit 32 by the same procedure as that described above.
[0130] For example, if the full-time staff's desired date and time management table illustrated in FIG. 4D , the part-time staff's desired date and time management table illustrated in FIG. 4E , and the service user's desired date and time management table illustrated in FIG. 4F are given by the above processing, the service scheduling management table illustrated in FIG. 5A is created as a result.
[0131] Hereinafter, the processing by the service scheduling information reference unit 332 is explained. The service scheduling information reference unit 332 refers to and presents the service scheduling to the service provider.
[0132] Specifically, if the service scheduling information reference unit 332 receives a request to refer to the service scheduling from the mobile terminal 2 via the server communication unit 31 , the service scheduling information reference unit 332 creates the service scheduling display screen display data based on the service scheduling.
[0133] In other words, the service scheduling information reference unit 332 refers to the service scheduling management table stored in the server storage unit 32 using a predetermined date as a key and specifies the corresponding individual service scheduling. Further, the service scheduling information reference unit 332 refers to the service user attribute information management table stored in the server storage unit 32 using the ID of the service user relating to the specified individual service scheduling and extracts the name of the corresponding service user. Furthermore, the service scheduling information reference unit 332 refers to the full-time staff attribute information management table and the part-time staff attribute information management table that are stored in the server storage unit 32 using the ID of the service provider relating to the specified individual service scheduling as a key and extracts the name of the corresponding service provider. Then, the service scheduling information reference unit 332 creates the service scheduling display screen display data for the specified individual service scheduling, including the ID of the individual service scheduling or the like, and for displaying the extracted name of the service user, the extracted name of the service provider, the service provision time relating to the individual service scheduling, icons and buttons for receiving various instructions, etc., in a predetermined layout. FIG. 7A is an example of a service scheduling screen display.
[0134] The service scheduling information reference unit 332 transmits the created service scheduling display screen display data to the mobile terminal 2 via the server communication unit 31 .
[0135] If the service scheduling information reference unit 332 receives a request to refer to the service scheduling of the specified date from the mobile terminal 2 via the server communication unit 31 , the service scheduling information reference unit 332 creates the service scheduling display screen display data based on the service scheduling.
[0136] In other words, the service scheduling information reference unit 332 refers to the service scheduling management table stored in the server storage unit 32 using the date given as a parameter as a key and specifies the corresponding individual service scheduling. Then, the service scheduling information reference unit 332 creates the service scheduling display screen display data based on the specified individual service scheduling by the same procedure as that described above.
[0137] On the other hand, if the service scheduling information reference unit 332 receives a request to refer to the individual service scheduling, the service scheduling information reference unit 332 creates the individual service scheduling display screen display data based on the individual service scheduling.
[0138] In other words, the service scheduling information reference unit 332 refers to the service scheduling management table stored in the server storage unit 32 using the ID of the individual service scheduling given as a parameter as a key and specifies the corresponding individual service scheduling. Further, the service scheduling information reference unit 332 refers to the service user attribute information management table stored in the server storage unit 32 using the ID of the service user relating to the specified individual service scheduling as a key and extracts the name of the corresponding service user. Furthermore, the service scheduling information reference unit 332 refers to the full-time staff attribute information management table and the part-time staff attribute information management table that are stored in the server storage unit 32 using the ID of the service provider relating to the specified individual service scheduling as a key and extracts the name of the corresponding service provider. Furthermore, the service scheduling information reference unit 332 refers to the work procedure management table stored in the server storage unit 32 using the ID of the service action to be provided relating to the specified individual service scheduling as a key and extracts the name of the corresponding service action to be provided. Then, the service scheduling information reference unit 332 creates the individual service scheduling display screen display data for the specified individual service scheduling, including the ID of the individual service scheduling, the ID of the service user relating to the individual service scheduling, the ID of the service action to be provided, etc., and for displaying the extracted name of the service user, the extracted name of the service provider, the extracted name of the service action to be provided, the service provision date and time relating to the individual service scheduling, the service provision situation, icons and buttons for receiving various instructions, etc., in a predetermined layout. FIG. 7B is an example of an individual service scheduling screen display.
[0139] Hereinafter, the processing by the service scheduling information updating unit 333 is explained. The service scheduling information updating unit 333 provides a unit configured to update service scheduling to the service provider.
[0140] Specifically, if the service scheduling information updating unit 333 receives a request to change the service provision situation from the mobile terminal 2 via the server communication unit 31 , the service scheduling information updating unit 333 changes the service provision situation relating to the individual service scheduling.
[0141] In other words, the service scheduling information updating unit 333 refers to the service scheduling management table stored in the server storage unit 32 using the ID of the individual service scheduling given as a parameter as a key and specifies the corresponding individual service scheduling. Then, the service scheduling information updating unit 333 changes the service provision situation relating to the specified individual service scheduling from “not yet” to “done”. For example, as illustrated in FIG. 7B , when the “Change” button 714 is pressed down, the service provision situation is changed from “not yet” to “done”, instructions to change the service provision situation are transmitted to the server 3 , and the data of the service provision situation is updated.
[0142] Hereinafter, the processing by the service user management information reference unit 334 is explained. The service user management information reference unit 334 refers to and presents the service user attribute information or the like to the service provider.
[0143] Specifically, if the service user management information reference unit 334 receives a request to refer to the service user attribute information from the mobile terminal 2 via the server communication unit 31 , the service user management information reference unit 334 creates the attribute information display screen display data.
[0144] In other words, the service user management information reference unit 334 refers to the service user attribute information management table stored in the server storage unit 32 using the ID of the service user given as a parameter as a key and extracts the corresponding service user attribute information. Then, the service user management information reference unit 334 creates the attribute information display screen display data for displaying the extracted service user attribute information or the like in a predetermined layout. FIG. 6C is an example of a service user attribute information screen display.
[0145] On the other hand, if the service user management information reference unit 334 receives a request to refer to the service action work procedure, the service user management information reference unit 334 creates the work procedure display screen display data.
[0146] In other words, the service user management information reference unit 334 refers to the work procedure management table stored in the server storage unit 32 using the ID of the service action given as a parameter as a key and extracts the name and the work procedure of the corresponding service action. Then, the service user management information reference unit 334 creates the work procedure display screen display data for displaying the extracted name and work procedure of the service action or the like in a predetermined layout. FIG. 7C is an example of a work procedure information screen display.
[0147] On the other hand, if the service user management information reference unit 334 receives a request to refer to the service provision record, the service user management information reference unit 334 creates service provision record display screen display data.
[0148] In other words, the service user management information reference unit 334 refers to the service scheduling management table stored in the server storage unit 32 using the ID of the individual service scheduling given as a parameter as a key and specifies the corresponding individual service scheduling. Further, the service user management information reference unit 334 refers to the service user attribute information management table stored in the server storage unit 32 using the ID of the service user relating to the specified individual service scheduling as a key and extracts the name of the corresponding service user. Furthermore, the service user management information reference unit 334 refers to the full-time staff attribute information management table and the part-time staff attribute information management table that are stored in the server storage unit 32 using the ID of the service provider relating to the specified individual service scheduling and extracts the name of the corresponding service provider. Furthermore, the service user management information reference unit 334 extracts the ID of the service provision record relating to the specified individual service scheduling. Furthermore, the service user management information reference unit 334 refers to the service provision record management table stored in the server storage unit 32 using the ID of the extracted service provision record as a key and extracts the ID of the corresponding input form and the service provision situation. Furthermore, the service user management information reference unit 334 acquires the input form data corresponding to the extracted ID of the input form from the server storage unit 32 . Then, the service user management information reference unit 334 creates the service provision record display screen display data for displaying the extracted name of the service user, the extracted name of the service provider, the service provision date and time relating to the specified individual service scheduling, the extracted service provision situation, etc., in a predetermined layout by using the acquired input form data.
[0149] The service user management information reference unit 334 transmits the created attribute information display screen display data or the like to the mobile terminal 2 via the server communication unit 31 .
[0150] Hereinafter, the processing by the service user management information updating unit 335 is explained. The service user management information updating unit 335 provides a unit configured to update the service user management information to the service provider.
[0151] Specifically, if the service user management information updating unit 335 receives a request to transmit the service provision record input form from the mobile terminal 2 via the server communication unit 31 , the service user management information updating unit 335 creates the service provision record input screen display data.
[0152] In other words, the service user management information updating unit 335 refers to the service scheduling management table stored in the server storage unit 32 using the ID of the individual service scheduling given as a parameter as a key and specifies the corresponding individual service scheduling. Further, the service user management information updating unit 335 refers to the service user attribute information management table stored in the server storage unit 32 using the ID of the service user relating to the specified individual service scheduling as a key and extracts the name of the corresponding service user. Furthermore, the service user management information updating unit 335 refers to the full-time staff attribute information management table and the part-time staff attribute information management table that are stored in the server storage unit 32 using the ID of the service provider relating to the specified individual service scheduling and extracts the name of the corresponding service provider. Furthermore, the service user management information updating unit 335 extracts the ID of the service action to be provided relating to the specified individual service scheduling. Furthermore, the service user management information updating unit 335 refers to the work procedure management table stored in the server storage unit 32 using the ID of the extracted service action to be provided as a key and extracts the ID of the corresponding service provision record input form. Furthermore, the service user management information updating unit 335 acquires the input form data corresponding to the extracted ID of the input form from the server storage unit 32 . Then, the service user management information updating unit 335 creates the service provision record input screen display data including the ID of the given individual service scheduling, the extracted ID of the input form, etc., and for displaying the extracted name of the service user, the extracted name of the service provider, the service provision date and time relating to the specified individual service scheduling, the input boxes, etc., in a predetermined layout by using the acquired input form data. FIG. 7D is an example of a service provision record input form screen display.
[0153] The service user management information updating unit 335 transmits the created service provision record input screen display data to the mobile terminal 2 via the server communication unit 31 .
[0154] If the service user management information updating unit 335 receives a request to store the service provision record from the mobile terminal 2 via the server communication unit 31 , the service user management information updating unit 335 stores the service provision record in the server storage unit 32 .
[0155] In other words, the service user management information updating unit 335 refers to the service scheduling management table stored in the server storage unit 32 using the ID of the individual service scheduling given as a parameter as a key and specifies the corresponding individual service scheduling. Further, the service user management information updating unit 335 stores the ID of the input form similarly given as a parameter and the data input to the input boxes (service provision situation) in the service provision record management table stored in the server storage unit 32 after giving a service provision record ID newly adopted. Then, the service user management information updating unit 335 stores the given service provision record ID as the ID of the service provision record relating to the specified individual service scheduling.
[0156] (3) Operation of Server 3
[0157] FIG. 8 , FIGS. 9A and 9B , and FIGS. 10A and 10B are diagrams illustrating an example of an operation flow of the server 3 . The operation flow to be explained in the following is performed mainly by the server processing unit 33 in cooperation with each element of the server 3 based on the programs stored in the server storage unit 32 in advance.
[0158] FIG. 8 is a diagram illustrating an example of an operation flow of the service scheduling information creation unit 331 .
[0159] If the service scheduling information creation unit 331 receives a request to create service scheduling from the mobile terminal 2 via the server communication unit 31 , the service scheduling information creation unit 331 extracts the service user's desired date and time of service use (step S 100 ).
[0160] The service scheduling information creation unit 331 extracts the part-time staff's desired date and time of service provision (step S 102 ).
[0161] The service scheduling information creation unit 331 creates the part-time staff service scheduling based on the extracted service user's desired date and time of service use and the extracted part-time staff's desired date and time of service provision (step S 104 ).
[0162] The service scheduling information creation unit 331 creates the service scheduling editing screen display data based on the created part-time staff service scheduling (step S 106 ).
[0163] The service scheduling information creation unit 331 transmits the created service scheduling editing screen display data to the mobile terminal 2 via the server communication unit 31 (step S 108 ).
[0164] If the service scheduling information creation unit 331 receives a request to refer to the service scheduling of the specified date from the mobile terminal 2 via the server communication unit 31 (step S 110 —Yes), the service scheduling information creation unit 331 creates the service scheduling editing screen display data based on the created part-time staff service scheduling (step S 112 ). Then, the service scheduling information creation unit 331 returns to the transmission processing of the service scheduling editing screen display data (step S 108 ).
[0165] On the other hand, if the service scheduling information creation unit 331 receives a request to modify the service scheduling (step S 114 —Yes), the service scheduling information creation unit 331 creates the part-time staff service scheduling again based on the extracted service user's desired date and time of service use and the extracted part-time staff's desired date and time of service provision so that the modification is reflected ((step S 116 ). Then, the service scheduling information creation unit 331 returns to the creation processing of the service scheduling editing screen display data (step S 106 ).
[0166] On the other hand, if the service scheduling information creation unit 331 receives a request to store the service scheduling (step S 114 —No), the service scheduling information creation unit 331 stores the created part-time staff service scheduling in the server storage unit 32 (step S 118 ).
[0167] The service scheduling information creation unit 331 specifies the service user's unassigned desired date and time of service use (step S 120 ).
[0168] The service scheduling information creation unit 331 extracts the full-time staff's desired date and time of service provision (step S 122 ).
[0169] The service scheduling information creation unit 331 creates the full-time staff service scheduling based on the specified service user's unassigned desired date and time of service use and the extracted full-time staff's desired date and time of service provision (step S 124 ).
[0170] The service scheduling information creation unit 331 creates the service scheduling editing screen display data based on the created full-time staff service scheduling (step S 126 ).
[0171] The service scheduling information creation unit 331 transmits the created service scheduling editing screen display data to the mobile terminal 2 via the server communication unit 31 (step S 128 ).
[0172] If the service scheduling information creation unit 331 receives a request to refer to the service scheduling of the specified date from the mobile terminal 2 via the server communication unit 31 (step S 130 —Yes), the service scheduling information creation unit 331 creates the service scheduling editing screen display data based on the created full-time staff service scheduling (step S 132 ). Then, the service scheduling information creation unit 331 returns to the transmission processing of the service scheduling editing screen display data (step S 128 ).
[0173] On the other hand, if the service scheduling information creation unit 331 receives a request to modify the service scheduling (step S 134 —Yes), the service scheduling information creation unit 331 creates the full-time staff service scheduling again based on the specified service user's unassigned desired date and time of service use and the extracted full-time staff's desired date and time of service provision so that the modification is reflected (step S 136 ). Then, the service scheduling information creation unit 331 returns to the creation processing of the service scheduling editing screen display data (step S 126 ).
[0174] On the other hand, if the service scheduling information creation unit 331 receives a request to store the service scheduling (step S 134 —No), the service scheduling information creation unit 331 stores the created full-time staff service scheduling in the server storage unit 32 (step S 138 ). Then, the service scheduling information creation unit 331 terminates the processing.
[0175] FIG. 9A is a diagram illustrating an example of an operation flow of the service scheduling information reference unit 332 .
[0176] If the service scheduling information reference unit 332 receives a request to refer to the service scheduling from the mobile terminal 2 via the server communication unit 31 , the service scheduling information reference unit 332 creates the service scheduling display screen display data based on the service scheduling (step S 200 ).
[0177] The service scheduling information reference unit 332 transmits the created service scheduling display screen display data to the mobile terminal 2 via the server communication unit 31 (step S 202 ).
[0178] If the service scheduling information reference unit 332 receives a request to refer to the service scheduling of the specified date from the mobile terminal 2 via the server communication unit 31 (step S 204 —Yes), the service scheduling information reference unit 332 creates the service scheduling display screen display data based on the service scheduling (step S 206 ). Then, the service scheduling information reference unit 332 returns to the transmission processing of the service scheduling display screen display data (step S 202 ).
[0179] On the other hand, if the service scheduling information reference unit 332 receives a request to refer to the individual service scheduling (step S 204 —No), the service scheduling information reference unit 332 creates the individual service scheduling display screen display data based on the individual service scheduling (step S 208 ).
[0180] The service scheduling information reference unit 332 transmits the created individual service scheduling display screen display data to the mobile terminal 2 via the server communication unit 31 (step S 210 ). Then, the service scheduling information reference unit 332 terminates the processing.
[0181] FIG. 9B is a diagram illustrating an example of an operation flow of the service scheduling information updating unit 333 .
[0182] If the service scheduling information updating unit 333 receives a request to change the service provision situation from the mobile terminal 2 via the server communication unit 31 , the service scheduling information updating unit 333 changes the service provision situation relating to the individual service scheduling (step S 300 ). Then, the service scheduling information updating unit 333 terminates the processing.
[0183] FIG. 10A is a diagram illustrating an example of an operation flow of the service user management information reference unit 334 .
[0184] If the service user management information reference unit 334 receives a request to refer to the service user attribute information from the mobile terminal 2 via the server communication unit 31 (step S 400 —Yes), the service user management information reference unit 334 creates the attribute information display screen display data (step S 402 ). Then, the service user management information reference unit 334 proceeds to the transmission processing of the attribute information display screen display data or the like (step S 410 ).
[0185] On the other hand, if the service user management information reference unit 334 receives a request to refer to the service action work procedure (step S 404 —Yes), the service user management information reference unit 334 creates the work procedure display screen display data (step S 406 ). Then, the service user management information reference unit 334 proceeds to the transmission processing of the attribute information display screen display data or the like (step S 410 ).
[0186] On the other hand, if the service user management information reference unit 334 receives a request to refer to the service provision record (step S 404 —No), the service user management information reference unit 334 creates the service provision record display screen display data (step S 408 ).
[0187] The service user management information reference unit 334 transmits the created attribute information display screen display data or the like to the mobile terminal 2 via the server communication unit 31 (step S 410 ).
[0188] FIG. 10B is a diagram illustrating an example of an operation flow of the service user management information updating unit 335 .
[0189] If the service user management information updating unit 335 receives a request to transmit the service provision record input form from the mobile terminal 2 via the server communication unit 31 , the service user management information updating unit 335 creates the service provision record input screen display data (step S 500 ).
[0190] The service user management information updating unit 335 transmits the created service provision record input screen display data to the mobile terminal 2 via the server communication unit 31 (step S 502 ).
[0191] If the service user management information updating unit 335 receives a request to store the service provision record from the mobile terminal 2 via the server communication unit 31 , the service user management information updating unit 335 stores the service provision record in the server storage unit 32 (step S 504 ). Then, the service user management information updating unit 335 terminates the processing.
[0192] As explained above, in scheduling of the service provider, by preferentially assigning the part-time staff over the full-time staff, it is made easier for the part-time staff to perform the service provision task in the time period desired by him/herself, and therefore the chance to work of the service provider and to improve the chance to use a service of the service user may be improved.
[0193] The present invention is not limited to the present embodiment. For example, in the present embodiment, although the part-time staff's each desired date and time of service provision is assigned to the service user's each desired date and time of service use, and the full-time staff's each desired date and time of service provision is assigned to the service user's each unassigned date and time of service use, the full-time staff's each desired date and time of service provision and the part-time staff's each desired date and time of service provision to the service user's each desired date and time of service use may be simultaneously assigned, in accordance with a restriction condition that gives priority to the part-time staff's each desired date and time of service provision over the full-time staff's each desired date and time of service provision. Thus, the same working and effect as those of the present embodiment may be obtained.
[0194] In the present embodiment, although the assignment processing is performed for all the service users and the service providers, the assignment processing for part of the service users and the service providers may be performed. For example, the assignment processing for the service users belonging to a predetermined group and for the service providers belonging to the same predetermined group may be performed, after grouping the service providers based on attributes (e.g., qualification or the like) or based on the relationship (e.g., chemistry or the like) with service users belonging to the assignment-target group as well as also grouping the service users based attributes (e.g., address or the like). Further, in accordance with the results of grouping, the assignment-target service user group and/or service provider group may be sequentially change or enlarge. Then, the burden of assignment processing may be reduced.
[0195] In the present embodiment, although the assignment processing is performed based on the service user's desired date and time of service use and the service provider's desired date and time of service provision, the assignment processing may be performed based on conditions other than the date and time (e.g., the address of the service user and the area where the service provision by the service provider is available, the service action to be used by the service user and the service action that the service provider can provide, the service user's desired service provider and the service provider's desired service user, etc.). Then, preferable service scheduling may be crated.
[0196] Further, it is possible to provide the computer programs for causing a computer to implement each function included in the terminal processing unit 25 and the server processing unit 33 in the form of being stored in a storage medium that can be read by the computer, such as a semiconductor storage medium, a magnetic storage medium, and an optical storage medium, and to install the computer programs into the terminal storage unit 22 and/or the server storage unit 32 from the storage medium by using publicly known setup programs or the like.
[0197] It should be noted that the person skilled in the art can perform a variety of alterations, replacements, and modifications without departing from the sprit and scope of the present invention.
EXPLANATIONS OF LETTERS OR NUMERALS
[0000]
1 visiting service management support system
2 mobile terminal
21 terminal communication unit
22 terminal storage unit
23 operation unit
24 display unit
25 terminal processing unit
251 browsing execution unit
3 server
31 server communication unit
32 server storage unit
33 server processing unit
331 service scheduling information creation unit
332 service scheduling information reference unit
333 service scheduling information updating unit
334 service user management information reference unit
335 service user management information updating unit
4 base station
5 mobile communication network
6 gateway
7 Internet
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The purpose of the present invention is to provide a server or the like for a home-visit-service management assistance system, said server enabling the utilization opportunities of a home-visit service to be improved. A server ( 3 ) according to the present invention is provided with: a storage unit ( 32 ) having, stored therein, information related to preferred dates and times of a first service provider, information related to preferred dates and times of a second service provider, and information related to preferred dates and times of a service user; a service-provision-plan information generation unit ( 331 ) which allocates, to each of the dates and times indicated by the information related to the preferred dates and times of the service user, each of the dates and times indicated by the information related to the preferred dates and times of the second service provider, further allocates each of the dates and times indicated by the information related to the preferred dates and times of the first service provider, to each of the unallocated dates and times among each of the dates and times indicated by the information related to the preferred dates and times of the service user, said unallocated dates and times being those not having, allocated thereto, any of the dates and times indicated by the information related to the preferred dates and times of the second service provider, and generates service-provision-plan information on the basis of the allocation results; and a service-provision-plan information reference unit ( 332 ) for transmitting the service-provision-plan information.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/660,163 filed on Jun. 15, 2012. The entirety of the above-noted application is incorporated by reference herein.
ORIGIN OF THE INVENTION
The embodiment described herein was made by an employee of the United States Government and may be manufactured and used by or for the Government for Government purposes without the payment of any royalties thereon or therefore.
The invention described herein was also made in the performance of work under a NASA contract and is subject to the provisions of Section 305 of the National Aeronautics and Space Action of 1958, Public Law 85-568 (72 Stat. 435; 42 U.S.C. 2457).
FIELD OF THE INVENTION
The invention relates to fiber composite tows or yarns, in general, and, in particular, to methods and apparatus for deposition of electrospun nanofiber materials on fiber composite tows or yarns.
BACKGROUND OF THE INVENTION
Fiber-reinforced plastic, which is also known as fiber-reinforced polymer, and most generally as composite material, is made of a polymer matrix that is reinforced with fibers that are characterized by high strength and stiffness. The fibers are usually made from glass, carbon, quartz, basalt or aramid, although other fibers such as cellulose and asbestos are sometimes used. The polymer matrix is usually a thermosetting-type plastic such as epoxy, vinylester, bismaleimide, polyimide, phenolic, or polyester but other resins are also used. The fiber reinforcement can be present in various forms including continuous fibers, chopped fibers, woven fabrics, braided fabrics, or other forms. Fiber composites, especially those of the strongest and most rigid fiber, such as carbon fiber, can exhibit a significantly higher strength to weight ratio in comparison to metals, resulting in a potential weight savings of up to about 50 percent. Composite materials are commonly used in the aerospace, automotive, marine, and construction industries. Generally speaking, fiber composites have superior fatigue properties in comparison to metallic structures and are corrosion resistant. With such advantageous structural properties, fiber composites are most suitable for use in aircraft components.
Fiber composite materials are made by first creating bundles of fibers called tows or yarns that typically contain thousands of individual fibers. The fiber tows that are then dipped in polymer resin to produce a “towpreg” in which the resin is impregnated between the individual fibers in the tow. Alternatively, fiber tows can be combined side by side to form a sheet of fibers which are then dipped in a polymer resin or coated with a polymer resin to produce a “prepreg”. The towpreg or prepreg material is then stacked in layers by processes such as filament winding, hand layup, and tape laying and cured by means of cross-linking of polymer chains by means of catalysts, heat, and/or radiation to form a rigid composite structure. An alternative process first forms the fiber tows into a “preform” fabric by weaving or braiding. The dry fabric can then be coated with a resin to form a woven or braided prepreg, or the thy fabric can be placed into a mold followed by infusion of the resin into the mold and curing of the composite within the mold.
One major difficulty in the use of fabricated fiber composite engineered products is that, during use when repeated stresses are applied to the final products, high local stresses develop within individual tows and between tows causing cracking within the fiber tows and delamination between tows that can lead to parts failure. There are methods by which to reduce the potential for such internal failure processes, such as by various modifications of and additions to the resin matrix material, so as to strengthen it. More generally speaking, toughening and other property enhancements of composite materials are typically implemented by modifying the bulk properties of the constituents, either the fiber or matrix materials, though this often leads to difficulties in processing and thus to higher costs.
Investigations of the failure and damage mechanisms of textile composites has led to the conclusion that toughening of the matrix material would result in increased material performance. In this regard, several methods have been used in which the bulk of the matrix is modified either through chemical formulation or the addition of fillers. However, such methods can detrimentally affect the processability of the resulting matrix material. Other methods exist that rely on modification of the fiber material (so-called “fuzzy fiber” approaches) that can also result in reduced fiber performance.
Attempts have been made to overcome the processing challenges associated with fiber composite production while improving the fiber's structural properties according to the final use of various composite structures. But there still exists a need for more efficient methods of enhancing or improving the structural properties of carbon and other fibers.
SUMMARY OF THE INVENTION
According to an embodiment of the invention, a method of coating a towpreg with electrospun fibers comprising the steps of coating a tow fiber bundle with a resin matrix material to form the towpreg; passing the towpreg through an electrospinning apparatus; and depositing an electrospun fiber on the towpreg. Further according to an embodiment of the invention, an apparatus for coating a towpreg with electrospun fibers includes a towpreg of a tow fiber bundle with a resin matrix material; a system for guiding the towpreg through an electrospinning apparatus; and the electrospinning apparatus for depositing an electrospun fiber on the towpreg.
DEFINITIONS
“Tow” or yarn refers to a group or bundle of fibers before coating with a resin.
“Prepreg” refers to tow, sheet of tows aligned in the same direction, or fabric dipped in a matrix material or resin but before curing.
“Towpreg” an individual tow which has been impregnated with uncured resin.
“Preform” refers to tows assembled into a fabric material which is then infused with a matrix material or resin during final processing by a variety of resin infusion methods. “Composite” and/or “composite material” refers to a rigid material that is formed upon curing of the resin material subsequent to the prepregging process or the resin infusion process.
BRIEF DESCRIPTION OF THE DRAWINGS
The structure, operation, and advantages of the present invention will become further apparent upon consideration of the following description taken in conjunction with the accompanying figures (Figures). The figures are intended to be illustrative, not limiting.
Certain elements in some of the figures may be omitted, or illustrated not-to-scale, for illustrative clarity. The cross-sectional views may be in the form of slices, or near-sighted cross-sectional views, omitting certain background lines which would otherwise be visible in a true cross-sectional view, for illustrative clarity.
Often, similar elements may be referred to by similar numbers in various figures (Figures) of the drawing, in which case typically the last two significant digits may be the same, the most significant digit being the number of the drawing figure (Figure).
FIG. 1 is a cross-sectional schematic view of a tow fiber bundle prior to immersion in a polymer resin matrix material, according to the present disclosure.
FIG. 2 is a cross-sectional schematic side view of a polymer resin bath with a tow fiber bundle going through it, according to the present disclosure.
FIG. 3 is a cross-sectional view of the composite material prepreg after the tow has been immersed in polymer resin, according to the present disclosure.
FIG. 4 is a cross-sectional view of a group of composite threads/yarns/tows that have been gathered into a bundle of composite material, according to the present disclosure. This is shown as all tows parallel, but would also include tows arranged with relative angle such as in filament wound structure with various angles between tows.
FIG. 5 is a schematic view that of the polymer resin bath of FIG. 2 , modified in accordance with the present invention.
FIG. 6 is an oblique view of an electrospun fiber deposition chamber wherein electrospun nanofibers are deposited on towpreg, according to the present disclosure.
FIG. 7A is a schematic view of electrospinning apparatus in operation.
FIG. 7B is a schematic view of electrospinning apparatus operating in such a way that nanofiber precursor material falls in liquid droplets from the spinning needle.
FIG. 7C is a schematic view of electrospinning apparatus for operation in an inverted position, according to the present invention.
FIG. 8 is a cutaway orthogonal side view of an electrospinning fiber deposition chamber wherein towpreg receives a coating of electrospun fibers, according to the present disclosure.
FIG. 9 is an end-on sectional view through A-A of the electrospun fiber deposition chamber, according to the present disclosure.
FIG. 10A is a schematic end-on view of the chamber, showing the locations and angles of the electrospinning fiber needles within the lower part of the chamber according to the present disclosure.
FIG. 10B is a schematic end-on view of the chamber, showing alternative locations and angles of the electrospinning fiber needles within the lower part of the chamber according to the present disclosure.
FIG. 11 is a cross-sectional view of a prepreg fiber bundle that has been coated with a layer of electrospun nanofibers, according to the present disclosure.
FIG. 12 is a cross-sectional view of a group of composite electrospun-nanofiber-coated threads/yarns/tows that have been gathered into a bundle of composite material, according to the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
By using a direct electrospun deposition method to apply thermoplastic or other nanofiber materials to the surface of towpregs, the towpreg-towpreg, or tow-tow, interface in the resulting composite can be modified while using otherwise conventional materials and handling processes. Other materials of Electrospun fiber coated towpreg 42 , at the right end of FIG. 6 , reaches a pulley or roller 50 , where its direction is reversed for a second pass through chamber 40 so as to receive a second coating of electrospun fiber, after which it exits through portal 41 and is guided by a wheel 53 toward further processing treatments. Companies that produce fabric products, such as those based on textiles or carbon, for use in composite material manufacturing, could apply direct electrospun deposition in their operations. Fiber-based composite materials could significantly benefit from local toughening through the use of electrospun, nanofiber coatings. Nanofibers, thermoplastic or otherwise, such as polyethersulfone, can be applied to the surface of a tow, prepreg, or fabric dipped in a matrix material or resin before curing, or the tow or fabric material infused with a matrix material or resin during final processing immediately after it has been coated with resin, achieving toughening of the fiber tow contact surfaces so as to result in tougher and more damage-resistant and tolerant composite structures. The same technique can also be applied to other technologies such as tape laying, fiber placement, and filament winding operations. Other modifications to the composite properties such as thermal and electrical conductivity can be made through selection of appropriate electrospun, nanofiber coatings of composite material tows and fiber bundles.
Typical tow material consists of many individual fibers (commonly˜12,000) arranged in small bundles that are round in cross-section, or larger bundles that can be round or flattened some degree. The individual fibers are commonly made or carbon, though, for the purposes of the present embodiment, the fibers might be of any sort that confers strength, toughness, and stiffness to composite materials.
Composite materials can be fabricated from such tow by immersing the tow in polymer resin, or otherwise applying polymer resin to the tow, either prior to or after the tow has been woven, braided, filament wound or otherwise incorporated into practical engineered shapes and objects.
FIG. 1 is a cross-sectional view a tow fiber bundle 10 prior to immersion in a bath of a resin matrix material. The bundle 10 consists of separate strands of strength-giving fibers 14 .
FIG. 2 is an orthogonal cross-sectional schematic side view of a bath 20 containing resin 22 with the tow fiber bundle 10 being immersed as it travels (direction is indicated by the arrows) over a first pulley 24 a , a second pulley 24 b , which is submerged in the resin, and then emerging onto as a towpreg 16 and being guided by a third pulley 24 c to further treatments such as curing of the resin and later hardening and/or giving it further treatments in a region 26 .
FIG. 3 is a cross-sectional view of the prepreg of composite material tow 16 consisting of the tow fiber 10 of FIG. 1 after it has been immersed in the resin 22 in resin bath 20 . Towpreg 16 consists of the same types of carbon or other fibers 14 which are now shown embedded in a matrix polymer resin 18 .
FIG. 4 is a cross-sectional view of a group of composite towpreg threads/yarns/tows 16 , containing fibers 14 , gathered into a unidirectional bundle of composite material 28 .
FIG. 5 shows the process of FIG. 2 altered according to the preferred embodiment by the addition of a chamber 40 wherein the original tow fiber bundle 10 , after having been coated with resin 22 in the bath 20 and becoming the towpreg 16 , then receives a coating of electrospun fibers, as described below, in the chamber 40 .
FIG. 6 is an oblique view of the chamber 40 , showing the resin-coated tow or towpreg 16 entering the chamber through a left enter/exit portal 41 on the left side of the view and traversing the chamber (dotted line) to receive a first coating of electrospun fibers (not shown) on its surface, as discussed below, and thus to become electrospun-fiber coated towpreg 42 .
Electrospun fiber coated towpreg 42 , at the right end of FIG. 6 , reaches a pulley or roller 50 , where its direction is reversed for a second pass through chamber 40 so as to receive a second coating of electrospun fiber, after which it exits through portal 41 and is guided by a wheel 53 toward further processing treatments. The pulley 50 is housed within an extension 54 shown in partial cutaway view at the right end. The chamber 40 has a left end 44 a and a right end 44 b having attached respectively thereto a left vent connection housing 46 a and a right vent connection 46 b . Alternately, the tow could pass through coating chamber once.
The left vent connection 46 a is a conduit for the towpreg fiber bundle 10 as it enters the chamber 40 and the electrospun-fiber-coated towpreg 42 as it exits after having been so coated inside the chamber. Tail piece 48 a on the left vent connection 46 a connects to pressure and ventilation gas handlers (not shown) so as to control the internal environment of chamber 40 with respect to such variables as temperature, humidity, and flow rate of air or other gas. Tail piece 48 b on the right vent connection 46 b likewise connects to pressure and ventilation gas handlers (not shown) so as to control the internal environment of the chamber 40 and to recover solvent that evaporates during the electrospinning process.
The right vent connection 46 b contains the pulley 50 over which the electrospun-fiber-coated towpreg 42 moves so as to reverse its direction for a second pass through chamber 40 . Positive air pressure is maintained inside chamber 40 by the introduction of purge air 67 (arrow) through an inlet conduit 66 shown at the top left end of the chamber. Purge air 67 exits from chamber 40 by way of the tail pieces 48 a , 48 b of the vent connections 46 a , 46 b at each end 44 a , 44 b of the chamber 40 . There is located in the bottom of chamber 40 , within the region 60 denoted by a dotted line, a plurality of upward-pointing electrospinning needle injectors, as will be discussed in greater detail in relation to FIGS. 8 and 9 . The electrospinning needles could also be replaced with a roller/bath type electrospinning coater or other high volume electrospinning device.
In FIG. 6 , a housing 70 at the bottom of chamber 40 contains pressurized reservoirs (not shown) for delivery of nanofiber precursor material (not shown) that is ejected by the electrospinning needle injectors disposed (but not shown in this FIGURE) within the region 60 in the bottom region of chamber 40 .
The region 60 , which contains a multiplicity of electrospinning needle injectors (shown in detail in FIGS. 8 and 9 and numbered as 74 a , 74 b , 74 c , 76 a , 76 b , 76 c , 78 a , 78 b , 78 c ), is disposed in the lower region of chamber 40 for reasons that are illustrated in FIGS. 7 A, 7 B, and 7 C. FIG. 7A is a schematic view of an electrospinning apparatus 100 in which an electrospun nanofiber 116 is being deposited upon a substrate 118 that is moving in a direction as indicated by the arrow 120 . The electrospinning apparatus 100 consists of a needle 102 that conveys electrospinning precursor fluid 104 from a reservoir 106 with which the needle communicates. A pump 108 supplies the pressured fluid 104 to the reservoir 106 by way of s conduit 110 . A high-voltage power supply 112 , operating at a voltage of between about 5,000 volts and 50,000 volts, conveys, by way of electrical connection 121 , an electrical charge to the needles, while the substrate material 118 is maintained in an electrically grounded state by way of electrical connection 122 from the power supply to a location A on the substrate material. Note that the needle 102 emits a jet 114 of electrically charged nanofiber precursor material 104 which is drawn towards the electrically grounded substrate material 118 that is formed of a towpreg. After the jet 114 of electrically charged nanofiber precursor material 104 leaves the needle 102 , the precursor material immediately beginning to thicken as solvent within the precursor material begins to evaporate, and, as doing so the jet transforms into the nanofiber 116 which, because it moves relatively slowly from the needle 102 , and also because of electric charge which it carries, takes on a moving shape more or less as illustrated in the spiral nanofiber's spiral aspect. During the electrospinning process, the jet 114 appears to an observer as, more or less, a straight filament, which the fast-moving nanofiber itself 116 , has an appearance resembling that of an expanding cloud of spray particles which, in FIGS. 8 and 9 , are represented as clouds 72 and 72 ′.
FIG. 7B is a schematic view of the same arrangement of FIG. 7A , but with liquid droplets falling from the needle 102 . The point here is to indicate that sometimes, during the electrospinning process, the jet 114 fails to consolidate as a jet, and droplets 124 can form, the result being that the droplets, which have a low surface-to-volume ratio compared to the jet 114 and nanofiber 116 does not readily dissipate the solvent component of the precursor material 104 . The still wet droplets 124 of nanofiber precursor material 104 thus can fall downward upon the substrate material 118 , which it can soak into and, because of its solvent component or components, have a deleterious effect upon the substrate.
In the case of the present invention, the substrate material 118 is towpreg 16 , as shown in FIG. 6 . Thus, as shown in FIG. 7C , the needle 102 is shown disposed beneath the towpreg 16 , with the jet 114 and nanofiber 116 being projected upward so that if or when droplets emerge from the needle, they will fall on the chamber and away from the towpreg 16 that is undergoing an electrospun nanofiber coating process 100 .
FIG. 8 is a schematic cross-sectional side view of the chamber 40 wherein the resin-coated towpreg 16 receives a coating of electrospun fibers 72 which, as explained in relation to FIGS. 7 A, 7 B and 7 C, are shown as “clouds” 72 from three arrays 74 , 76 , 78 of electrified nanofiber injector needles. Each array 74 , 76 , 78 consists of three needles 74 a , 74 b , 74 c , 76 a , 76 b , 76 c , 78 a , 78 b , 78 c ( FIG. 9 ). The resin-coated towpreg 16 is maintained in an electrically grounded state during the electrospinning coating operation. FIG. 9 is an end-on view, according to section A-A of FIG. 7 , showing right-most needle array 78 displayed as three electrically charged needles 78 a , 78 b , 78 c . While three arrays 74 , 76 , 78 are illustrated, it is within the terms of the preferred embodiment to have two or more arrays. Also, it is within the terms of the preferred embodiment to have two or more needles in each array.
In FIG. 8 , the three “clouds” 72 , representing what are fast-moving, continuous strands of polymeric nanofiber, one from each injection needle in each array 74 , 76 , 78 of three needles, that, before being deposited upon the grounded towpreg 16 , 42 , whip about at high speed so as to appear as a cloud or a spray.
In FIG. 9 , “clouds” 72 ′ represent end-on views of overlapping nanofibers moving from nine electrospinning injector needles 74 a , 74 b , 74 c , 76 a , 76 b , 76 c , 78 a , 78 b , 78 c.
In FIGS. 8 and 9 , the nanofiber needle arrays 74 , 76 , 78 , and needles 74 a , 74 b , 74 c , 76 a , 76 b , 76 c , 78 a , 78 b , 78 c are disposed in the lower region 81 of the chamber 40 as explained in relation to FIG. 7C . FIG. 10A is a more detailed cross-sectional view of FIG. 9 , showing the locational and angular relationships of the of the needles 78 a , 78 b , 78 c of needle array 78 with respect to one another and with respect to chamber 40 . The other needle arrays 74 , 76 (not shown in FIG. 10A ) and the respective needles within each, 74 a , 74 b 74 c , 76 a , 76 b , 76 c , are intended herein to be according to similar locational and angular relationships.
In the view of FIG. 10A , the needles 78 a , 78 b , 78 c all point to a center point CP within the chamber 40 ; that is to say, the respective axes 79 a , 79 b , 79 c converge at center point CP, in this representative view. The respective axes 79 a , 79 b , 79 c stand in angular relationship to one another according to the angles X and Y, which might or might not be equal angles. Angles X and Y can be between 10° and 90° and preferably between 30° and 60°. The tip 78 a ′ of needle 78 a is at a distance of Da from the center point CP, while the tip 78 b ′ of needle 78 b is at a distance Db from center point CP, and the tip 78 c ′ of needle 78 c is at a distance Dc from center point CP. It is anticipated by the inventors that the distances Da,Db,Dc might be equal or different from one another.
FIG. 10B is another detailed cross-sectional view that is intended to show alternative locational and angular relationships of the needles 78 a , 78 b , 78 c of needle array 78 with respect to one another and with respect to chamber 40 . The other needle arrays 74 , 76 (not shown in FIG. 10B ) and the respective needles within each, 74 a , 74 b 74 c , 76 a , 76 b , 76 c , are intended herein to be according to similar locational and angular relationships. Note that the respective axes 79 a , 79 b , 79 c of the needles 78 a , 78 b , 78 c do not necessarily converge at the center point CP, and that their respective angles p,q,r preferably between 0° and 90° with respect to the vertical reference lines d,e,f are not necessarily equal to one another. Note yet further, in the view shown in FIG. 10B , that the needles 78 a , 78 b , 78 c , while shown to be located within the lower region 81 of chamber 40 , are all shown to be on one side of the center line C-C′ of the chamber, which is meant to indicate that the needles can be, if deemed beneficial to the implementation of the present invention, can be so located within the spirit of this disclosure.
During the electrospinning deposition process shown in the FIGS. 8 and 9 , control of the electrical potential of the needles 74 a , 74 b , 74 c , 76 a , 76 b , 76 c , 78 a , 78 b , 78 c as well as control of precursor solutions of the precursor spinning material, with respect to such variables as viscosity and density and/or additives, and also, inside chamber 40 , the air temperature and humidity, airflow rate, pressure, and other variables are used to vary the diameter and nanofiber coating morphology as needed. Post-coating heat treatments may also be used for the purpose of curing, drying, oxidation, annealing, etc. The arrays 74 , 76 , 78 of electrospinning needles 74 a , 74 b , 74 c , 76 a , 76 b , 76 c , 78 a , 78 b , 78 c may be varied in their locational relationships, as described above in reference to FIGS. 7 A, 7 B and 7 C, so as to achieve uniform, quality coatings, and may involve the controlled use of gas flow within the chamber 40 so as to direct and otherwise control nanofiber deposition. An adhesive coating may also be applied (pre- or post-application) to the receiving material 16 , 42 so as to enhance the mechanical stability of the nanofiber coating. Additionally, any number of different nanofiber materials can be simultaneously applied. And the number and arrangement of the electrospinning needles and arrays can be varied.
FIG. 11 is a cross-sectional view of a towpreg fiber bundle 42 , having fibers 14 and matrix polymer resin 18 , that is coated with a layer 80 of electrospun nanofiber.
FIG. 12 , which is analogous to FIG. 4 , is a cross-sectional view of a group of unidirectional electrospun nanofiber-coated towpreg threads/yarns/tows 42 , gathered into a bundle of composite material 90 wherein regions of contact 92 are of respective electrospun coating layers 80 , which locally reinforces the resin in the interface and increases fracture toughness.
This invention produces a product with an electrospun fiber toughening agent applied to the surfaces of fiber tow or other continuous composite precursor material where it is needed (at interfaces and boundaries) without interfering with other composite processing characteristics.
Although the invention has been shown and described with respect to a certain preferred embodiment or embodiments, certain equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described components (assemblies, devices, etc.) the terms (including a reference to a means) used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiments of the invention. In addition, while a particular feature of the invention may have been disclosed with respect to only one of several embodiments, such feature may be combined with one or more features of the other embodiments as may be desired and advantageous for any given or particular application.
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Method and apparatus for enhancing the durability as well as the strength and stiffness of prepreg fiber tows of the sort used in composite materials are disclosed. The method involves adhering electrospun fibers onto the surface of such composite materials as filament-wound composite objects and the surface of prepreg fiber tows of the sort that are subsequently used in the production of composite materials of the filament-wound, woven, and braided sorts. The apparatus performs the methods described herein.
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INVENTION FIELD
[0001] This invention concerns, in general, the field of light firearms, both long and short barrelled such as parallel barrel or over-and-under shotguns, rifles, handguns etc., and in particular refers to a safety device for these arms, namely a mechanical supplementary safety device in the form of a false cartridge.
STATE OF THE ART
[0002] On the one hand the use of so-called false cartridges is already established: devices inserted into the chamber of the barrel(s) of a light firearm when it is not in use, in place of a real cartridge, with view to at least preventing the gun going off accidentally and indicating that it cannot be arbitrarily used. These means however have no real safety device function in the sense that they cannot effectively block abusive use of the firearm since the false cartridge may easily be removed without specific tools even by a child or by unauthorised and incompetent persons.
[0003] On the other hand, though the firearms mentioned above are usually equipped with safety catches with the function of preventing them going off accidentally, for example by blocking the trigger mechanism and/or the hammer action, today there is a pressing demand and consequent need to equip these arms with an additional safety device that can be activated and deactivated by a personalised means available only to the owner of the firearm or someone delegated thereby, thus avoiding effective use of the firearm by unauthorised persons.
PURPOSES AND SUMMARY OF THE INVENTION
[0004] One purpose of this invention is to offer a supplementary safety device created in the form of a false cartridge which can be inserted and stably locked in the chamber of light firearms without the possibility of removal other than voluntary and only by using a specific means correlated to the device itself.
[0005] Another purpose of the invention is to supply a mechanical safety device that fully corresponds to the current, sought-after requirement of increased safety in the use of light firearms such as to permit their use only and exclusively to those who have a personalised method, such as a key, that can control and remove the device once the latter has been activated.
[0006] A further purpose of the invention is to create and supply a safety device for light firearms, shotguns, rifles, handguns and similar that is supplementary to the safety catches with which these firearms are already equipped.
[0007] Yet another purpose of the invention is to supply a safety device for the above mentioned firearms that has two distinct locking sections for maximum efficiency: the first section can be voluntarily activated and deactivated by a specific and personalised method, while the second section, normally inactive, is activated following surreptitious attempted breakage and removal of the device when it is locked in the barrel of a firearm.
[0008] The invention achieves these purposes with a mechanical safety device for light firearms, at least according to claim 1 .
[0009] Correspondingly, the safety device proposed herewith, substantially in the form of a false cartridge or of a form suitable for insertion into the chamber of a firearm, possesses first of all a radially expandable portion controlled by a lock and specific key for locking/unlocking it in the barrel in which it is lodged, thus making it removable only voluntarily.
[0010] However, depending on the state and/or the lubrication of the barrel cartridge chamber internal surface, this controlled expansion lock might not prevent the sliding and forced ejection of the device if axial thrust were to be applied by means of a tool such as a rod, inserted into the muzzle of the barrel.
[0011] So the second locking portion of the device is aimed at preventing all unauthorised forced removal, thanks to an accentuation of the locking action. In fact any axial thrust applied to the device with the intention of ejecting it from the part of its introduction into the barrel results in activation of this second portion which, expanding, tightens against the interior of the barrel; and the greater the thrust the greater the tightening. The advantages of the new supplementary safety device invention may therefore be summarised as follows:
[0012] great ease, convenience and immediacy of use;
[0013] maximum efficiency and reliability in preventing unauthorised use of the firearm;
[0014] possibility of breakage minimised, and even more so if the command lock is made in drill-resistant material.
[0015] Moreover, its configuration and absence of appendices mean that when the device is set in place in the chamber it offers no part that might be gripped by an extracting tool. Lastly, a safety device of this type may be easily manufactured and adapted with the same efficacy and safety to firearms of all calibres, without any modification of the firearm whatsoever.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention is described in greater detail below with reference to the attached indicative and not limitative drawings in which:
[0017] [0017]FIG. 1 shows a blow-up view of the elements comprising the device;
[0018] [0018]FIG. 2 shows an analogous blow-up view of the elements of FIG. 1, but in section;
[0019] [0019]FIG. 3 shows an external view of the assembled device;
[0020] [0020]FIG. 4 shows the device in longitudinal section;
[0021] [0021]FIG. 5 shows an external view of the device in a variant version; and
[0022] [0022]FIG. 6 shows the FIG. 5 device in longitudinal axial section.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The safety device in question is inserted into the chamber of a firearm from the breech towards the muzzle. It consists of a first body 10 pointing towards the breech of the barrel, a second intermediate body 11 and a final spigot and socket body 12 , this last pointing towards the muzzle. The first body and the second intermediate body are joined and axially moveable each with regard to the other, but without the possibility of rotation, thanks to an axial appendix 16 integral with the intermediate body and having the purpose of insertion into corresponding housing 17 in the first body.
[0024] The first body 10 and the intermediate body 11 are joined by a rotating screw pin 13 with head 13 ′ housed in the first body, abutting against a shoulder which impedes axial movement of the pin without obstructing its rotation. The screw pin 13 may be screwed directly to the intermediate body 11 or, as shown in the drawings, to a threaded element 14 associated with that body, in such a way that rotation of the screw pin in one direction causes the approach and in the other direction the distancing of the intermediate body with regard to the first body.
[0025] An anti-rotation gasket 15 is mounted around the first body 10 to prevent rotation of the device when it is placed in the chamber for use.
[0026] The contiguous extremities 10 ′ and 11 ′ of the two bodies 10 and 11 respectively are in truncated cone form and extend from the respective shoulders 10 ″ and 11 ″. Together they delimit an annular peripheral housing 18 at which level is envisaged at least one deformable and expandable by compression element such as, for example, a gasket 19 in an elastomer material, a cup spring 20 , or some other element, which is radially squeezed and expanded between the two shoulders 10 ″ and 11 ″ when the two bodies 10 and 11 are brought together.
[0027] The first body 10 houses and retains a safety lock 21 , linked with the screw pin 13 for rotation of the latter and activated by means of a personalised key supplied to the firearm owner.
[0028] So when the device is placed in the chamber of a firearm barrel, by turning the screw pin 13 with lock and key in one direction, the intermediate body 11 is brought close to the first body 10 and there is consequent radial expansion of the expandable element 19 or 20 , resulting in the device being locked into the chamber. Thus the device cannot be extracted from the breech and the firearm cannot be used by unauthorised persons or those not in possession of the key. Turning the key and therefore the screw pin in the opposite direction, the device is unlocked.
[0029] The spigot and socket body 12 is linked to the forward extremity of the intermediate body 11 by the interposing of a spacer 27 . This is axially bound to the free extremity of the screw pin 13 , for example by a Seeger 22 , and has a side wall 23 which is winged and expandable and delimits a conical cavity 24 , tapering towards the bottom of the body itself. The cavity contains an axially moveable conical plug 25 and is closed by a cover 26 to prevent exit of the plug.
[0030] So when the safety device has been locked in the barrel of the firearm with the special key, any action or thrust on the device, perhaps with a rod inserted into the muzzle with view to ejecting the device at the breech, will cause in-depth penetration of the conical plug 25 , consequent expansion of the winged wall 23 of the spigot and socket body against the internal wall of the barrel and an accentuation of the blocking of the device, making it practically immoveable also in such cases.
[0031] The same result is obtained, as shown FIGS. 5 and 6, when the spigot and socket body is not independent but integrated with or integral to the intermediate body.
[0032] Lastly it should be noted that as a means of impeding forced and unauthorised ejection of the device from a firearm barrel, the spigot and socket body could be replaced by other elements such as a permanent deformation organ, a conical screw or an inclined sector, without this being a departure from the context of the invention.
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This invention concerns a supplementary safety device in the form of a false cartridge to be inserted into the chamber of a light firearm barrel, including a radially expandable portion controlled by a lock operated by a specific key for locking/unlocking it in the barrel in which it is housed, so it may be removed only voluntarily.
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CROSS REFERENCE TO RELATED PROVISIONAL APPLICATION
This application claims the benefit under 35 USC §119(e) of U.S. Provisional Application No. 60/285,342, filed Apr. 20, 2001, and entitled “Separate Quad,” the contents of which are incorporated herein in their entirety.
FIELD OF THE INVENTION
This invention relates to methods and apparatus for accurately positioning one or more optical prisms in an optical assembly. More particularly, the invention relates to accurately positioning the diagonal of an optical prism where the diagonal divides (or is adapted to divide) incident light into a transmitted portion and a reflected portion. Accurate positioning of such a light-dividing diagonal is of importance since misalignment of the diagonal causes misdirection of reflected light and the introduction of parallax into transmitted light.
BACKGROUND OF THE INVENTION
Optical prisms having light-dividing diagonals are used in a variety of optical systems. In recent years, a particularly important application for such prisms has been in projection systems which employ Liquid-Crystal-On-Silicon (LCoS) panels.
The architecture and principals of operation of one such system are described in M. Robinson, J. Kogan, G. Sharp, and J. Birge, “High Contrast Color Splitting Architecture Using Color Polarization Filters,” SID 00 DIGEST , pages 92-95. This system employs a COLORQUAD™ prism assembly produced by Colorlink Inc., of Boulder, Colo. This prism assembly in conjunction with three LCoS panels provides excellent contrast and acceptable throughput, and a rear screen projection TV with an optical engine utilizing such a prism assembly has been demonstrated (CES, Las Vegas, Nev., 2001).
Examples of other architectures employing prisms having light-dividing diagonals can be found in, for example, Conner et al., U.S. Pat. Nos. 6,273,567 B1, Huang et al., 6,304,302 B1; Huang et al., 6,309,071 B1; Johnson et al., 6,183,091 B1; and Japanese Patent Publication No. 10-253922.
The above COLORQUAD™ prism assembly suffers from two major problems. First, the assembly consists of four polarization beam splitters (PBSs) and five COLORSELECT™ polarization filters (Colorlink Inc., Boulder, Colo.). All of these components are optically cemented to each other. Optical cementing is a non-reversible process, which means that if something is wrong with any of the cemented components (scratched, displaced, tilted, etc.), the entire assembly must be rejected. Accordingly, the COLORQUAD™ assembly suffers from low yields and high assembly costs.
The second major problem with the COLORQUAD™ assembly relates to its manner of use. In an optical engine, three LCoS panels are used with one COLORQUAD™ assembly to create a color image on a screen. At the screen, all three images (red, green and blue) should coincide with each other with a very high degree of accuracy, which can be achieved by tilting and displacing of the panels (convergence). After completing this process the panels are fixed in space.
Simultaneously, red, green and blue light patches from the illuminator should overlap the corresponding panels. Any misalignment in the COLORQUAD™ assembly cannot be compensated for by moving the panels themselves (they are fixed as described in the previous paragraph) and will require increasing the light patch from the illumination system to provide complete illumination of all three panels. This significantly reduces the throughput of the optical engine from its theoretical maximum value.
The overlapping of images through the illumination path of the COLORQUAD™ assembly depends on the accuracy with which the assembly is constructed and cannot be compensated for once the assembly process has been completed. In the other words, the COLORQUAD™ assembly must be assembled with very high accuracy, which requires active alignment of the components during the process of cementing. Like the problem of rejecting an entire assembly due to damage of any one component, active alignment during cementing increases the final cost of the COLORQUAD™ assembly.
In view of the foregoing, it is an object of the present invention to provide improved methods and apparatus for positioning of optical prisms.
It is a further object of the invention to provide improved methods and apparatus for positioning a plurality of optical prisms without the need for cementing those prisms to one another.
SUMMARY OF THE INVENTION
In accordance with a first aspect, the invention provides an optical assembly comprising:
(A) at least one prism which has a top, a bottom, a plurality of sides, and a diagonal which has a top and a bottom, said prism comprising:
(i) first and second sub-prisms, each of which has a surface that is parallel to the diagonal, and
(ii) a first mechanical reference surface for the top of the diagonal and a second mechanical reference surface for the bottom of the diagonal; and
(B) a housing comprising:
(i) a plurality of fixed mechanical references, each of which is adapted to engage one of the first mechanical reference surface, the second mechanical reference surface, or a first side of the prism; and
(ii) a locking element which engages a second side of the prism and presses the first side and the first and second mechanical reference surfaces against the plurality of fixed mechanical references.
In accordance with a second aspect, the invention provides a prism which has a top, a bottom, a plurality of sides, and a diagonal which has a top and a bottom, said prism comprising:
(A) first and second sub-prisms, each of which has a surface that is parallel to the diagonal;
(B) a first mechanical reference surface for the top of the diagonal which comprises an extension of the parallel-to-the-diagonal surface of the first sub-prism above the parallel-to-the-diagonal surface of the second sub-prism; and
(C) a second mechanical reference surface for the bottom of the diagonal which comprises an extension of the parallel-to-the-diagonal surface of the first sub-prism below the parallel-to-the-diagonal surface of the second sub-prism.
In accordance with a third aspect, the invention provides a method for positioning a prism, said prism having a diagonal which has a top and a bottom, said method comprising:
(A) providing a first mechanical reference surface for the top of the diagonal;
(B) providing a second mechanical reference surface for the bottom of the diagonal;
(C) providing a plurality of fixed mechanical references, each of which is adapted to engage one of the first mechanical reference surface or the second mechanical reference surface; and
(D) applying a force to the prism to press the first and second mechanical reference surfaces against the plurality of fixed mechanical references.
In accordance with a fourth aspect, the invention provides a method for positioning a prism, said prism (i) having a diagonal which has a top and a bottom and (ii) comprising first and second sub-prisms, each of which has a surface that is parallel to the diagonal, said method comprising:
(A) providing a first mechanical reference surface for the top of the diagonal which comprises an extension of the parallel-to-the-diagonal surface of the first sub-prism above the parallel-to-the-diagonal surface of the second sub-prism;
(B) providing a second mechanical reference surface for the bottom of the diagonal which comprises an extension of the parallel-to-the-diagonal surface of the first sub-prism below the parallel-to-the-diagonal surface of the second sub-prism;
(C) providing a plurality of fixed mechanical references, each of which is adapted to engage one of the first mechanical reference surface or the second mechanical reference surface; and
(D) applying a force to the prism to press the first and second mechanical reference surfaces against the plurality of fixed mechanical references.
The foregoing summary of the various aspects of the invention, as well as the claims appended hereto, refer to the prism of the invention as having a “top” and a “bottom”. The summary and the claims also use the terms “above” and “below.” This “top”, “bottom”, “above”, and “below” terminology has been adopted to facilitate the description of the invention and is not intended to and should not be interpreted as limiting the invention in any manner. In particular, this terminology should not be interpreted as requiring any particular orientation of the prism with respect to gravity, e.g., the top of the prism need not be “up” in a gravitational sense, but could be “sideways” or even “down” in a gravitational sense. These considerations also apply to the rest of the specification and the drawings.
Additional features and advantages of the invention are set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described herein.
It is to be understood that both the foregoing general description and the following detailed description are merely exemplary of the invention, and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed.
The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate various embodiments of the invention, and together with the description serve to explain the principles and operation of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram illustrating the four components of a “Separate Quad” constructed in accordance with the invention.
FIG. 2 is a perspective drawing of a prism, specifically, a polarization beam splitter (PBS), constructed in accordance with the invention.
FIG. 3 is a schematic diagram illustrating the position of mechanical bases and locking elements, e.g., spring-loaded lockers, for use with the Separate Quad of FIG. 1 .
FIG. 4 is a schematic diagram illustrating another embodiment of the invention employing three prisms and a wire grid polarizer.
FIG. 5 is a schematic diagram illustrating a further embodiment of the invention employing two prisms and two wire grid polarizers.
The reference numbers used in the drawings correspond to the following:
5 A blue LCoS
5 B red LCoS
5 C green LCoS
7 light from illumination
9 light to projection
11 overall optical assembly
13 prism diagonal
15 A prism
15 B prism
15 C prism
15 D prism
17 A longer sub-prism
17 B shorter sub-prism
19 A top mechanical reference surface
19 B bottom mechanical reference surface
21 locking elements (represented by open arrows in FIG. 3 with the point of the arrow engaging a side of the prism)
23 fixed mechanical references (represented by closed arrowheads in FIG. 3 with the point of the arrowhead engaging either a mechanical reference surface or a side of the prism)
25 filter
27 wire grid polarizer
DETAILED DESCRIPTION OF THE INVENTION
In certain embodiments, the present invention provides an opto-mechanical assembly 11 (also referred to herein as a “subassembly”) of four prisms or prism units 15 , which together form a “Quad” or “Separate Quad” for use in a reflective LCoS projection system. As shown in FIG. 1, the prism subassembly 11 consists of four pre-assembled components 15 A, 15 B, 15 C, and 15 D.
Components 15 A, 15 B, 15 C, and 15 D are each a polarization beam splitter (PBS) with components 15 A, 15 B, and 15 C having one optically cemented polarization filter, while component 15 D has two cemented filters. In each case, the polarization filters can be COLORSELECT™ filters produced by Colorlink Inc., of Boulder, Colo. These four components are assembled in the mechanical housing for the light engine to the required accuracy without any additional alignment. The most critical optical elements of the Quad from a positioning point of view are the diagonals 13 of the four polarization beam splitters.
To provide high accuracy for component positioning, the PBS preferably has the shape shown in FIG. 2 . Each PBS consists of two cemented right angle prisms or sub-prisms ( 17 A, 17 B), with a polarization coating on the PBS's diagonal. The polarization coating can, for example, be a multilayer structure as used in the MacNeille polarizing cube (see E. Stupp, M. Brennesholtz, Projection Displays, 1999, p. 130-133) or a polarization birefringence film such as that manufactured by 3M under the tradename 3M CARTESIAN POLARIZER (see Private Line Report on Projection Display, Volume 7, No. 11, Jul. 20, 2001, pages 6-8).
As can be seen in FIG. 2, one sub-prism 17 A is taller (longer) than the other sub-prism 17 B, which allows the open or extended sections of the diagonal surface of the longer sub-prism to be used as mechanical reference surfaces 19 A and 19 B for positioning.
The housing for the Separate Quad subassembly preferably consists of a top plate, bottom plate and four locking elements 21 (e.g., spring-loaded lockers), one per each PBS. The top and bottom plates have four sets of three pads (mechanical references), with each set forming a base for its respective prism 15 A, 15 B, 15 C, and 15 D. In each set, two pads are in contact with the PBS's diagonal and one in contact with a side surface of the PBS, as shown in FIG. 3 (pads or mechanical basis shown in the drawing as black triangles/arrowheads).
Each PBS is placed against its own set of pads as shown in FIG. 3 . The spring-loaded locker forces the PBS to slide along the diagonal until full contact between the glass and the mount is achieved. In this method of assembly, the position of each PBS is determined by the position of the mechanical pads which can be fabricated to the required accuracy.
FIGS. 4 and 5 show variations of the system of FIG. 1 wherein a wire grid polarizer has been substituted for one (FIG. 4) or two (FIG. 5) of the polarization beam splitters. The remaining PBS's ( 15 B, 15 C, and 15 D in FIG. 4; 15 C and 15 D in FIG. 5) will have a construction of the type shown in FIG. 2 and the housing for these PBS's will have appropriate fixed mechanical references and locking elements like those shown in FIG. 3, adjusted to take account of the reduced number of PBSs. The housing will also include suitable fixtures for mounting the wire grid polarizers. The wire grid polarizers can be of the type manufactured by MOXTEK (Orem, Utah, USA) under the PROFLUX trademark. See also U.S. Pat. No. 6,122,103.
From the foregoing, it can be seen that the prism positioning system of the invention has the following benefits:
1. The system provides a drop-in assembly method which does not require alignment.
2. The accuracy of a diagonal's positioning does not depend on the PBS geometry or the accuracy of the filters (e.g., COLORSELECT™ filters) mounted on the PBS. Rather, it depends on the accuracy of the pad positioning and spacer geometry, which can be provided by fabricated mechanical components.
3. The system provides low assembly costs.
4. The system provides high assembly yields since if one of the components in the assembly is damaged or defective, it can be replaced without damaging the other components.
Although specific embodiments of the invention have been described and illustrated, it is to be understood that modifications can be made without departing from the invention's spirit and scope. For example, although it is preferred that each prism and its associated light-dividing diagonal is positioned independently of all other prisms in an assembly, the invention can be employed for only a subset of the prisms of an assembly (including only one prism of an assembly), with the remaining prisms being cemented together and positioned as one or more groups.
Also, although the invention has been illustrated in terms of a prism diagonal which divides incident light based on polarization, the invention can be used with prism diagonals that divide light based on color, e.g., prisms whose diagonals comprise a dichroic coating. Such dichroic prisms can have the same geometrical configuration as shown in FIG. 2 or can comprise two sub-prisms and a plane parallel plate between the sub-prisms which constitutes the prism's light-dividing diagonal. The plane parallel plate can extend above and below the sub-prisms to form the top and bottom mechanical reference surfaces which engage the fixed mechanical references of the prism's housing.
As a further variation, the number of fixed mechanical references used for an individual prism can differ from that shown in FIG. 3 . For example, instead of four fixed mechanical references for the light dividing diagonal, i.e., two at the top and two at the bottom, only three can be used, e.g., two at the top and one at the bottom or vice versa. Similarly, although the use of side-engaging fixed mechanical references at both the top and bottom of the prism is preferred, one of these fixed mechanical references can be eliminated if desired. More generally, the minimum number of fixed mechanical references needed to define the position of the light-dividing diagonal is four—three which engage the diagonal and one which engages a side of the prism, with the locking element being appropriately located to effectively press the prism against the four fixed references.
As to locking elements, although spring loaded lockers are preferred because of their low cost and ready availability, other force applying locking elements can be used if desired. For example, lockers which employ a resilient polymeric material which is compressed during positioning of the prism can be used, rather than a metallic spring. A turn screw or similar mechanical force generator, e.g., a cam mechanism, can also be used for this purpose if desired.
Additional variations include using prisms of differing heights with the housing and its associated fixed mechanical references being adjusted to accommodate those heights, e.g., the housing can have a stepped configuration. In connection with these or other embodiments, the housing can, and typically will, comprise multiple components connected to one another.
In addition to using prisms of different heights, the heights of mechanical reference surfaces 19 A and 19 B can vary both between prisms and/or for a given prism, e.g., mechanical reference surface 19 A can be longer than (or shorter than) reference surface 19 B for a given prism and the dimensions of the reference surfaces can be different for different prisms in an assembly. Also, although using two sub-prisms of different heights is the preferred approach for producing the mechanical reference surfaces, other approaches can be used if desired, e.g., one of the sub-prisms can be formed with or machined to have projecting portions at its top and bottom which will serve as mechanical reference surfaces or projections can be attached to a sub-prism using a suitable cement or other fixation technique.
A variety of other modifications which do not depart from the scope and spirit of the invention will be evident to persons of ordinary skill in the art from the disclosure herein. The following claims are intended to cover the specific embodiments set forth herein as well as such modifications, variations, and equivalents.
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An optical assembly ( 11 ) is formed by individually positioning a plurality of prisms ( 15 ) using mechanical reference surfaces ( 19 ) which are associated with the prism's diagonal ( 13 ) and are preferably formed by extensions of a first sub-prism ( 17 A) beyond a second sub-prism ( 17 B). The mechanical references surfaces and a first side of the prism engage fixed mechanical references ( 23 ) associated with a housing. A locking element ( 21 ) engages a second side of the prism and forces the mechanical reference surfaces and the first side of the prism against the fixed mechanical references to achieve accurate positioning of the prism's diagonal ( 13 ).
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BACKGROUND OF THE INVENTION
Pipelines are utilized throughout the world for the long-distance transportation of oil, gas, industrial chemicals and other such fluids. A pipeline is typically constructed from large steel pipe sections (40-80 feet in length and 20-48 inches in diameter) which are welded together along the pipeline route and then buried underground. However, while the pipe sections delivered to the pipeline construction site are typically straight, pipeline routes rarely follow a straight line. Rather, most pipeline routes include numerous horizontal and/or vertical curves provided to follow the contours of the earth, to detour around obstacles, or because of land ownership considerations. Efficiently bending the massive sections of pipe to allow the pipeline to follow the preselected route remains a major challenge to the pipeline construction industry.
Portable pipe bending machines have been developed which permit the bending of massive pipe sections to the desired degree of curvature at the site of installation. Because of the size of the pipes being bent, the pipe bending equipment is generally massive in nature and operated hydraulically. Examples of such hydraulically-operated pipe bending machines are disclosed in U.S. Pat. No. 5,092,150 to Cunningham, U.S. Pat. No. 3,834,210 to Clavin, et al., and U.S. Pat. No. 3,851,519 to Clavin, et al., the disclosures of which are incorporated herein by reference. The pipe section is typically inserted into the bending machine to the location desired for the bend and then clamped into place. Next, the bending force is applied to bend the pipe. Finally, the machine releases the pipe for repositioning. In many cases, the degree of curvature needed for a particular pipe section exceeds the amount which can be formed by a single bend without damaging the pipe. In such cases, a succession of laterally spaced-apart bends will be made on a single pipe section to obtain the desired curvature.
The operation of hydraulic pipe bending machines may be controlled manually by a human operator or it may be controlled by a microprocessor or other form of automatic controller. Regardless of the form of control, however, hydraulically powered mechanisms are generally used for moving the pipe section into the bending position, for clamping it in place, for applying the bending force, and then for releasing the section in preparation for the next successive bending operation. It will be readily apparent that the time required for these hydraulic mechanisms to move through their operational ranges defines the lower limit on the time necessary to perform a single bend. Increasing the operating speed of the hydraulic apparatus will thus allow a reduction in the time required for bending, thus increasing the efficiency of the bending machine.
Increasing the speed of a hydraulic cylinder is usually achieved by increasing the fluid flow rate to the cylinder or by reducing the area of the cylinder. However, increasing the flow rate generally requires increasing the size of the hydraulic pump power source. Decreasing the cylinder area requires higher fluid pressure to maintain the same output force, and achieving this higher pressure also requires increasing the size of the hydraulic pump power source. A more powerful hydraulic power source raises the initial cost of the bending machine as well as its hourly operating cost due to increased fuel usage.
It can be seen from the foregoing that a need exists for a pipe bending machine which operates faster than a conventional machine having a comparably sized power source and maximum bending force. A further need exists for equipment that is easily retrofit to existing pipe bending machines to increase their operating speed without reducing their maximum bending force. Another need exists for a method of bending a pipe which provides increased bending speed without requiring additional hydraulic power or reducing the maximum bending force.
SUMMARY OF THE INVENTION
The present invention is for an apparatus and a method for bending pipes of large diameter. The apparatus includes two major portions, a bending mechanism and a hydraulic system to power the bending mechanism. The bending mechanism includes three components: a bending die, a stiffback, and at least one outboard bending cylinder. The bending die is rigidly attached to a frame of the apparatus, while the stiffback is flexibly attached to the frame and moves via operation of the bending cylinder. Operation of the bending cylinder moves the stiffback toward the bending die to clamp or bend the pipe.
The hydraulic fluid supply system includes two components: a hydraulic pump and at least one pressure-sensitive regenerative valve assembly. When the pressurized hydraulic fluid being supplied from the hydraulic pump to a blind end of the bending cylinder is less than a predetermined pressure, the hydraulic fluid exits a rod end of the bending cylinder and is routed into the blind end of the bending cylinder. This regenerative flows allows for rapid action, albeit at reduced force, of the stiffback for clamping the pipe. When the supplied hydraulic fluid has pressure greater than the predetermined pressure, the hydraulic fluid is routed back to the hydraulic pump. This conventional hydraulic fluid flow allows for the application of full force by the stiffback for bending of the pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages will become more apparent from the following and more particular description of the invention, as illustrated in the accompanying drawings, in which like referenced characters generally refer to the same parts throughout the views, and in which:
FIG. 1 is a side view of a pipe bending apparatus according to a preferred embodiment of the current invention with a pipe section loaded therein in the starting position for a bend;
FIG. 2 is a side view of the pipe bending apparatus of FIG. 1, showing the operation of placing a bend in the pipe;
FIGS. 3A and 3B are cross sectional views of the outboard and inboard bending cylinders, respectively, for the apparatus of FIG. 1 showing the direction of fluid flow and rod movement during the leveling operation;
FIG. 4 is a schematic diagram of a hydraulic system suitable for use in the bending machine of FIG. 1;
FIG. 5 is an enlarged schematic diagram of the regenerative manifold assembly of FIG. 4;
FIGS. 6A-6D are right side, front, left side and bottom views, respectively, of a regenerative manifold assembly suitable for use in the system of FIG. 4;
FIG. 7 is a pipe bending apparatus according to another embodiment of the current invention;
FIG. 8 is a schematic diagram of a hydraulic system suitable for use in the bending machine of FIG. 7;
FIG. 9 is an enlarged schematic diagram of a dual regenerative manifold assembly suitable for use in the hydraulic system of FIG. 8;
FIGS. 10A-10C are top, left side and front views, respectively, of a dual cylinder regenerative manifold assembly suitable for use in the system of FIG. 8;
FIG. 11 is a graph showing stiffback velocity versus time for the bending apparatus of the current invention and for the prior art when bending a first type of pipe; and
FIG. 12 is a graph showing stiffback velocity versus time for the apparatus of the current invention and for the prior art when bending a second type of pipe.
DETAILED DESCRIPTION
With reference now to the drawings, there is illustrated in FIGS. 1 and 2 a pipe bending apparatus 20 according to a preferred embodiment of the current invention. The pipe bending apparatus 20 is used to bend a pipe section 22 into a desired curvature by the use of hydraulic force. It can be observed that the pipe bending apparatus 20 includes a frame 24 for supporting the remaining components. A caterpillar assembly 26 is mounted to the frame 24 to provide mobility for the apparatus.
The pipe bending apparatus 20 using a bending mechanism that includes a bending die 28, a stiffback 30, and a pin-up shoe 32. FIG. 1 shows the pipe bending apparatus 20 in the starting position for a bend. A length of pipe section 22 has been inserted into the pipe bending apparatus 20 from the rear end 34, over the pin-up shoe 32, and onto the stiffback 30. Rollers 36 may be provided to facilitate movement of the pipe section through the apparatus. An axial positioning mechanism (not shown) is used to move the pipe section 22 axially along the stiffback 30 until the appropriate portion of the pipe section is positioned beneath the bending die 28. Such axial positioning mechanisms are known in the art and will not be further described here. The bending die 28 is rigidly attached to the upper portion 38 of the frame 24. The bending die 28 has a curved lower surface 40 designed to impart the desired bend radius onto the pipe section 22 during bending. The stiffback 30 has a trough-like cross section for supporting the lower surface 39 of the pipe section 22 during bending. The stiffback 30 is connected to the frame 24 by at least one hydraulic bending cylinder which, when operated, moves the stiffback relative to the frame (hence, also relative to the bending die 28). In the preferred embodiment shown in FIGS. 1 and 2, two outboard hydraulic bending cylinders 42 (one on each side) are connected between the front portion 44 of the frame 24 and the front portion 46 of the stiffback 30, and four inboard hydraulic bearing cylinders 48 (two on each side) are connected between the upper portion 38 of the frame and the rear portion 50 of the stiffback. The pin-up shoe 32 is connected to the rear portion 52 of the frame 24 for supporting the rear portion of the pipe section 22 during bending. The vertical position of the pin-up shoe 32 can be adjusted by axially sliding a pin-up wedge 54 using a hydraulic pin-up cylinder 56. In the starting position illustrated in FIG. 1, the pin-up cylinder 56 is retracted such that the pin-up shoe 32 is at its lowest vertical position and spaced apart from the lower surface 39 of the pipe section 22 in order to facilitate movement of the pipe through the apparatus. It will also be noted that in the starting position as illustrated in FIG. 1, the stiffback 30 is vertically positioned such that the upper surface 57 of the pipe section 22 supported therein is spaced apart from the lower surface 40 of the bending die 28 by a clearance distance (denoted by reference number 58) to further facilitate movement of the pipe section through the apparatus.
This clearance distance 58 is typically within the range of about 21/2 inches to 31/2 inches, and preferable is about 3 inches.
Once the pipe section 22 has been axially positioned for the bend, the stiffback 30 is raised vertically to bring the upper surface 57 of the pipe into contact with the bending die 28. This is often referred to as the leveling operation. In the preferred embodiment, leveling is accomplished by supplying pressurized hydraulic fluid to the outboard and inboard bending cylinders 42, 48. Referring now also to FIGS. 3A and 3B, in the preferred embodiment raising the front end 46 of the stiffback 30 is performed by supplying high pressure hydraulic fluid to the blind end 60 of the outboard bending cylinders 42 thereby causing cylinder rod 62 to extend as indicated by arrow 64. Raising the rear end 50 of the stiffback is performed by applying high pressure hydraulic fluid to the rod end 66 of the inboard bending cylinders 48, thereby causing the cylinder rod 62 to retract as denoted by arrow 68. Of course, as the bending cylinders move (i.e., extend or retract) during the leveling operaiton, movement of the cylinder pistons 69 will force hydraulic fluid out from the opposite end.
During the leveling operation, both the pipe section 22 and the stiffback 30 are raised vertically for a distance (denoted by reference numbers 70 and 72, respectively) approximately equal to the original die clearance distance 58, resulting in a final configuration as shown by the dotted lines in FIG. 1.
After leveling is completed, the pipe section 22 and stiffback 30 will have the configuration shown by the dotted lines in FIG. 2. The pin-up cylinder 56 is now extended to move the pin-up wedge 54 against the pin-up shoe 32 until the shoe contacts the lower surface 39 of the pipe section 22. Next, high pressure hydraulic fluid is again supplied to the bending cylinders 42, 48 as previously described, to perform the actual bending of the pipe section. However, because the upper surface 57 of the pipe section is already positioned against the bending die 28, the inboard cylinders 48 cannot retract further when pressurized but merely clamp the pipe tightly to the die (the combined force of the inboard cylinders 48 is limited to prevent them from exceeding the strength of the pipe). The outboard bending cylinders 42, however, are not similarly restrained and therefore extend rods 62 by a bending distance (denoted by reference number 74) causing the front end 46 of the stiffback 30 to force the pipe section 22 against the bending die 28 and pin-up shoe 32 creating the bend. A hydraulic pin-up clamp 76 positioned adjacent to the pin-up shoe 32 may also be pressurized during bending for securing the rear end of the pipe section to the shoe. The bending distance 74 for a typical bend is in the range of about 4 inches to about 6 inches, and more preferably about 5 inches. After the bend has been formed, the flow of hydraulic fluid to the bending cylinders 42, 48 and pin-up clamp 76 is reversed from that previously described, causing the outboard bending cylinders 42 to retract their cylinder rods 62 back to the starting position and causing the inboard bending cylinders 48 to extend their cylinder rods 62 back to the starting position and causing the pin-up clamp 76 to release the rear portion of the pipe section 22 so that it can be repositioned with the next bend (if additional bends are required) or for removal from the apparatus (if bending is completed).
It is significant to note that the force required to raise the pipe section 22 during the leveling operation is typically much less than the force required to bend the pipe during the bending operation. For example, a forty foot section of 36 inch diameter of 1/2 inch wall thickness pipe made of 90 ksi steel weighs approximately 7,600 pounds and the weight of the mandrel positioned in the pipe at the time of bending is approximately 3,200 pounds. Thus, the bending cylinders 42, 48 must produce a total force of approximately 18,400 pounds during the leveling operation. To actually bend the same pipe, however, requires the stiffback to exert approximately 361,000 pounds of force which must be supplied by the outboard cylinders 42 only. The current invention utilizes this differential force requirement to provide an improved bending apparatus and a new method for bending a pipe which allows for the more efficient operation of such apparatus.
To power and control the various hydraulic mechanisms comprising the pipe bending apparatus 20, a hydraulic fluid supply system is provided. FIG. 4 shows a schematic diagram of a hydraulic system 80 suitable for use on the preferred apparatus of FIG. 1. The hydraulic system 80 includes an engine 82 powering a hydraulic pump 84, various hydraulic supply lines 86 connected between the components of the bender and the components of the hydraulic system and hydraulic control valves 88, 90 and 92 for controlling, respectively, the axial positioning mechanism 94 (in this case, a hydraulic winch), the bending mechanism (including outboard bending cylinders 42, inboard bending cylinders 48 and pin-up clamp 76) and the pin-up cylinder 56 of the pin-up mechanism. With the exception of two pressure-sensitive regenerative valve assemblies 96, the purpose of which will be discussed below, the hydraulic system 80 is of a type generally known, the design and components of which can be readily understood from a review of the schematic shown in FIG. 4, thus it will not be further discussed here.
Referring now also to FIG. 5, an enlarged schematic diagram is provided showing a pressure sensitive regenerative valve assembly 96 of a type suitable for use in the system of FIG. 4 to operate an apparatus according to the current invention. The regenerative valve 96 comprises a counterbalance valve 98 and a check valve 100 installed in a manifold 102. The "raise bender" supply line is connected to port 104, the "lower bender" supply line is connected to port 106, the port 108 is connected to the blind end 60 of the outboard bending cylinder 42 and the port 110 is connected to the rod end 66 of the outboard bending valve. The counterbalance valve 98 includes a pressure sensitive pilot valve 112 which senses the pressure between ports 104 and 108 (i.e., the pressure at the blind end of the outboard bending cylinder). When the pressure in the blind end of the outboard bending cylinder 62 is less than a predetermined pressure, the pilot valve 112 remains closed, blocking the flow of fluid from the rod end of the outboard bending cylinder and forcing this fluid to flow through check valve 100 and through port 108 where it is added to the pump flow being supplied to the blind end of the outboard bending cylinder. This additional flow causes the bending cylinder to advance much more rapidly than it would on pump flow alone. A consequence of this regenerative flow is, however, a reduction in the effective force produced by the outboard bending cylinder. Whereas the normal output force would be equal to the blind end area times the fluid supply pressure, when regenerative flow is being used, the effective force is reduced to the rod area times the fluid pressure. For example, for an outboard cylinder having a bore diameter of 11 inches and a rod diameter of 9 inches, the effective force at 1,000 psi fluid pressure would equal 95,030 pounds, whereas with regeneration, the effective output force would be reduced to 63,600 pounds, a 33 percent reduction. Even though the literature teaches that regeneration is useful only with a 2:1 ratio between cylinder and rod diameters, the present invention is useful with an 11:9 ratio. For the same cylinder, however, the extension speed without regeneration for an assumed flow of 25 gallons per minute, would equal 1.01 inches per second, whereas the extension speed with regeneration would be 1.51 inches per second, an increase of approximately 50 percent. When, however, the pressure at the blind end of the outboard bending cylinder meets or exceeds the predetermined pressure, the pilot valve 112 will move to the open position such that fluid exiting the rod end of the outboard bending cylinder will flow out port 106 and return to the hydraulic system tank in a conventional manner, thus terminating the regenerative effect. Of course, termination of fluid regeneration causes the extension speed of the cylinder to return to its normal speed but also causes the extension force to return to its conventional force. Thus, by use of a pressure sensitive regenerative valve assembly, a "two-speed" hydraulic system is provided which allows increased cylinder extension speed when relatively low forces are required, for example during the leveling operation, but then allows the system to automatically switch into a non-regenerative mode with a somewhat slower extension speed but with greatly increased extension force when relatively high forces are required, for example during the bending operation.
Referring now to FIGS. 6A-6D, shown is a regenerative valve assembly 114 corresponding to the schematic circuit of FIG. 5. The regenerative valve assembly 114 comprises the counterbalance valve 98 and check valve 100 previously described installed in a manifold block 116 providing the necessary passages and ports as shown. The regenerative valve assembly 114 may be used in the construction of new pipe bending apparatus according to the current invention, and it can also be retrofit on existing non-regenerative pipe bending apparatus so as to provide a very inexpensive way of achieving the benefits of regenerative operation. Those of ordinary skill will readily appreciate how the regenerative valve assembly 114 can be integrated into a prior art (non-regenerative) type of pipe bending apparatus, therefore the specifics of such retrofit will not be discussed further here.
Referring now to FIGS. 7, a pipe bending apparatus 120 according to another embodiment of the current invention is shown. The pipe bending apparatus 120 is identical to the pipe bending apparatus of FIGS. 1 and 2 except for the fact that it incorporates four outboard bending cylinders 42 (two on each side) and utilizes a different hydraulic control system. Therefore, the description of the second embodiment will be confined primarily to the differences between this embodiment and that disclosed in FIGS. 1 and 2. As previously indicated, the pipe bending apparatus 120 has four outboard bending cylinders, and two front outboard cylinders 142 (one on each side) and two rear outboard cylinders 143 (one on each side). The outboard cylinders 142, 143 may be the same size as one another, or the cylinders 142 may be a different size from the cylinders 143, depending upon the operational characteristics desired.
Referring now also to FIG. 8, a modified hydraulic fluid supply system 122 is provided for operation of the pipe bending apparatus 120. The hydraulic system 122 is similar in most respects to the system 80 previously disclosed. Thus, only the significant modifications will be discussed in detail. A significant change is that hydraulic system 122 now includes supply lines for four outboard cylinders, the two front outboard cylinders 142 and the two rear outboard cylinders 143. Further, regenerative control for each pair of outboard cylinders 142, 143 is provided by a dual regenerative valve assembly 124, 126, respectively. Referring now also to FIG. 9, an enlarged schematic diagram is provided showing the dual regenerative manifold assembly 124 of a type suitable for use in a system of FIG. 8. The dual valve assembly 124 is identical in all ways with dual valve assembly 126 except possibly for flow capacity and pressure settings, therefore it will not be separately discussed. The dual regenerative valve comprises two pressure sensitive regenerative valve assemblies installed in a single manifold in order to facilitate installation and operation. Each of the regenerative valves comprises a counterbalance valve 98 and a check valve 100 operating as previously described for valve 96. The supply port connections 104, 106 and cylinder connections 108, 110 are also identical to those previously disclosed for valve 96 except that two sets of cylinder connection ports are provided so that a pair of cylinders can be controlled with a single set of supply lines.
Referring now to FIGS. 10A-10C, shown is a regenerative valve assembly 128 corresponding to the schematic circuit of FIG. 9. The regenerative valve assembly 128 comprises two counterbalance valves 98 and two check valves 100 as previously described installed in a dual manifold block 130 which provides the necessary passages and ports as shown. The dual regenerative valve assembly 128 may be used in the construction of new pipe bending apparatus according to the current invention, and it can also be retrofit on existing non-regenerative pipe bending apparatus having dual outboard bending cylinders so as to provide an inexpensive way of achieving benefits of regenerative operation.
Operation of the pipe bending apparatus 120 with four outboard bending cylinders 142, 143 using the hydraulic system 122 or other hydraulic systems allowing the predetermined pressure at which regeneration starts to be set for each individual cylinder provides the system operator with several options for operation. First, if the pilot valves in the regenerative valve assemblies are set to operate at the same predetermined pressure, then all of the outboard bending cylinders 142, 143 controlled by these valves will begin and end regenerative operation in unison. This will essentially provide for two speed and two force level operations as previously described. Second, if the pilot valves controlling the front outboard bending valves are set to operate at different predetermined pressure from the pilot valves controlling the rear outboard bending cylinders, then the system will operate in a three speed, three force mode which may result in even greater effeciencies in operation. Referring now to FIGS. 11 and 12, examples showing the benefits of the current invention are provided. In both examples, it is assumed that the pipe bending apparatus has two outboard bending cylinders, each having a bore diameter of 11 inches and a rod diameter of 9 inches and four inboard bending cylinders, each having a bore diameter of 7 inches and a rod diameter of 21/2 inches. The outboard bending cylinders are set up to bend in push mode (fluid to blind end) while the inboard bending cylinders are set up to bend in pull mode (fluid supplied to rod end). Further, these examples assume the hydraulic pump has a total output of 50 gpm. Finally, it is assumed in these examples that the leveling operation involves a lift distance (i.e., clearance distance) of approximately 3 inches for both the inboard and outboard bending cylinders, and that the bending operation requires an additional 5 inches of extension for the outboard bending cylinders only. In the first example, a bend is produced in a section of 36 inch by 1/2 inch wall pipe made from 90 ksi steel. Since the leveling operation requires only 18,400 pounds of force, this can be accomplished with the outboard bending cylinders in regenerative mode. In this mode, the lifting operation proceeds at 0.72 inches per second, thus requiring 4.13 seconds for the 3 inch lift. Once the pipe engages the die, however, approximately 361,000 pounds of force is required to actually bend the pipe, requiring a rise in the fluid pressure to approximately 1900 psi, which causes the regenerative valve assemblies to terminate the regenerative mode and enter conventional mode, in which the outboard cylinders travel at only 0.59 inches per second. Thus, the bending operation requires approximately 8.47 additional seconds for a total leveling and bending time of 12.75 seconds. Producing a bend under identical conditions on a prior art pipe bending apparatus without regeneration would involve allowing the outboard cylinders to travel through both the leveling and bending operations at a constant speed of 0.59 inches per second, thus requiring approximately 13.73 seconds for the combined leveling and bending operation. Thus the time saved per bend is approximately 0.98 seconds or approximately one second. Although one second may not seem like significant savings, if twenty bends are performed on each pipe section, then the time savings per pipe section would amount to approximately 19.6 seconds. Further assuming that an operator bends 100 forty-foot joints per day, the time savings of 19.6 seconds per joint would amount to almost 2,000 seconds, or over one-half hour. This represents a significant increase in efficiency of the bending operation which can be of real benefit to the pipeline contractor.
The second example involves the bending of a smaller diameter pipe having a lower yield strength. To bend a section of 30 inch by 1/2 inch wall pipe made of 72 ksi steel, only about 196,000 pounds of force are required from the outboard bending cylinders. Therefore, it is possible to run the entire bending cycle in regenerative mode since the maximum fluid pressure required is only 1,540 psi. As seen in FIG. 12, leveling and bending in regenerative mode at a travel speed of 0.73 inches per second takes a total time of approximately 11 seconds, whereas leveling and bending with a non-regenerative pipe bending apparatus according to the prior art will again require the entire bend to be performed at a speed of 0.58 inches per second for a total time of 13.73 seconds. Thus in this example, the savings per bend are approximately 2.73 seconds. Again assuming 20 bends per pipe section and 100 pipe sections per day, the time savings using the current invention would amount to approximately 91 minutes per day.
While two embodiments of the present inventions have been described in detail herein and shown in the accompanying drawings, it will be evident that further modifications or substitutions of parts and elements are possible without departing from the scope of the current invention.
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A pipe bending apparatus is disclosed for bending pipe sections, particularly pipe sections of the type used in pipelines. The apparatus allows rapid clamping of the pipe section at reduced pressure via hydraulic fluid regeneration, while providing full hydraulic force for pipe section bending.
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This application is a continuation in part to U.S. patent application Ser. No. 14/011,278 filed Aug. 27, 2013, which claims priority to U.S. Pat. No. 8,521,092 filed May 26, 2010, which claims the priority of U.S. Provisional Pat. App. Ser. No. 61/217,001 filed on May 27, 2009, the disclosures of which are hereby incorporated by reference. This application also claims priority to U.S. Provisional Pat. App. Ser. No. 61/783,199 filed Mar. 14, 2013.
The present disclosure relates to the field of behavior evaluation of radio frequency (“RF”) systems. More specifically, this disclosure describes a system and method for providing a laboratory-based, field realistic, virtual RF environment where RF systems (communications, radar, jammers, etc.) produced by unassociated third parties can participate in an interactive gaming environment to evaluate behavior.
BACKGROUND
Radio spectrum is scarce and the Federal Communications Commission (“FCC”), Department of Defense (“DoD”) and other international spectrum management organizations are constantly looking for ways to more efficiently utilize this limited spectrum. Demand for spectrum is continuing to rise due to the explosive growth of data, voice, messaging, and video applications. One solution to meeting the need for improved spectral efficiency as measured by bits/Hz/user is adaptive radios (also referred to as dynamic spectrum access (DSA) or cognitive radios (CR)). Adaptive radios can change their transmission characteristics to maximize transmission capacity and coverage while conserving spectral usage. Because CR represents a rich technical research area, as well as a potentially significant commercial and military products market opportunity, large numbers of research and development entities from academic, commercial and government organizations are participating in activities towards producing CR devices and systems.
One of the challenges of deploying adaptive radio technology is that it cannot be fielded without comprehensive behavior evaluation, and it cannot be evaluated in a densely populated, live environment for fear of potentially interfering with existing spectrum users (primary users). Field evaluation is preferable to lab evaluation but requires a realistic environment where it can be verified that the System under Test (SUT) will not interfere with primary users or other spectrum users. Laboratory evaluation is more cost and schedule effective, repeatable, controllable and observable, but generally lacks in realism, especially with respect to RF environmental considerations including the interactive effects of other devices/systems operating in the RF environment. These interactive effects can be between devices/systems that are adaptive/cognitive and operate in different spectrum bands, but dynamically change their frequencies in response to spectrum conditions. Addressing this phenomena has not been a part of prior art testing approaches.
There is an established and growing need to comprehensively evaluate behavior of these new adaptive devices/systems in known and postulated environments which include other representative RF systems to establish behavior characteristics. Traditional evaluation methods are increasingly stressed by the proliferation and diversity of the devices/systems and operating environments. Historically, device/system evaluation has fallen into two broad categories, field evaluation and laboratory simulation/evaluation. Field evaluation as illustrated in FIG. 1 involves placing some number of devices in a realistic field environment and exercising them to evaluate performance against specified functionality. Full-featured field evaluations place the wireless transceivers in a field scenario containing some representative RF environment where they will be operated while evaluation data is collected. These sorts of evaluations are often expensive and complex to orchestrate, and can lack flexibility since mixes of test transceiver numbers/types/locations, incumbent RF user numbers/types/locations and RF propagation conditions cannot be systematically varied to collect comprehensive data. FIG. 1 schematically depicts a typical field evaluation equipment setup. Wireless Transceiver Units Under Test (UUT) 100 operate in some RF environment 110 . The RF emissions are subject to the noise, path loss, multipath transmission and interferers found in the local RF environment 110 . Test instrumentation 120 is established to measure the performance of the UUT and other primary users (PU) of the RF environment. In order to accomplish a field evaluation of this variety, the UUT 100 must be physically located in the evaluation RF environment 110 , and test instrumentation 120 must be constructed. In order to vary the numbers/types/locations of UUT and PU, physical units must be acquired and placed in the RF environment. In order to vary the RF environment, different field venues must be available. Additionally, test instrumentation must be provided and adapted for each UUT/PU/test environment scenario where testing is to be accomplished.
Many factors must be considered when selecting and configuring the field evaluation area including the specific type and host platform for the SUT, the characteristics and quantity of other RF devices and interferers in the environment, and environmental factors that affect the radio propagation including terrain and morphology. Field evaluation methods have been viewed as the most realistic, but many growing challenges limit their ability to be compelling. These challenges include:
Difficulty and complexity in evaluating high platform dynamic systems More devices/systems to evaluate More functionality & complexity to exercise including adaptive/cognitive behavior Evaluation ranges require a broad set of realistic physical layouts Requirements to emulate location-specific RF environments including propagation and interferers Requirements for conditions not realizable on evaluation ranges including prohibition by FCC rules RF environment control difficult due to encroachment of commercial RF sources.
All of the above lead to increased costs, longer schedules, more requirements on field evaluation assets and ranges, and potentially lower confidence in results.
For adaptive RF systems, field evaluation is not practical. Laboratory evaluation methods are generally more cost and schedule effective, are more controllable and observable, but generally are lacking in realism, especially with respect to RF environmental considerations including other RF sources.
There exist many variations of lab evaluation approaches, but they can be generally bounded by “RF Path Simulator” and “Software Modeling” variants. The RF Path Simulator approach shown in FIG. 2 , which interconnects RF systems/devices with conventional laboratory test equipment such as signal/noise generators, is only applicable to simple RF environments, small numbers of devices/systems under test with simple antenna systems, and small number of primary users/interferers. Lab-based evaluation using cable-based interconnection for RF emissions of UUT and the RF environment is a prior art approach to testing to overcome the challenges of placing and monitoring devices in the field environment. FIG. 2 depicts a typical lab-based equipment setup. As in field evaluations, Wireless Transceiver Units Under Test (UUT) 100 are acquired and instrumented with Test Instrumentation 120 . Instead of the RF environment being that found in the field, RF test equipment such as signal generators are used to produce Interferers 210 , Noise Generators 220 , and Path Simulators 200 to simulate path loss and multipath in an RF channel. RF Interconnection 230 is accomplished using RF cables such as coaxial cables. This test set up approach reduces some of the complexities of field evaluation, but introduces new concerns over RF environment realism. Further, it still requires the physical introduction of new UUT and RF test equipment into the configuration for comprehensive transceiver configuration and RF environment results.
Traditional methods that use software modeling approaches as shown in FIG. 3 have historically made simplifications about the physical environment/radio propagation effects, and generally cannot support any hardware in the loop (HITL) test cases. Their validity is therefore limited to a narrow group of test cases and not well suited to the adaptive RF system evaluation problem. A variation on RF cable-connected lab testing has become more prevalent and straightforward as wireless transceiver devices have tended towards digital waveforms and digital hardware or software implementation. FIG. 3 depicts a typical framework for modern wireless communications devices as defined by the prior art OSI model. Here, different functions in the Wireless Transceiver 100 are allocated to layers in the functional stack 300 . The physical layer in stack 300 is where the waveform-related functionality is contained. The physical layer can be segregated into a digital implementation portion 310 and an analog portion 320 . Typical functions in the digital transmit portion 310 are waveform generation 330 and digital to analog conversion 340 . Typical functions found in the analog portion 320 are baseband to RF conversion 350 . Other digital processing functions associated with non-physical layers (2 through 7) are performed through digital data processing blocks 360 .
A laboratory-based evaluation approach that combines the advantages of true RF path/environment emulation and HITL, but implemented in the digital domain under software control, has the potential to deliver the advantages of the different lab methods with the realism of field testing. The test platform disclosed in commonly owned U.S. Pat. No. 8,521,092, titled “Wireless Transceiver Test Bed System and Method”, which is hereby incorporated by reference, follows this approach. The present disclosure adds improvements directed to a system and method for providing a laboratory-based, field realistic, virtual RF environment where RF systems (communications, radar, jammers, etc.) produced by unassociated third parties can participate in an interactive gaming environment to evaluate behavior. This facet of the test bed problem is further described below.
FIG. 4 of U.S. Pat. No. 8,521,092, titled “Wireless Transceiver Test Bed System and Method” is included as FIG. 4 in the current disclosure to describe the operation of one embodiment. FIG. 4 illustrates the virtual wireless channel (VWC) 400 and test instrumentation plane (TIP) and metadata manager 410 . The TIP may also be embodied as a database. The UUT physical layer digital portion is connected to the VWC 400 via interconnections 420 , as is the TIP via 425 . The VWC function is to provide a realistic wireless channel model including noise, interference, UUT signal path loss and UUT signal multipath transmission. The VWC 400 can be configured with a selectable number of virtual spectrum users (VSU) and other interferers to accurately simulate the RF environment that might be encountered in different parts of the world. The VSU may have selectable interactivity parameters, including transmission parameters and kinetics, or physical characteristics. For example, transmission parameters may include frequency, bandwidth, power, modulation. Physical characteristics, or kinetics, may include location, speed, direction of motion, and antenna parameters including type, elevation gain, azimuth gain, phase, polarization and orientation. The VSU can be selected to be a transmitter only, a receiver only or a transceiver. The VSU can be selected to be a communication device, a sensor such as a radar, a navigation device, or a jammer and can be the same type or different than the UUT. The VWC also allows for selecting transmission parameters and physical characteristics of the physical UUT.
A key feature of the VWC is that it accepts and passes analog RF or digitized RF to and from the UUT. In this way, the full effects of the wireless channel can be included in the simulation. The TIP 410 acts as a control mechanism to orchestrate the sequencing of the test bed simulation, and to collect instrumentation data at the RF and other OSI layers of the UUT. A key part of the TIP is the metadata manager. Metadata is defined as data that must be passed between the VWC and the UUT to allow real time parameters to be modeled and analyzed. As an example, metadata can include the relative locations of the UUT and VSU in a geographic region. As the simulation progresses, the delay characteristics of the multipath and relative time of arrival of the signals at each node can be accurately modeled.
Perhaps the most challenging part of adaptive RF system behavior evaluation is addressing the interaction between RF systems (including adaptive RF systems) in the field. An anticipatable adaptive RF system behavior pattern (“system 1”) may be that it adapts in response to another RF system (“system 2”) in the field (like changing RF frequency of operation), which causes system 1 to adapt (like lowering its transmission pattern), which causes system 2 to adapt (by changing RF frequency back to its original center frequency), and so on. These conditions are not producible in the field or laboratory today, in part, because many of the adaptive RF systems that will be in the field in the future do not exist today in either a “test equipment” form or “prototype form” to facilitate behavior evaluation. In fact, many future adaptive devices are only available as laboratory R&D models in university, commercial and government R&D facilities.
Based on a review of the available RF system test beds that exist in industry and academia (including those referenced in U.S. Pat. No. 8,521,092), a wireless transceiver test bed approach, capable of allowing unassociated third parties to participate in interactive spectrum gaming environments to evaluate behavior is not known.
The present disclosure utilizes emerging technologies and trends in the areas of computer networking, digital signal processing, wireless device design, wideband networks, computer and software architecture/capability and software-based modeling to provide a means to address these shortcomings. Specific technology innovations that contribute to various aspects of the present disclosure include:
digital signal processing power and available algorithms and models ability to digitize RF with high fidelity emerging software defined radio (SDR) software architectures, such as SCA (Software Communications Architecture) emerging commercial off-the-shelf digital radio and SDR components (hardware and software) ever increasing broadband connectivity between distributed sites comprehensive and advanced RF propagation models RF emitter models being built in software proliferation of radio functionality being digital and implemented in software with discrete events (bits, bursts, frames, etc.). standardization of baseband digitized interfaces to SDRs (such as the VITA-49 Radio Transport Protocol).
The present disclosure is not limited to adaptive wireless devices in the application area of communications, but broadly applies to all wireless devices and networks including receive only, transmit only and diverse applications such as sensing, radar, and jamming. Further, it is not limited to behavior evaluation of adaptive RF systems and could also be used to evaluate conventional RF systems.
In summary, a large number of organizations are involved in the development of adaptive RF systems including industry, academia, and government. Methods, tools, and metrics to collaboratively and comparatively judge the behavior of these systems (either individually or interactively) do not exist. Progress in maturing the designs for cognitive RF systems, understanding their performance, and introducing them into the field are hampered by the lack of behavior evaluation capabilities. The disclosed system provides a means to enable the behavior evaluation in a cost effective and engaging way.
SUMMARY OF DISCLOSURE
The disclosed system creates an interactive virtual RF environment where RF devices operate and/or compete with other RF devices or the environment. A useful analogy is a video game where opposing players create real time strategies to battle each other or the computer-controlled enemy; or where many players participate in a massively multi-player online role-playing game (for example, the commercial game Warcraft).
The disclosed system could be used in a fashion comparable to the DARPA robot challenge. DARPA's goals for robot challenge are similar to the use goals for the disclosed system which are: facilitating the development of advanced robotic capabilities; making robot technology more accessible, and creating a widely available, validated, affordable, community-supported, and enhanced virtual test environment (DARPA equates this last goal to the development of SPICE (Simulation Program with Integrated Circuit Emphasis) for integrated circuits). A key attribute of the DARPA robot challenge virtual test environment is eliminating the need for physical prototyping in the evaluation of hardware and software designs. Similarly, a key attribute of the proposed system is to allow developmental cognitive RF system designs to be evaluated without creating a full RF hardware suite by implementing the testing at digital baseband (“digitized RF”, where the RF hardware can be modeled if desired). The disclosed system also make available RF system building blocks to challengers to build new RF systems.
In one aspect, the present disclosure is a method of evaluating interacting RF devices, including receiving selected interactivity parameters for a first virtual spectrum user, receiving selected interactivity parameters for a second virtual spectrum user, providing a virtual RF environment for the first and second remote spectrum users, evaluating the performance of the first and second virtual spectrum users in the virtual RF environment, assigning a score to the first virtual spectrum user as a function of the evaluated performance of the first virtual spectrum user, assigning a score to the second virtual spectrum user as a function of the evaluated performance of the second virtual spectrum user, and identifying whether the first or second virtual spectrum user was assigned the higher score.
In another aspect, the present disclosure is a system for evaluating interacting RF including a first virtual spectrum user having first selectable interactivity parameters, a second virtual spectrum user having second selectable interactivity parameters, a first remote user for controlling the first virtual spectrum user through a first web browser, a second remote user for controlling the second virtual spectrum user through a second web browser, a real-time modeler processor responsive to the first and second virtual spectrum users in real time to track the physical location of the first and second virtual spectrum users, a virtual spectrum processor responsive to the real-time modeler processor to emulate a virtual RF environment in which the first and second virtual spectrum users operate, a database of the first and second selectable interactivity parameters for the first and second virtual spectrum users in communication with the first and second remote users, and an evaluation processor for evaluating the performance of the first and second virtual spectrum in the virtual RF environment and assigning a score to the first and second virtual spectrum users as a function of the evaluation.
The disclosed system incorporates functionality from two sources. The first is the test platform disclosed in commonly owned U.S. Pat. No. 8,521,092 titled “Wireless Transceiver Test Bed System and Method”. In this disclosed system, third parties can attach “spectrum users” at digital baseband through an open interface and interact with the virtual RF environment including accurate propagation (terrain-appropriate path loss, fading, multipath, Doppler, and delay), host platform motion, antenna patterns, environmental interferers, other spectrum users, etc. Second, the disclosed system architecture can be implemented with IP interconnections, which facilitates third party/multi-platform configurations, and also allows processing and GUI functions to be separated and operated via a web browser or similar means. With these features, the functionality of remote users operating their RF systems through their web browsers while interacting with other RF systems in a virtual RF environment can be realized.
With reference to FIG. 5 , in one embodiment, the disclosed system allows virtual spectrum users (VSUs), attributable to third parties, to exist in the Software-based Emulation Platform 500 . These VSUs can be provided by third parties, and/or controlled/monitored by third parties. For disclosure clarity, we will refer to these VSUs as being Contestant VSUs, and the operator of the Software-based Emulation Platform as the Spectrum Master. FIG. 5 shows these Contestant VSUs 530 in the context of the Software-based Emulation Platform. Their interconnection to the other functions in the Software-based Environment Emulator are substantially similar to those for non-Contestant VSUs 540 . Contestant VSUs 530 can be controlled and/or monitored remotely through the internet 520 using Contestant Clients 510 . For disclosure clarity, we will refer to a time session where VSUs interact with the Virtual Wireless Channel 550 and Instrumentation data 560 is collected as “Spectrum Wars” (″game duration or period over which VSU behavior is being evaluated).
The following is an example of a Spectrum Wars game scenario to illustrate how strategies and scoring can occur. Some number of parties participate in the game. The first participant is the Spectrum Master who establishes the conditions for the game including the geographic area, the spectrum availability rules (“policy”) and number/identity/roles of the players. The other players compete for points during the game (“Contestants”). Contestants may provide a communications link/network/jammers/radars/etc. as VSUs 530 , configured in the context of the spectrum policy and the selected geographic area. He also selects a vehicular host platform and antenna system.
The contestants gain points as the session progresses by performing their intended function (i.e. communicating), and/or not interfering with other contestants. As the game progresses, all players have displays showing selected geographic and spectral activity, information about the behavior of their VSU, and scoring information. The Spectrum Master has access to all information (it is also recorded for post analysis). Each contestant has access to other contestant information through the emulated spectrum only, just as in the real-world.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a simplified block diagram illustrating the components in a typical prior art field-based testing configuration for an RF device or system.
FIG. 2 is a simplified block diagram illustrating the components in a typical prior art RF interconnected laboratory-based testing configuration for an RF device or system.
FIG. 3 is a simplified block diagram illustrating the components in a typical prior art software model-based testing configuration for an RF device or system.
FIG. 4 is a simplified block diagram illustrating the placement and function of a virtual wireless channel in a laboratory-based testing configuration for use in the present disclosure.
FIG. 5 is a is a simplified block diagram illustrating one embodiment of the present disclosure showing the placement and function of a Contestant VSUs and Contestant Clients interconnected over the internet.
FIG. 6 illustrates one embodiment of a Software-based Evaluation Platform with components to support Spectrum Wars.
FIG. 7 illustrates one embodiment of a Contestant Client operational flow.
FIG. 8 illustrates one embodiment of the functional flow of a VSU to support streaming data transfer.
DETAILED DESCRIPTION
FIG. 6 illustrates one embodiment of a distributed system architecture used to host “Spectrum Wars”. In its simplest form, it is comprised of two distinct components. The first component is a locally hosted Server Farm 600 which provides much of the computational power for the game. The second component includes Contestants Clients 610 that interface with the Server Farm 600 via the internet.
Furthermore, the server farm is made up of the DYnamic Spectrum Environment emulator (DYSE) 620 , the DYSE Real-Time Modeler 630 and any number of VSU hosts 640 . DYSE 620 provides an interface for the Spectrum Master via the Spectrum Master GUI 650 , and also serves as the RF emulation host via the Virtual Wireless Channel 660 . In this embodiment, DYSE 620 functionality can be distributed between two compute hosts, the Spectrum Master GUI 650 and the VWC 660 . The Spectrum Master GUI 650 may be any specially programmed general purpose computer, such as a Windows PC. The Spectrum Master GUI may be specifically programmed to specify the entire RF operating environment. This may include specifying the contest location and time, the Contestant VSUs, the primary users, the jammers, etc., the contest duration, the rules of the game and scoring method. In this embodiment, the DYSE virtual wireless channel 660 may be implemented by graphics processor units (GPUs) (“GPU Engine”). The DYSE GPU Engine may be a high powered, multi GPU based Linux PC which emulates the propagation path between all RF entities in the contest in real time. FIG. 9 illustrates one embodiment of a DYSE GPU Engine.
With reference to FIG. 6 , the VSU Hosts 640 may be implemented as virtual machines that reside on a separate server class PC (VSU Server 1 . . . VSU Server N 670 ). In one embodiment, there is one VSU Host per contestant and per primary user, jammer, etc. The number of allowable contestants may scale with the number of server class PCs in the Spectrum Wars system architecture. Although VSU Hosts are associated with contestants, in one embodiment, it is desirable to host them locally in the Spectrum Wars system architecture due to the bandwidth requirements of VSUs, which cannot be guaranteed over the bandwidth limited internet.
The Contestant Clients 610 can communicate remotely via for example, a web browser into their respective VSU hosts 640 . They can be thought of as “remote desktop” clients. Using this approach, complete control of VSUs by the contestants can be achieved without requiring the VSUs to reside locally on the Contestant Client.
In a typical operational scenario, the Spectrum Master sets up the game. For each contestant in the game, the Spectrum Master 650 signals the VSU Server(s) 670 to instantiate a VSU Host 640 and then initiates the RF emulation on the DYSE GPU Engine 660 . During the RF emulation, each VSU Host 640 and thus each contestant 610 streams IF/Digital data 665 to the DYSE GPU Engine 660 . While this is happening, the Contestant Client 610 has full visibility into, and control of, his respective VSU 690 and can alter (through prior VSU programming or in real time) signal strength, wave form, frequency, etc. to try and score points.
In addition to the components described above, a VSU Building Blocks Library 680 , which may reside in a database on a server farm, can be used by contestants to construct their VSU 690 . The VSU Building Blocks Library 680 is comprised of VSU components that can be linked together to fully define a VSU.
In one embodiment, a Real Time Modeler (RTM) 630 can be incorporated on another distributed host in the Spectrum Wars architecture to allow Contestants the additional flexibility of changing their VSU physical location during the emulation. For example, the VSU Hosts 640 can communicate their new location, as specified by the Contestant Client 610 , to the RTM 630 . The RTM 630 in turn, re-computes the propagation path coefficients associated with all transmit and receive paths affected by this change in position, and passes them to the DYSE Compute Engine 660 to be used in real time path loss calculations. In one embodiment, the Spectrum Master creates 650 a KML stream 655 representative of the entire scenario. The stream is sent to each Contestant Client 610 and is fed to Google Earth via a resident custom application. Google Earth will display a global map of the scenario. FIG. 10 illustrates one embodiment of a real time modeler.
Before the game begins the Spectrum Master decides which contestants will participate and notifies them for (for example, via email) of their selection. It also informs them of other necessary game related administrative information such as their location (IP) and (remote desktop login) credentials.
FIG. 7 is block a diagram of one embodiment of a Contestant Client 700 . Upon receiving credentials, the Contestant may log into his respective VSU host 710 and can either assemble his VSU from the VSU Building Blocks Library 720 or select a previously built VSU. VSUs can be written in either an interpreted programming language (Matlab, Python) or a compiled programming language (C/C++). If the language is compiled than it must be built and assembled directly on the VSU Host 730 . In one embodiment, it cannot be built locally as the Contestant Client Host CPU may not match that of the VSU Host Server, which is where it will be executed. Interpreted languages have no dependency on CPU architecture so they can be constructed anywhere, although they too must be executed on the VSU Host. Once the VSU has been created or selected, it is then loaded onto the VSU host and instantiated 740 . Next, signaling to and from DYSE is established 750 and the processes begin execution. During execution, the contestant, who now controls aspects of his VSU through a web browser interface 760 , may relocate the VSU. If he chooses to change position, then the new location is passed to the RTM 770 . In one embodiment, during execution, IF/Digital data is passed to/from DYSE to/from the VSU 780 . Execution continues until the game ends.
The shaded blocks in FIG. 7 represent one embodiment of a method used to give each Contestant Client full visibility into the entire scenario. In addition to what is described above, the Spectrum Master creates a KML stream representative of the entire scenario[ 780 . The stream may be sent to each Contestant Client and is fed to Google Earth via a resident custom application. Google Earth will display a global map of the scenario 790 .
FIG. 8 shows a functional block diagram of one embodiment of a streaming VSU 800 . In this embodiment, VSUs can either be interpreted (Matlab) 810 or compiled (C/C++) 820 . In either case all communications to DYSE are provided through a VSU Gateway 830 that may reside on the VSU Host 800 . This effectively abstracts the details of the low level communications channel from the VSU developer. The API for communications with the VSU Gateway 830 is simple and well documented. Also shown in FIG. 8 is a flow chart identifying one embodiment for both transmit 840 and receive VSUs 850 . Receiver VSUs 850 may receive sample data by sending requests to DYSE 851 . They then may wait until DYSE responds with a batch of sample data and then process it. Processing usually entails executing an algorithm on the data and then visually displaying the processing results 852 . This may lead to altering the processing on subsequent batches of data. Transmitter VSUs operate in reverse fashion. Initially a transmitting VSU may receive a data request [ 841 ] from the gateway and then it generates samples as prescribed by an algorithm. It then stuffs those samples into a batch data message response and forwards that message to the gateway[ 842 . The gateway sends the data on to DYSE.
In one embodiment, the present disclosure can be used in the context of a Spectrum Wars game scenario, For example, four parties participate in the game. The first participant is the Spectrum Master who establishes the conditions for the game including the geographic area, the spectrum availability rules (“policy”) and number/identity/roles of the players. The other three players compete for points during the game (“Contestants”). The first Contestant provides a communications link/network as VSUs, configured in the context of the spectrum policy and the selected geographic area. He also selects a vehicular host platform and antenna system. The second Contestant provides a jammer as a VSU. He also configures the VSU and selects a vehicular host platform and antenna system. The third Contestant provides a set of “primary users” as VSUs who are stationary in the geographic area. He also configures the VSU and selects locations for his primary users (in accordance with Spectrum Master guidance).
The contestants gain points as the session progresses as follows:
the communications network gains points by measuring throughput on his link(s), and loses points when he interferes with primary users The jammer gains points when he reduces throughput of the communications network link(s), and loses points when he interferes with primary users the primary users gain points when they detect that the communications or jammer contestants are creating interference in the primary user systems.
As the game progresses, all players have displays showing selected geographic and spectral activity, information about the behavior of their VSU, and scoring information. The Spectrum Master has access to all information (it is also recorded for post analysis). Each contestant has access to other contestant information through the emulated spectrum only, just as in the real-world. Contestants are free to execute their own algorithms and signal processing techniques in the VSU as needed for their own application areas (spectral sensing, DF, geolocation, exploitation, jamming, spoofing, etc.). A handicapping scheme is used to normalize point scoring and deductions to arrive at a game winner.
Another example of a Spectrum War example is an embodiment with three parties participate in the game. The first participant is again the Spectrum Master who establishes the conditions for the game including the geographic area, the spectrum availability rules (“policy”) and number/identity/roles of the players. The other two players compete for points during the game (“Contestants”). These two Contestants provides communications link/network as VSUs, configured in the context of the spectrum policy and the selected geographic area. They also select a vehicular host platform and antenna system.
The contestants gain points as the session progresses as follows:
the communications network gains points by measuring throughput on his link(s), and loses points when he interferes with primary users installed in the scenario by the Spectrum Master the contestant with the most points at the end wins this game pits two like VSU against one another vs. the prior game which included three different types of VSUs as contestants.
As the game progresses, the players again have displays showing selected geographic and spectral activity, information about the behavior of their VSU, and scoring information. The Spectrum Master has access to all information (it is also recorded for post analysis). Each contestant again has access to other contestant information through the emulated spectrum only, just as in the real-world.
It may be emphasized that the above-described embodiments, particularly any “preferred” embodiments, are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiments of the disclosure without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and the present disclosure and protected by the following claims Embodiments of the subject matter and the functional operations described in this specification can be implemented in digital electronic circuitry, or in computer software, firmware, or hardware, including the structures disclosed in this specification and their structural equivalents, or in combinations of one or more of them. Embodiments of the subject matter described in this specification can be implemented as one or more computer program products, i.e., one or more modules of computer program instructions encoded on a tangible program carrier for execution by, or to control the operation of, data processing apparatus. The tangible program carrier can be a computer readable medium. The computer readable medium can be a machine-readable storage device, a machine-readable storage substrate, a memory device, a composition of matter affecting a machine-readable propagated signal, or a combination of one or more of them.
The term “circuitry” encompasses all apparatus, devices, and machines for processing data, including by way of example a programmable processor, a computer, or multiple processors or computers. The circuitry can include, in addition to hardware, code that creates an execution environment for the computer program in question, e.g., code that constitutes processor firmware, a protocol stack, a database management system, an operating system, or a combination of one or more of them.
A computer program (also known as a program, software, software application, script, or code) can be written in any form of programming language, including compiled or interpreted languages, or declarative or procedural languages, and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. A computer program does not necessarily correspond to a file in a file system. A program can be stored in a portion of a file that holds other programs or data (e.g., one or more scripts stored in a markup language document), in a single file dedicated to the program in question, or in multiple coordinated files (e.g., files that store one or more modules, sub programs, or portions of code). A computer program can be deployed to be executed on one computer or on multiple computers that are located at one site or distributed across multiple sites and interconnected by a communication network.
The processes and logic flows described in this specification can be performed by one or more programmable processors executing one or more computer programs to perform functions by operating on input data and generating output. The processes and logic flows can also be performed by, and apparatus can also be implemented as, special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application specific integrated circuit).
Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor will receive instructions and data from a read only memory or a random access memory or both. The essential elements of a computer are a processor for performing instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data, e.g., magnetic, magneto optical disks, or optical disks. However, a computer need not have such devices. Moreover, a computer can be embedded in another device, e.g., a mobile telephone, a personal digital assistant (PDA), a mobile audio or video player, a game console, a Global Positioning System (GPS) receiver, to name just a few.
Computer readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media and memory devices, including by way of example semiconductor memory devices, e.g., EPROM, EEPROM, and flash memory devices; magnetic disks, e.g., internal hard disks or removable disks; magneto optical disks; and CD ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.
To provide for interaction with a user, embodiments of the subject matter described in this specification can be implemented on a computer having a display device, e.g., a CRT (cathode ray tube) or LCD (liquid crystal display) monitor, for displaying information to the user and a keyboard and a pointing device, e.g., a mouse or a trackball, by which the user can provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well; for example, input from the user can be received in any form, including acoustic, speech, or tactile input.
Embodiments of the subject matter described in this specification can be implemented in a computing system that includes a back end component, e.g., as a data server, or that includes a middleware component, e.g., an application server, or that includes a front end component, e.g., a client computer having a graphical user interface or a Web browser through which a user can interact with an implementation of the subject matter described is this specification, or any combination of one or more such back end, middleware, or front end components. The components of the system can be interconnected by any form or medium of digital data communication, e.g., a communication network. Examples of communication networks include a local area network (“LAN”) and a wide area network (“WAN”), e.g., the Internet.
The computing system can include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.
While this specification contains many specifics, these should not be construed as limitations on the scope of any invention or of what may be claimed, but rather as descriptions of features that may be specific to particular embodiments of particular inventions. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.
Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.
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A system and method for evaluating the interactivity of RF devices in a virtual RF environment having selective virtual spectrum users remotely controlled by a web browser, where the virtual spectrum users have selectable interactivity parameters, and the virtual RF spectrum can be selectively changed, and the performance of the virtual spectrum users is evaluated and assigned scores as a function of the evaluation to determine which virtual spectrum user receives the highest amount of points.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of our application Ser. No. 381,059 filed Mar. 7, 1989, now abandoned, which is a continuation of application Ser. No. 171,350 filed Mar. 21, 1988, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a stable gel formulation for the topical application of a combination of an imidazole antifungal agent and a 17-ester steroid antiinflammatory agent. The product is particularly suitable for treating fungal diseases such as tinea capitis, tinea corporis or tinea cruris. Decomposition of the 17-ester steroid resulting from interaction with water and the imidazole antifungal agent during storage is drastically reduced by the present gel formulation.
A fungus is a very small microscopic type of plant cell which may grow on the skin and, under certain conditions, produce an infection. Such infections caused by fungi, the mycoses, are among the oldest known to man and have long been recognized as a highly prevalent public health problem. When the fungus infection involves the scalp, it is known as tinea capitis; when it involves the feet it is known as tinea pedis (athlete's foot); when it occurs on the body it is known as tinea corporis; and when it occurs in the groin it is known as tinea cruris.
A variety of methods have been used for the treatment of fungal infections including the use of potassium iodide, Whitfield's ointment, undecylenic acid, antibiotics (e.g. nystatin and amphotericin B), griseofulvin and the imidazole antifungal agents such as miconazole, clotrimazole, econazole and sulconazole.
Although the systemic administration of antibiotics such as nystatin and amphotericin B has been used with some success, the low bioavailability and systemic toxicity of these agents have restricted their use in treating mycotic infections.
The imidazoles are the first broad-spectrum antifungals and are of considerable importance in clinical practice. Their broad spectrum of antifungal activity, extending to most pathogenic fungi, has provided an important advance in antifungal therapy.
As used herein the term "imidazole antifungal agent" means any agent having an imidazole functional group in the molecule and possessing topical antifungal activity. A large number of suitable imidazoles have been described in the literature and are well-known to those skilled in the art. Examples of suitable imidazole antifungal agents include sulconazole nitrate, econazole nitrate, miconazole nitrate and clotrimazole.
The fungal infections are commonly associated with signs of erythema and scaling and with symptoms of itching or painful burning. Clinical treatment for fungal disease requires at least two to four weeks for complete relief of symptoms. More recently, it has been found that fungal infections can be effectively treated with a combination product containing corticosteroids and imidazole antifungal agents. It is known that the sensitivity of fungal organisms varies with their life cycles; spores are more resistant to treatment than are mycelia. Steroids may induce fungal spores to produce mycelia, thereby making them more sensitive to treatment. Also, steroids are known to produce vasoconstriction at the site of application. This activity may delay or prevent the elimination of the antifungal agent from the application site, permitting the antifungal agent to remain in the epidermis for longer periods of time. It is therefore believed that a locally applied antiinflammatory agent would offer direct and immediate relief for the inflammatory component of the lesion. The combination product should then provide fast relief of symptoms and eradicate the infection. Based on this concept, certain combinations of an antifungal agent and an antiinflammatory agent have recently been developed for treatment of fungal disease. Currently, the commercially available combination products using this concept are Lotrisone cream (clotrimazole 1%/betamethasone dipropionate 0.05%), Daktacort cream (miconazole nitrate 2%/hydrocortisone 1%) and Canesten HC cream (clotrimazole 1%/hydrocortisone 1%).
Katz and other dermatologists 1 ,2 found that Lotrisone cream was therapeutically and mycologically better than clotrimazole 1% and betamethasone dipropionate 0.05% alone. Notwithstanding its clinical advantages, Lotrisone cream possesses some undesirable attributes. It contains a rather strong fluorinated steroid, betamethasone dipropionate, which can be quite cosmetically dangerous to use in intertrigious regions. Other undesirable attributes include skin atrophy, rebound phenomenon and telengiectasia.
Other marketed combination products of this type, e.g. Daktacort cream and Canesten HC cream, are combinations of low-potency steroids and imidazoles. Such combination products always fail to provide the fast relief of the inflammatory symptoms which is normally desired for the treatment of a fungal infection.
A combination of a non-halogenated mid-potency steroid and an imidazole antifungal agent would appear to be an ideal choice for the topical treatment of fungal disease. It was the object of the present invention to develop such a combination product.
The mid-potency steroid used in the combination product of the present invention is a 17-ester steroid which possesses enhanced activity relative to the parent alcohol but fewer undesirable side effects than the halogenated steroids which are comparable in activity. Examples of 17-ester corticosteroids included within the scope of the invention are hydrocortisone 17-acetate, hydrocortisone 17-butyrate, hydrocortisone 17-valerate, hydrocortisone 17-propionate, betamethasone 17-valerate, cortisone 17-acetate, prednisone 17-acetate and prednisone 17-valerate.
The 17-ester steroids per se have excellent stability in conventional topical dosage forms. In our studies topical dosage forms are tested for stability by determinining their t 90% values where t 90% is the time in days required for a dosage form to lose 10% of its chemical and/or biological activity. A 0.2% hydrocortisone 17-valerate o/w cream in this test had a t 90% of 536 days at room temperature (25° C.±2° C.). Use of a standard 10% overage of active ingredient in the cream would mean that such a product would have an acceptable shelf life (time required for potency to decrease to 90% of label strength) at room temperature of 1072 days or more than 2.9 years.
A cream formulation is generally more acceptable to a patient than other topical dosage forms, e.g. liquid, petrolatum ointment, oil, etc., from the point of view of aesthetics and ease of application. Unfortunately, when one attempts to combine a 17-ester steroid and an imidazole antifungal agent to make a combination product as described above, the stability of the 17-ester steroid is drastically reduced to unacceptable levels in almost all conventional cream formulations. To develop a cream vehicle for a combination product of a 17-ester steroid and an imidazole, we have prepared for stability evaluation more than 60 different types of cream vehicles including o/w creams, w/o creams, creams with high or low petrolatum content, with low or high surfactant content, with high or low water content, and with different propylene glycol content. Almost all creams failed our stability test, either due to the chemical instability of the 17-ester steroids or the physical separation of emulsion caused by the salting effect of the imidazole salt when used in concentrations of about 1% or more. Cream formulations often necessitate the use of emulsifiers or surfactants to maintain their physical stability and the use of antimicrobial preservatives to prevent microbiological contamination. These additives tend to generate an undesirable environment which can accelerate the hydrolysis of 17-ester steroids and the physical separation due to the salting out. In addition, it is known that imidazoles can also be catalysts for the hydrolysis of esters 3-7 . Such degradation was in fact observed in our preliminary studies (see Table I below).
TABLE 1______________________________________Degradation rates of hydrocortisone 17-valerates(HC 17-V) in the presence of 1% imidazoles invarious topical creams at 25° C. ± 2.0° C. t.sub.90%,Formulations k, day.sup.-1 **** days***______________________________________1. Sulconazole nitrate 1%/ 3.07 × 10.sup.-3 34HC 17-V 0.2% in aqueous-alcohol solution atpH 4.72. Sulconazole nitrate 1%/ 5.96 × 10.sup.-3 18HC 17-V 0.2% in o/w creamat pH 4.73. Sulconazole nitrate 1%/ 7.40 × 10.sup.-3 14HC 17-V 0.5% in USP XXIOint. at 4.74. Sulconazole nitrate 1%/ 6.50 × 10.sup.-3 16HC 17-V 0.2% in Carbapol*gel5. Sulconazole nitrate 1%/ physicalHC 17-V 0.2% in Methocel** separationgel6. Sulconazole nitrate 1%/ 2.24 × 10.sup.-3 47HC 17-V 0.2% in purepetrolatum base7. Econazole nitrate 1%/ 1.34 × 10.sup.-2 7.8HC 17-V 0.2% in USP XXIhydrophilic ointment8. Miconazole nitrate 1%/ 2.99 × 10.sup.-2 3.5HC 17-V 0.2% in o/w cream9. Miconazole nitrate 1%/ 4.28 × 10.sup.-2 2.5HC 17-V 0.2% in USP XXIhydrophilic ointment10. Clotrimazole 1%/HC 17-V 4.39 × 10.sup.-3 240.2% in o/w cream11. Clotrimazole 1%/HC 17-V 2.26 × 10.sup.-2 4.60.2% in USP XXI hydrophilicointment______________________________________ *Carbopol gel is a carboxy vinyl polymer of high molecular weight (CTFA names: carbomer934p, 940, 961 **Methocel gel is the methyl ether of cellulose (CTFA name: methylcellulose, trade names: Methocel MC, Cellulose Methyl Ether). ***t.sub.90% = time required for hydrocortisone 17valerate activity to be reduced to 90% of original ****k = degradation rate of hydrocortisone 17valerate component
Based on our studies it is believed that the necessity of using emulsifiers or surfactants in most cream formulations results in increased interaction of the 17-ester steroid with water and imidazole molecules, thereby causing rapid hydrolysis of the 17-ester steroid (see Table I, formulations 2, 3 and 7-11).
Several commonly used gel formulations prepared without any emulsifier or surfactant and with a gelling agent selected from a group consisting of an acidic carboxy polymer, such as those available under the trade names Carbopol 934, Carbopol 940, and a methyl ether of cellulose available under the trade name Methocel MC, were used for combination products. As shown in Table I, formulations 4 and 5, a fast degradation at the carbon-17 position of the 17-ester steroids was still observed.
Moreover, in a subsequent experiment, a mixture of an imidazole with hydrocortisone 17-valerate also showed rapid hydrolysis even in pure petrolatum. Poor dispersibility is considered the cause of the stability failure in the pure petrolatum system (see Table I, formulation 6).
Since ester hydrolysis is known to be affected by pH, the stability of an imidazole with a 17-ester steroid o/w cream system adjusted to different pHs was studied. The results (Table II) show that simple pH adjustment will not impart the required stability.
TABLE II______________________________________Degradation rates of hydrocortisone 17-valerate0.2% in the presence of 1% sulconazole nitratein USP XXI hydrophilic ointment (an o/w cream)at 25° C. ± 2.0° C. at different pH.pH k, day.sup.-1 t.sub.90%, days______________________________________2.10 2.10 × 10.sup.-3 504.00 3.80 × 10.sup.-3 284.70 4.45 × 10.sup.-3 246.50 5.20 × 10.sup.-3 20______________________________________
In order to prevent the degradation of hydrocortisone and its derivatives in topical formulations, it has been proposed to use the steroid active ingredient in association with certain stabilizers (e.g. EDTA, antioxidants) or to reduce the amount of propylene glycol used in the formulation 8-10 . Despite using stabilizers or reducing the concentration of propylene glycol in the steroid formulations of the prior art, it has not been possible to obtain topical solutions, gels or creams of a combination product having acceptable (two years or more) long term stability.
To fulfill the unmet needs, it remained highly desirable to obtain a combination of an imidazole antifungal agent and a 17-ester antiinflammatory corticosteroid in a topical dosage form which would be stable for at least two years at room temperature (25°±2° C.). It was an object of the present invention to provide such a stable combination product from which the imidazole and 17-ester steroid would be readily available for absorption by the skin. It was also an object to provide a combination product formulation which could be applied to the affected skin, e.g. the intertrigious area, without flowing onto the healthy parts of the skin. This latter property would minimize the undesirable side effects that might be caused by absorption through surrounding tissue. Such a combination product then, would not only provide fast relief of symptoms and the eradication of the fungal infection but would also minimize the risk of undesirable side effects.
It was a further object of the present invention to provide a topical antifungal treatment which can effectively provide fast relief of symptoms and eradication of the fungal infection while minimizing the risk of undesirable side effects caused by high-potency and/or fluorinated steroids.
It was another object of the invention to provide topical gel formulations of mid-potency 17-ester steroids and imidazole antifungal agents which possess good dispersibility and good physical and chemical stability without refrigeration and without the need for special additives such as emulsifiers or surfactants or antimicrobial preservatives.
It was another object of the invention to provide topical gel formulations of 17-ester steroids and imidazoles having other desirable qualities such as being cosmetically acceptable and allowing accurate application of effective amounts of the two active ingredients to the desired lesion.
It was still another object of the invention to provide topical gel formulations which enhance delivery of a 17-ester steroid and imidazole to their respective target sites, thereby ensuring that a maximum therapeutic advantage could be achieved.
These and other objects of the present invention will be more fully understood in the light of the specific examples and description set forth below.
SUMMARY OF THE INVENTION
The present invention provides a stable gel formulation for topical administration comprising a therapeutically effective amount of a mixture of an imidazole antifungal agent and a 17-ester steroid antiinflammatory agent in a vehicle system comprising (a) a co-solvent system for the imidazole and 17-ester steroid consisting essentially of a lower alkanol in combination with a dihydroxy alcohol or a trihydroxy alcohol, or a mixture thereof and (b) an effective amount to cause gelling of hydroxypropyl cellulose or hydroxyethyl cellulose. Such gel formulation may contain 0 to 20% (by weight) water.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents a comparison of the skin penetration rates of hydrocortisone 17-valerate in aqueous and anhydrous gel formulations of the present invention with the rates in hydrocortisone 17-valerate cream and ointment formulations.
FIG. 2 represents a comparison of the skin penetration rates of sulconazone nitrate in aqueous and anhydrous gel formulations of the present invention with the rates in sulconazone nitrate creams and aqueous solutions.
DETAILED DESCRIPTION
It was discovered during experiments carried out by the present inventors that the stability of formulations containing both imidazoles and 17-ester steroids seemed to be dependent on dispersibility. For example, in cream or solution formulations, the stability improved as the concentration of water in the formulation decreased. Also, viscous creams or pure petrolatum bases did not provide good stability. Thus, only cream formulations with higher solvency of the 17-ester steroid and imidazole can provide satisfactory stability due to their better dispersibility which reduces the interaction of these two agents.
Imidazoles are insoluble in most common aqueous and non-aqueous solvents including water. They can be solubilized in aqueous vehicles only if the vehicles contain high concentrations of surfactants (greater than 10%). With high surfactant concentration, however, 17-ester steroids are subject to rapid hydrolysis.
It has been discovered by the present inventors that the only vehicles in which 17-ester steroids and imidazoles are soluble, evenly dispersed and stable are certain organic solvents. More particularly, the two active components must be dissolved in a co-solvent system consisting essentially of a lower alkanol in combination with a dihydroxy alcohol or trihydroxy alcohol or mixtures thereof. Examples of suitable dihydroxy alcohols are hexanediols such as 2-ethyl-1,3-hexanediol and glycols such as ethylene glycol, propylene glycol and 1,3-butylene glycol. The most preferred glycol is propylene glycol. Examples of trihydroxy alcohol are hexanetriols such as 1,2,6-hexanetriol. Lower alkanols include such alcohols as methanol, ethanol, propanol, isopropanol, butanol, and the like. The most preferred lower alkanols are isopropanol and ethanol, or mixtures thereof. Preferably, the dihydroxy alcohol is present in an amount of 0 to 45% by weight and/or trihydroxy alcohol is present in an amount of from about 0 to 40% by weight and the lower alkanol in an amount of from about 30-65% by weight. The skin penetration rates of imidazole and steroid can be adjusted by varying the concentrations of co-solvent system in the formulation. Higher concentrations of alcohol give a higher depot effect and an enhanced skin penetration rate. However, higher alcohol concentrations also increase skin irritation with concentrations over about 60% by weight resulting in excessive irritation. Therefore, a balance has to be maintained between a desire to enhance skin penetration rates of the active components, particularly the imidazole component, and a desire to achieve a non-irritating product.
As indicated in Table III, the formulations of the present invention enhance the stability of 17-ester steroids almost 5-40 times in terms of t 90% . The substantial stability enhancement seen here is in startling contrast to the instability found in other cream and gel formulations. With 10% overage of 17-ester steroid, the stability profile for the formulations of the present invention supports a 2 year expiration dating period at room temperature. All t 90% values given in Table III below were determined at 25° C.±2° C.
TABLE III______________________________________Degradation rates of 17-ester hydrocortisone inthe presence of 1% imidazoles in the presentinvention gel formulations at 25° C. ± 2.0° C.(1) R&D Product No. 30159-B-19-A(FN7-969-06)Ingredient % w/w______________________________________Sulconazole nitrate 1%Hydrocortisone 17-valerate 0.2%SD Alcohol 40 50%Propylene glycol 30%PPG-5-Ceteth-20 12.3%Isopropyl myristate 5%Hydroxypropyl cellulose 0.9%Salicylic acid 0.5%Ascorbyl palmitate 0.1%______________________________________FN7-969-06 k, day.sup.-1 t.sub.90%, days______________________________________Chemical 2.39 × 10.sup.-4 440Stability result______________________________________(2) R&D Product No. 30159-B-23-A(FN7-994-02)Ingredient % w/w______________________________________Sulconazole nitrate 1%Hydrocortisone 17-valerate 0.2%SD Alcohol 40 35%Propylene glycol 40%PPG-5-Ceteth-20 12.3%Water for production 5%Isopropyl myristate 5%Hydroxypropyl cellulose 0.9%Salicylic acid 0.5%Ascorbyl palmitate 0.1%______________________________________FN7-994-02 k, day.sup.-1 t.sub.90%, days______________________________________Chemical 2.20 × 10.sup.-4 477Stability result______________________________________(3) (FN7-944-18)Ingredient % w/w______________________________________Miconazole nitrate 1%Hydrocortisone 17-valerate 0.2%SD Alcohol 40 50%Propylene glycol 30%PPG-5-Ceteth-20 12.45%Isopropyl myristate 5%Hydroxypropyl cellulose 0.75%Salicylic acid 0.5%Ascorbyl palmitate 0.1%______________________________________FN7-994-18 k, day.sup.-1 t.sub.90%, days______________________________________Chemical 2.08 × 10.sup.-4 506Stability result______________________________________(4) (FN7-944-19)Ingredient % w/w______________________________________Econazole nitrate 1%Hydrocortisone 17-valerate 0.2%SD Alcohol 40 50%Propylene glycol 30%PPG-5-Ceteth-20 12.45%Isopropyl myristate 5%Hydroxypropyl cellulose 0.75%Salicylic acid 0.5%Ascorbyl palmitate 0.1%______________________________________FN7-994-19 k, day.sup.-1 t.sub.90%, days______________________________________Chemical 3.33 × 10.sup.-4 316Stability result______________________________________(5) (FN7-944-20)Ingredient % w/w______________________________________Clotrimazole 1%Hydrocortisone 17-valerate 0.2%SD Alcohol 40 50%Propylene glycol 30%PPG-5-Ceteth-20 12.45%Isopropyl myristate 5%Hydroxypropyl cellulose 0.75%Salicylic acid 0.5%Ascorbyl palmitate 0.1%______________________________________FN7-994-20 k, day.sup.-1 t.sub.90%, days______________________________________Chemical 2.42 × 10.sup.-4 434Stability result______________________________________(6) (FN8-1094-20)Ingredient % w/w______________________________________Sulconazole nitrate 1%Hydrocortisone 17-valerate 0.2%SD Alcohol 40 50%2-Ethyl-1,3-Hexanediol 22%1,2,6-Hexanetriol 15%Isopropyl myristate 5%Water 4.99%Hydroxypropyl cellulose 0.9%Salicylic acid 0.5%BHT 0.2%BHA 0.2%Disodium EDTA 0.01%Q.S. NaOH 1N adjust pH to 4.0______________________________________FN8-1094-20 k, day.sup.-1 t.sub.90%, days______________________________________Chemical 3.33 × 10.sup.-4 316Stability result______________________________________
In addition to the two active components and the co-solvent system, there is also required in the present gel formulations an effective amount to cause gelling of either hydroxypropyl cellulose or hydroxyethyl cellulose. As noted previously, other gelling agents such as methyl cellulose and carboxy vinyl polymer gels gave unstable gel formulations. Generally the gelling agent will be present in an amount of from about 0.1 to 5%.
A general formula encompassing gel formulations within the scope of the present invention is set forth below. All amounts are in weight percent.
______________________________________General Gel Formula in % w/wComponent Amount, % w/w______________________________________Imidazole antifungal agent 0.2-2.017-Ester steroid 0.01-2.5Lower alkanol 30-65Dihydroxy alcohol 0-45Trihydroxy alcohol 0-40Gelling agent 0.1-5Water 0-20Emollient 0-30Fragrance 0-2.0Preservative 0-1.5______________________________________
Both anhydrous and hydrous gel formulations are encompassed by the present invention. Anhydrous formulations contain as essential components the two active ingredients, the dihydroxy alcohol and/or the trihydroxy alcohol, the lower alkanol and gelling agent. They may also contain other components conventionally employed in gel formulations, e.g. emollients such as isopropyl myristate, PPG-5-ceteth-20, PPG-10 methyl glucose ether, PPG-20 methyl glucose ether, PG dioctanate, methyl gluceth-10, methyl gluceth-20, isodecyl neopentanoate, glycerin, mineral oil, etc. (preferably in an amount of up to about 30%, more preferably about 5-30%), and antioxidants, e.g. ascorbyl palmitate, BHT, BHA, etc., chelating agents such as EDTA, and other preservatives such as salicylic acid, fragrances (up to about 2%), dyes, skin penetration enhancers, etc.
The preferred gel formulations of the present invention, both aqueous and anhydrous, contain an emollient component. The most preferred emollients are isopropyl myristate, PPG-5-ceteth-20, PPG-20 methyl glucose ether, or a mixture thereof.
A preferred anhydrous gel formulation of the present invention comprises sulconazole nitrate 1% and hydrocortisone 17-valerate 0.2% gel of the following composition:
______________________________________Component Amount, % w/w______________________________________sulconazole nitrate 1hydrocortisone 17-valerate 0.2ethyl alcohol 61.3propylene glycol 25isopropyl myristate 5hydroxypropyl cellulose 2salicylic acid 0.5PPG-5-ceteth-20 5______________________________________
Another preferred anhydrous gel formulation is that of the formula:
______________________________________Component Amount, % w/w______________________________________sulconazole nitrate 1hydrocortisone 17-valerate 0.2ethyl alcohol 50propylene glycol 30PPG-5-ceteth-20 17.45hydroxypropyl cellulose 0.75salicylic acid 0.5ascorbyl palmitate 0.1______________________________________
Hydrous (or aqueous) gel formulations of the present invention contain, in addition to the components described above for the anhydrous formulations, water in an amount up to about 20%, most preferably in an amount of from about 5 to 10%. In the hydrous gel formulations it is necessary that the pH of the formulation be within the range of about 3-5. This may be accomplished, if necessary, by use of conventional pharmaceutically acceptable acids or bases.
A preferred aqueous gel formulation of the present invention has the following formula:
______________________________________Component Amount, % w/w______________________________________sulconazole nitrate 1hydrocortisone 17-valerate 0.2ethanol 61.3propylene glycol 20water 10isopropyl myristate 5hydroxypropyl cellulose 2salicylic acid 0.5______________________________________
The gel-form compositions of the present invention may be formulated by the conventional mixing of the components described above. To illustrate preparation of a hydrous formulation, ethanol, propylene glycol and water are mixed together to form the co-solvent system. Salicylic acid, emollient, preservative and/or antioxidant are dissolved into the co-solvent system. Twenty-five percent of the solvent system is used to dissolve sulconazole nitrate. Another 25% of solvent is used to dissolve hydrocortisone 17-valerate. Gelling agent is added the remaining 50% of solvent and stirred vigorously for more than 45 minutes to hydrate the gel. After completion of the gelling process, sulconazole nitrate solution and hydrocortisone 17-valerate solution are added separately into the gel solution to form the final product.
The gel compositions of the present invention are clear and stable with a shelf life of two years or more at room temperature when a 10% overage of active ingredients is used.
It has been unexpectedly found that the gel formulations of the present invention also provide desirable skin penetration rates of imidazole and 17-ester steroid. For example, the skin penetration rate of 17-ester steroid in the combination product can be adjusted to the same level as exhibited by existing 17-ester steroid ointments and creams, while much higher levels of imidazole antifungal agent can be delivered as compared to the presently available imidazole solutions and creams. (see FIG. 1 and FIG. 2). This unique feature of the gel formulation enables it to provide an effective level of imidazole against fungal infection while still maintaining a safe level of 17-ester steroid. FIG. 1 demonstrates that, when compared to marketed hydrocortisone 17-valerate creams and ointments, the hydrous gel of the present invention achieves at least an equal skin penetration of the 17-ester steroid relative to such products while the anhydrous gel achieves a somewhat enhanced effect. FIG. 2 shows that, when compared to solution and cream formulations of sulconazole nitrate, both the hydrous and anhydrous gel formulations of the present invention achieve substantially increased skin penetration rates of the imidazole antifungal agent. As mentioned previously, the skin penetration rate in the gel formulations of the present invention can be controlled by the percentage of lower alkanol in the formulation, with higher alkanol concentrations giving higher skin penetration rates. We have found that the lower alkanol should be employed in the amount of from about 30-65% and the dihydroxy alcohol in an amount of from about 0-45% and/or the trihydroxy alcohol in an amount of from 0-40% for optimum stability, skin penetration effects and comfort, i.e. lack of irritation.
Topical treatment regimens according to the practice of this invention involve applying the compositions herein directly to the skin at the situs of the fungal infection. The rate of application and duration of treatment will depend upon the severity and nature of the condition, the response of a particular patient, and related factors within the sound medical judgment of an attending physician or the patient. In general, the gel formulation is applied at least daily, preferably twice or three times per day, until the eradication of the fungal infection.
The following non-limiting examples illustrate the pharmaceutical compositions of the present invention.
EXAMPLE 1
Preparation of Aqueous 1% Sulconazole Nitrate/0.2% Hydrocortisone-17-valerate Gel
______________________________________ % w/w______________________________________sulconazole nitrate 1hydrocortisone 17-valerate 0.2ethanol 50propylene glycol 33isopropyl myristate 5water 5PPG-5-ceteth-20 4.2hydroxypropyl cellulose 0.9salicylic acid 0.5ascorbyl palmitate 0.2q.s. NaOH 1N adjust pH to 4.0______________________________________
Ethanol (5.1 kg), propylene glycol (3.3 kg) and isopropyl myristate (0.5 kg) were added to a suitable mixing vessel. Then, with rapid mixing 0.420 kg of PPG-5-Cetech-20 was added and the reaction mixture was mixed until uniform. With rapid mixing, 0.020 kg ascorbyl palmitate, 0.105 kg sulconazole nitrate and 0.050 kg salicylic acid were slowly added and mixing was continued until all solids were dissolved. Into a separate premix vessel 0.075 kg water was added and then 0.004 kg NaOH was slowly added with mixing until the reaction mixture was uniform. To the original mixing vessel, there was then added 0.400 kg water and the NaOH solution with continued mixing for 5 to 10 minutes until a uniform consistency was achieved. The pH of the reaction mixture was determined to be 4.1. To the main vessel 0.025 kg water was added followed by 0.022 kg hydrocortisone 17-valerate. Rapid mixing was continued for about 15 minutes. Then, with rapid mixing, 0.090 kg hydroxypropyl cellulose was added and the reaction mixture was mixed rapidly for about two hours to obtain the desired gel.
______________________________________Example 2 % w/w______________________________________sulconazole nitrate 1hydrocortisone 17-valerate 0.2ethanol 50propylene glycol 30PPG-5-Ceteth-20 12.3isopropyl myristate 5hydroxypropyl cellulose 0.9salicylic acid 0.5ascorbyl palmitate 0.1______________________________________Example 3 % w/w______________________________________sulconazole nitrate 1hydrocortisone 17-valerate 0.2ethanol 35propylene glycol 40PPG-5-Ceteth-20 12.3water 5isopropyl myristate 5hydroxypropyl cellulose 0.9salicylic acid 0.5ascorbyl palmitate 0.1______________________________________Example 4 % w/w______________________________________miconazole nitrate 1hydrocortisone 17-valerate 0.2ethanol 50propylene glycol 30PPG-5-Ceteth-20 12.45isopropyl myristate 5hydroxypropyl cellulose 0.75salicylic acid 0.5ascorbyl palmitate 0.1______________________________________Example 5 % w/w______________________________________econazole nitrate 1hydrocortisone 17-valerate 0.2ethanol 50propylene glycol 30PPG-5-Ceteth-20 12.45isopropyl myristate 5hydroxypropyl cellulose 0.75salicylic acid 0.5ascorbyl palmitate 0.1______________________________________Example 6 % w/w______________________________________sulconazole nitrate 1hydrocortisone 17-valerate 0.2isopropanol 50propylene glycol 30PPG-5-Ceteth-20 12.45isopropyl myristate 5hydroxyethyl cellulose 0.75salicylic acid 0.5ascorbyl palmitate 0.1______________________________________Example 7 % w/w______________________________________sulconazole nitrate 1hydrocortisone 17-valerate 0.2ethanol 502-ethyl-1,3-hexanediol 22propylene glycol 15isopropyl myristate 5water 4.99hydroxypropyl cellulose 0.9salicylic acid 0.5BHT 0.2BHA 0.2disodium EDTA 0.01q.s. NaOH 1N adjust to pH 4.0______________________________________Example 8 % w/w______________________________________sulconazole nitrate 1hydrocortisone 17-valerate 0.2ethanol 501,2,6-hexanetriol 272-ethyl-1,3-hexanediol 7.5isopropyl myristate 7.5PPG-20 methyl glucose ether 5hydroxypropyl cellulose 0.9salicylic acid 0.5BHT 0.2BHA 0.2______________________________________
References
1. Wortzel, M. Y., H., A double-blind study comparing the superiority of a combination anti-fungal (clotrimazole/steroidal(betamethasone dipropionate)) product Cutis 30: 258 (1982).
2. Katz, H. I., Bard, J., Cole, G. W., Fischer, S., McCormick, G. E., Medansky, R. S., Nesbitt, L. T., and Rex, I. H., SCH 370 (clotrimazole-betamethasone dipropionate) cream in patients with tinea cruri or tinea corporis. Cutis, 34(2), 183-8(1984).
3. Bruice, T. C., and Schmir, G. L., Arch. Biochem. Biophys. 63: 484(1956).
4. Bruice, T. C., and Schmir, G. L., Imidazole catalysis. I. The catalysis of the hydrolysis of phenyl acetates by imidazole., J. Am. Chem., Soc., 79: 1663-9(1957).
5. Bruice, T. C., and Schmir, G. L., Imidazole catalysis. II. The reaction of substituted imidazoles with phenyl acetates in aqueous solution., J. Am. Chem. Soc., 80: 148-56(1958).
6. Bender, M. L., and Turnquest, B. W., General Basic catalysis of ester hydrolysis and its relationship to enzymatic hydrolysis., J. Am. Chem. Soc., 79: 1656-62(1957).
7. Richter Gedeon Vegy, Stable antifungal and anti-inflammatory ointment, JP 76576.
8. Yip, Y. W., Po, L. W., and Irwin, W. J., Kinetics of decomposition and formulation of hydrocortisone butyrate in semi-aqueous and gel systems, J. Pharm. Sci., 72, 776-81(1983).
9. Gupta V. D., Effect of vehicles and other active ingredients on stability of hydrocortisone., J. Pharm. Sci., 67:299(1978).
10. Hansen, J. and Bundgaard, H., Studies on the stability of corticosteroids V. The degradation pattern of hydrocortisone in aqueous solution., Int. J. Pharm., 6: 307-19(1980).
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An antifungal gel composition, effective at 0.2-2.0% by weight of an imidazole antifungal agent and 0.01-2.5% by weight of a 17-ester corticosteroid antiinflammatory agent, is provided for topical administration. This composition is highly effective in treating fungal infections and is capable of being stored without refrigeration for long periods of time without losing therapeutic effectiveness and while maintaining the uniformity and stability of the gel.
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This is a divisional patent application based on U.S. Continuation patent application Ser. No. 10/154,356 filed on May 23, 2002, now a U.S. Pat. No. 6,634,665 B2 issued Oct. 21, 2003.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the field of wheelchairs and, more specifically, to an electrical braking system and quick release, detachable wheels for manual wheelchairs.
2. Description of the Related Prior Arts
Numerous types of braking mechanisms for manual wheelchairs are known in the art. The most typical manual wheelchair brake is a manual “over center” locking device which is activated by a lever arm and, when forced into its locking position, presses a braking member against the surface of the wheelchair tire creating a frictional braking action. Several factors mitigate against the usefulness and reliability of these types of brakes. Loss of tire pressure reduces the frictional force exerted by the crossbar on the tire and hence reduces the braking effect. A significant air pressure loss leaves these brakes useless. During transfer in and out of the chair, this type of brake allows the tire to slide underneath the crossbar and the wheelchair to move. Similarly, the brakes are ineffective and will not adequately hold the wheelchair on an incline. Other types of manual brakes include caliper type brakes manually activated with a lever arm mounted to a cable and brake assembly causing brake pads to press against the rim of the wheelchair wheel.
In these types of brakes, the frictional braking force exerted is directly related to the manual force which must be exerted on the lever arm by the brake operator to activate the brake. Wheelchair users who have arm or hand limitations may not be physically able to operate these brakes. These braking mechanisms only apply a braking force to one wheel. If an equal braking force is desired on both wheels, the user is required to use both arms and attempt to apply an equal force to both lever arms at the same time. This is difficult, if not impossible. Wheelchair frame and wheel design most often require the placement of the lever arms on the frame of the wheelchair near the user's knees. The placement of these lever arms interferes with the user's transfer in and out of the wheelchair. These lever arms require lifting the user's body in order to clear the lever during transfer.
A patent to Ross and Gunther, U.S. Pat. No. 5,358,266 describes a plate attached to a braking member, which applies a braking frictional force to the wheelchair tire when electronically activated by a solenoid rod. The solenoid rod is activated by means of a switch attached to the seat of the wheelchair. When the wheelchair user is raised out of the seat, the switch is activated and operates the braking mechanism. Also disclosed in this patent is a manually activated lever arm to operate the same braking member when the wheelchair user is seated. The same deficiencies discussed above apply to this wheelchair while the wheelchair user is seated. A wheelchair user with arm or hand limitations may not be able to operate the hand lever and the lever arm braking mechanism to apply a braking force to one wheel. In addition, the position of the lever arm may interfere with transfer in and out of the wheelchair.
Electric wheelchairs with various forms of braking means are common in the prior art. These braking means include gear reduction mechanisms, electromagnetic braking by means of a resistance applied to the electric motors, electronically activated frictional braking mechanisms where a solenoid is electrically energized to move brake shoes into frictional contact with a brake drum, and conventional manual brakes operated by a lever mechanism. These electric wheelchairs are heavy, cumbersome, difficult to transport, and do not promote physical activity by the user.
Wheelchair users have reason to frequently remove the wheels from their wheelchairs. It is often done for storage purposes, for brake adjustment, for wheel repair, and for wheel exchange. For example, in order to store a wheelchair in a vehicle, it is often desirable to remove the wheels.
Heretofore, the wheels on manual wheelchairs and other types of wheelchairs have been attached to the wheelchair frame by some type of hub with the wheels secured to the hub with nuts and bolts. In order to remove the wheels from the wheelchair, it has been necessary to unscrew and remove each of the nuts and bolts securing the wheel to the hub. This is a time consuming and cumbersome process. Once again, wheelchair users who have arm or hand limitations may not be physically able to remove the nuts and bolts.
More recently, it has become common in the art to attach wheels to manual wheelchairs using quick release locking pins which hold the wheel to the axle. In this type of design, it is difficult to also have a braking means on the wheelchair wheel other than the manual “over center” locking device which presses a braking member against the surface of the tire as described herein. Heretofore, other brakes have been ineffective on wheelchairs with quick release locking pins because the braking means had to be released and moved or disassembled in order to remove the wheel and thereby defeating the purpose of the quick release locking pin.
It is desirable to have a lightweight, manual wheelchair with an effective easily operatable electronic braking mechanism and, at the same time, quick release detachable wheels.
SUMMARY OF THE INVENTION
It is an object of this invention to provide an electronically activated braking system for a lightweight, manual wheelchair, which allows the wheelchair to maintain its lightweight and maneuverability characteristics.
It is a further object of this invention to have an electronically activated braking system for manual wheelchairs which eliminates the need for users of the wheelchair to manually operate brakes by means of a lever mechanism.
It is a further object of this invention to provide a braking system for manual wheelchairs, which provides equal braking force to both wheels of a wheelchair simultaneously.
It is a further object of this invention to provide a braking means for a manual wheelchair, which can be activated without the use of a manually operated lever that interferes with transfer in and out of the wheelchair by the user.
It is a further object of this invention to provide a braking means for manual wheelchairs, which eliminates movement of the wheelchairs on inclines and during transfer in and out of the wheelchair by the user.
It is a further object of this invention to provide a braking means for manual wheelchairs, which allows for detaching the wheelchair wheels without disturbing the braking means.
It is a further object of this invention to provide for quick release, easily detachable wheels.
It is a further object of this invention to provide for detachable wheels, which eliminates the need for users of the wheelchair to unscrew numerous nut and bolt combinations in order to remove the wheel.
It is a further object of this invention to provide for quick release, easily detachable wheels which allow the wheels to be removed without removing the disk and brake assembly.
In order to achieve these objectives, this invention provides for an electronic braking system, which is comprised of a braking means, a cable pulley system for activating the braking means, a DC liner actuator with actuator rod connected to the cable pulley system, a motion limit switch, a rechargeable twelve-volt battery electronically connected to the DC actuator, and a double throw control switch electronically connected to the battery for activating the battery power.
It is anticipated that the preferred braking means is a caliper-type brake positioned to clamp onto a metal disk mounted axially to a hub which rotates on the axle of each wheelchair wheel. The hub on which the disk is mounted interlocks with the hub on which the wheelchair wheel is mounted. The interlocking hubs are locked together with a locking pin, which extends axially through the center of the mated hubs such that the hubs are locked and rotate together when the wheelchair wheel is turned.
The locking pin is equipped with retractable nipples which, when extended, hold the locking pin securely in place. The retractable nipples are spring biased in the extended position and are activated by a push button at one end of the locking pin which releases the spring and allows the nipples to retract. When the nipples are in the retracted position, the locking pin can be removed simply by sliding it out of the axle. This allows the wheelchair wheel to be removed since there is no longer anything holding the mated hubs together.
The braking means for each wheel are connected to opposite ends of a cable wire. The cable wire passes around a pulley such that displacement of the pulley provides equal force and displacement to said opposite ends of the cable wire. The ends of the cable wire are directed through small openings in a mounting bracket. The openings are spaced a distance equal to the diameter of the pulley so the cable wire remains parallel as it extends from the pulley through said openings. A circular pulley cap is placed concentrically over the pulley. The vertical side of the pulley cap has two openings to allow for the passage of the wire cable into the pulley cap through the first opening, around the pulley and out the second opening. The pulley cap, pulley, and cable wire assembly is then connected to the outer end of the actuator rod by a coupling bracket.
The DC linear actuator is mounted on the wheelchair in a manner to allow the actuator rod to extend and displace the pulley and cable wire in line with the actuator rod's axis. The DC linear actuator is electronically powered by a twelve-volt rechargeable battery mounted to the wheelchair. The battery power is activated by a double throw control switch mounted to the wheelchair in a position where it is easily accessed by both the wheelchair user and a person assisting the wheelchair user.
The double throw toggle switch can be thrown in two different directions. When the double throw toggle switch is thrown in the first direction, it will cause the actuator rod to retract, pulling the pulley and cable wires and activating the braking force. When the toggle switch is thrown in the second direction, it will cause the actuator rod to extend, pushing the pulley and cable wire and deactivating the braking force.
In order to limit the tension in the cable wire, a motion limit switch can be added to the electrical brake system. The motion limit switch is wired into the circuit between the double throw toggle switch and said DC linear actuator. The motion limit switch is activated by displacement of the actuator rod in the direction which pulls the cable wire and activates the braking means. Once a selected braking force is attained, the motion limit switch opens the circuit and stops the displacement of the actuator rod.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a elevational side view of a manual wheelchair depicting a caliper braking mechanism mounted to the wheelchair frame and positioned to clamp onto a metal disk mounted axially to the hub of the wheelchair wheel.
FIG. 2A is an enlarged exploded perspective view depicting the locking pin, wheelchair wheel, hub, disk, and axle assembly which has a spring biased push button type locking pin and first interlocking hub design.
FIG. 2B is an enlarged exploded perspective view depicting the locking pin, wheelchair wheel, hub, disk, and axle assembly wherein the locking pin is equipped with a lever which activates an expandable tip.
FIG. 2C is an enlarged exploded perspective view depicting FIG. 2A from the opposite angle.
FIG. 2D is an enlarged exploded perspective view depicting the locking pin, wheelchair wheel, hub, disk, and axle assembly. This figure depicts a second interlocking hub design.
FIG. 2E is an enlarged exploded perspective view depicting FIG. 2D from the opposite angle.
FIG. 3 is a bottom view of the wheelchair seat depicting the toggle switch, the battery recharging outlet, the electrical wiring, the twelve-volt rechargeable battery, the DC linear actuator, the cable wire and pulley assembly, and the motion limit switch.
FIG. 4 is an enlarged perspective view depicting the caliper braking mechanism.
FIG. 5 is an exploded perspective view depicting the cable wire and pulley assembly and actuator rod mount.
FIG. 6 is a bottom view of the cable wire, pulley, and actuator rod assembly brackets and the motion limit switch.
FIG. 7 is a elevational side view of the coupling bracket.
FIG. 8 is an electrical circuit diagram illustrating the electrical control circuit of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , a lightweight manual wheelchair 10 is equipped with a solid seat base 11 , seat cushion 12 , and seat back 13 mounted between first and second wheelchair wheels 24 generally to a frame 14 . The frame 14 has a vertical component 15 , a side horizontal component 16 , a frontal curved component 17 and a lower curved component 20 . A footrest 19 is mounted at the frontal extremity of the lower curved component 20 of the frame 14 . First and second caster wheels 21 are pivotally mounted toward the frontal extremity of the lower curved component 20 of the frame 14 . The manual wheelchair 10 is symmetrical about a centre line and the opposed side is identical to the side visible in FIG. 1 . Thus, when the first and second of numbered items are referred to without the second item being shown, it can be appreciated that the second numbered item is identical to the first but on the opposite side of the wheelchair.
First and second caliper brakes 18 are mounted to extension plates (not shown) which are in turn mounted to the frame 14 . The caliper brakes 18 are positioned to clamp onto first and second disks 22 (see FIGS. 1 and 4 ). In the preferred embodiment of this invention, the first and second caliper brakes 18 are manufactured by Hayes/HMX, model number BR3920. However, numerous other cable actuated caliper brakes are available on the market and can be used in this invention. The first and second wheelchair wheels 24 can be detached without removal of the first and second disks 22 or the first and second caliper brakes 18 .
Referring to FIGS. 2A through 2E , the first and second disks 22 are concentrically mounted to the inner face 83 first and second disk hubs 23 by means of a plurality of screws 29 passing through radially spaced interiorly threaded, aligned holes 51 in the first and second disk hubs 23 and the first and second disks 22 . In the preferred embodiment, as shown in FIGS. 2A , 2 B, and 2 C, the screws 29 are Allen screws where the heads 33 of the screws 29 extend from the outer vertical faces 27 of the first and second disk hubs 23 and are secured on the opposite end by nuts 38 . In a second preferred embodiment, as shown in FIGS. 2D and 2E , the screws 29 are of a length insufficient to extend beyond the outer vertical faces 27 of the first and second disk hubs 23 .
The first and second disk hub 23 and disk 22 assemblies are concentrically mounted to outer ends of first and second detachable axle pieces 80 and rotate thereon. The first and second detachable axle pieces 80 are tubular with a smooth surface portion 82 at their outer end and a exteriorly threaded portion 84 at their inner end. The smooth surface portion 82 and the exteriorly threaded portion 84 are divided by a flange 86 .
The first and second detachable axle pieces 80 are mounted to the frame 14 of the wheelchair 10 (see FIG. 1 ) by screwing the exteriorly threaded portion 84 into a tubular axle 25 . As shown in FIG. 3 , the tubular axle 25 is clamped to the first and second lower curved components 20 of the frame 14 (See FIG. 1 ) at its rear extremity by first and second frame clamps 72 .
Referring again to FIGS. 2A through 2E , the outer ends of the tubular axle 25 have mounting heads 88 . Each mounting head 88 has a threaded bore 90 with a diameter sufficient to accept and secure the exteriorly threaded portion 84 of the first and second detachable axle pieces 80 therein. The first and second detachable axle pieces 80 are mounted to the tubular axle 25 by screwing the exteriorly threaded portion 84 into the threaded bore 90 .
The first and second disk hub 23 and disk 22 assemblies are secured to the first and second detachable axle pieces 80 by means of a clip ring 39 . The clip ring 39 is spring biased to close around and fit in to a circumferential groove 78 cut into the smooth surface portion 82 of the first and second detachable axle pieces 80 at their extreme outer end. In order to allow the first and second disk hub 23 and disk 22 assemblies to rotate on the first and second detachable axle pieces 80 , the smooth surface portion 82 of the first and second detachable axle pieces 80 extend axially through a tubular opening 92 at the center of the first and second disk hubs 23 and the outer face of flange 86 abuts a concentric circular shoulder 87 (see FIGS. 2C and 2D ) on the inner face 83 of the first and second disk hubs 23 with a spacer ring 94 between. The spacer ring 94 prevents frictional contact between the outer face of flange 86 and the circular shoulder 87 on the inner face of the first and second disk hubs 23 . In the preferred embodiment, the spacer ring 94 is a Delrin washer. However it is anticipated that other smooth, durable material can be substituted.
Referring to FIGS. 2A , 2 B, and 2 E, the outer vertical face 27 of the first and second disk hub have a concentric circular recessed portion 93 surrounding the tubular opening 92 . The horizontal length of the smooth surface portion 82 of the detachable axle piece 80 is sufficient to allow the smooth surface portion 82 to extend through the tubular opening 92 of the first and second disk hubs 23 and expose the circumferential groove 78 on the opposite side of the first and second disk hubs 23 with minimal clearance at the concentric circular recessed portion 93 . This allows the clip ring 39 to close around circumferential groove 78 within the concentric circular recessed portion 93 .
As shown in FIGS. 2A through 2C , the first and second wheelchair wheels 24 are concentrically mounted on the first and second wheel hubs 37 . The inner surface 57 of the first and second wheelchair wheels 24 (See FIG. 2C ) is mounted flush against the outer vertical surface 70 (See FIG. 2E ) of the flanged inner portion 31 of the first and second wheel hubs 37 and are secured to the first and second wheel hubs 37 by first and second nuts 45 , which screw onto exteriorly threaded outer ends 75 of the first and second wheel hubs 37 . The first and second wheel hubs 37 have a tubular opening 43 through their center. As shown in FIGS. 2A and 2B , an outer circular bearing assembly 61 is pressed fit into the tubular opening 43 towards the outer end of the first and second wheel hubs 37 .
As shown in FIGS. 2B , 2 C, and 2 D, an inner circular bearing assembly 79 is pressed fit into the tubular opening 43 at the inner end of the first and second wheel hubs 37 . The outer bearing assembly 61 and inner bearing assembly 79 have inner rings 63 which turn within the bearing assemblies. The inner diameter of the inner rings 63 is equal to the inner diameter of first and second detachable axle pieces 80 . In the preferred embodiment, the outer circular bearing assembly 61 and inner circular bearing assembly 79 are manufactured by NICE, Model No. 1616 DC TN or KYK, Model No. R-8-DDHA1(IB). However, it is anticipated that other similar bearings could be used.
Referring again to FIGS. 2A through 2E , when the first and second wheelchair wheels 24 are mounted to the wheel hub 37 and in turn mounted to the wheelchair 10 (See FIG. 1 ), the outer vertical faces 27 of the first and second disk hubs 23 interlock with inner faces 77 of the flanged inner portion 31 of the first and second wheel hubs 37 . In the preferred embodiment, as shown in FIGS. 2A , 2 B, and 2 C, the inner faces 77 of the flanged inner portion 31 of the first and second wheel hubs 37 are flat with a plurality of radially spaced holes 96 shown in FIG. 2C . The heads 33 of the plurality of screws 29 fit snugly into the corresponding radially spaced circular holes 96 in the flanged inner portion 31 of the first and second wheel hubs 37 . In an alternate embodiment, as shown in FIGS. 2D and 2E , the inner face 77 of the flanged inner portion 31 of the first and second wheel hubs 37 have a raised surface 98 extending from the inner face 77 . The raised surface 98 is centered on the inner face 77 with parallel sides 100 extending to the circumference of the inner face 77 . The parallel sides 100 extend perpendicularly from the inner face. In this alternate embodiment, the outer vertical faces 27 of the first and second disk hubs 23 have a channel 102 . The placement and dimensions of the channel 102 are to allow the raised surface 98 to fit snugly into the channel 102 with minimal clearance at all contiguous surfaces when the first and second wheel hubs 37 are interlocked with the first and second disk hubs 23 .
In the preferred embodiment, as shown in FIGS. 2A , 2 B, and 2 C, the interlocking of heads 33 within the radially spaced circular holes 96 cause the first and second wheelchair wheels 24 and the first and second disks 22 to rotate together. In another alternate embodiment, as shown in FIGS. 2D and 2E , the interlocking of the raised surface 98 on the inner face 77 of the first and second wheel hubs 37 with the channel 102 in the outer vertical faces 27 of the first and second disk hubs 23 cause the first and second wheelchair wheels 24 (See FIG. 1 ) and the fist and second disks 22 to rotate together.
Still referring to FIGS. 2A through 2E , in order to hold the first and second disk hubs and the first and second wheel hubs together when interlocked, first or second locking pins 35 a and 35 b (see FIGS. 2A and 2B ) extend axially through the center of the first and second wheel hubs 37 , the first and second disk hubs 23 , and into the first and second detachable axle pieces 80 . The first or second locking pins 35 a and 35 b have a diameter which allows the first or second locking pins 35 a and 35 b to slide through the inner rings 63 of the outer circular bearing assembly 61 (See FIGS. 2A and 2B ) and the inner circular bearing assembly 79 (See FIGS. 2C and 2D ) and into the first and second detachable axle pieces 80 with minimal clearance.
The first and second wheelchair wheels 24 can be detached from the wheelchair 10 (See FIG. 1 ) without removing the first and second disks 22 or disturbing the first and second caliper brakes 18 by removing the first and second locking pins 35 a or 35 b and separating the first and second wheel hubs 37 from the first and second disk hubs 23 .
In the preferred embodiment of the invention (see FIGS. 2A , 2 C, 2 D, and 2 E), the first and second locking pins 35 a have a push button 47 , a rod 49 , an adjusting nut 53 , and a set of retractable nipples 55 . The push button 47 is spring biased in the released position, causing the retractable nipples 55 to extend from the rod 49 . When the push button 47 is depressed, the retractable nipples 55 retract into the rod 49 . The first and second locking pins 35 a can be inserted through the inner ring 63 of the outer circular bearing assembly 61 and into the tubular openings 43 of the first and second wheel hubs 37 by depressing the push button 47 and thereby causing the retractable nipples 55 to retract. When the first and second locking pins 35 a are further inserted through the first and second disk hubs 23 and into the first and second detachable axle pieces 80 and the push button 47 is released, the retractable nipples 55 extend into grooves (not shown) circumferentially cut into the tubular interior surface (not shown) of the first and second detachable axle piece 80 . The grooves (not shown) are of sufficient depth and width to allow the retractable nipples 55 to extend into the grooves (not shown) with minimal clearance. The grooves (not shown) are positioned in the first and second detachable axle pieces 80 to allow the retractable nipples 55 to extend into the first and second grooves (not shown) when the first and second locking pins 35 a are fully inserted into the first and second wheel hubs 37 such that the adjustable nut 53 contacts the outer surface of the outer circular bearing assembly 61 . In the preferred embodiment, the first and second locking pins 35 a are QRP Quick Release Push Button (large/small) Axle, Model No. 21QRP11CDASN.
In an alternate embodiment of the invention, the length of the exteriorly threaded portion 84 of the first and second detachable axle pieces 80 is sufficient to allow the position of the retractable nipples 55 on the first and second locking pins 35 a to extend beyond the inner lip 85 of the first and second detachable axle pieces 80 when the first and second locking pins 35 a are fully inserted into the first and second wheel hubs 37 such that the adjustable nut 53 contacts the outer surface of the outer circular bearing assembly 61 . Thus, when the first and second locking pins 35 a are fully inserted and the push button 47 is released, the retractable nipples 55 extend adjacent to the inner lip 85 of the first and second detachable axle pieces 80 with minimal clearance and thereby holding the first and second locking pins 35 a in place. In this embodiment, the first and second locking pins 35 a are, once again, QRP, Quick Release Push Button (large/small), Axle Model No. 21QRP11CDASN.
In yet another embodiment of the invention (see FIG. 2B ), the first and second locking pins 35 b have a release lever 65 at one end of a rod 67 , a spacer joint 69 between the release lever 65 and the rod 67 , an expandable tip 71 attached to the other end of the rod 67 , and a wedging cap 73 attached to the expandable tip 71 opposite the rod 67 . When the release lever 65 is rotated to the released position so that it extends parallel with the rod 67 , the diameter of the expandable tip 71 is not expanded and is equal to the diameter of the rod 67 . When the release lever 65 is rotated perpendicular to the rod 67 , the wedging cap 73 is pulled toward the release lever 65 causing the expandable tip 71 to expand to a diameter greater than the diameter of the rod 67 . When the release lever 65 is in the released position, the first and second locking pins 35 b can be inserted through the inner ring 63 of the outer circular bearing assembly 61 and into the tubular opening 43 of the first and second wheel hubs 37 . When the first and second locking pins 35 b are inserted through the first and second wheel hubs 37 , and into the first and second detachable axle pieces 80 and the release lever 65 is then rotated perpendicular to the rod 67 , the expandable tip 71 expands into and makes frictional contact with the interior surface (not shown) of the first and second detachable axle pieces 80 . The frictional force created is great enough to hold the first and second locking pins 35 b in place. The diameter of the spacer joint 69 is greater than the inner diameter of the inner ring 63 of the outer circular bearing assembly 61 , such that when the first and second locking pins 35 b are fully inserted, the spacer joint 69 contacts the outer face of the outer circular bearing assembly 61 . In this preferred embodiment, the locking pin 35 b is the Ultra Axle, 0.50″ O.D. manufactured by Rousson Chamoux.
The first and second caliper brakes 18 are activated by pulling a cable wire 26 (See FIGS. 4 and 5 ) attached to the caliper brakes 18 at first and second ends of the cable wire 26 . The first and second ends of the cable wire 26 are directed to the first and second caliper brakes 18 through a cable wire housing 28 which is attached to a nozzle 30 on the first and second caliper brakes 18 . The first and second ends of the cable wire 26 are attached to the first and second caliper brakes 18 , respectively, in typical fashion. The cable wire 26 passes through the nozzle 30 of the first and second caliper brakes 18 and into the cable wire housing 28 . The cable wire housing 28 directs the cable wire 26 to a mounting bracket 32 (See FIG. 5 ). The mounting bracket 32 has a vertical portion, and an upper horizontal portion. The mounting bracket 32 is mounted to the bottom of the solid seat base 11 by two screws (not shown) passing through interiorly threaded aligned holes in the solid seat base 11 and upper horizontal portion of the mounting bracket 32 .
The cable wire housing 28 is connected to the mounting bracket 32 by means of first and second hollow connectors 34 . The first ends of the first and second hollow connectors 34 fit snugly within first and second circular openings (not shown) in the mounting bracket 32 and the second ends of the first and second hollow connectors 34 fit snugly around the cable wire housing 28 . The centers of said first and second circular openings (not shown) are equidistant from the upper horizontal portion of the mounting bracket 32 and are horizontally spaced a distance equal to the diameter of the pulley 36 . The diameter of the first and second circular openings (not shown) is sufficient to allow the first and second hollow connectors 34 to fit snugly and the cable wire 26 to pass through first and second circular openings (not shown) within the first and second hollow connectors 34 . The cable wire 26 passes through the circular openings in the mounting bracket 32 within the first and second hollow connectors 34 and then passes around the pulley 36 .
The pulley 36 and cable wire 26 assembly is covered with a circular pulley cap 40 . The inner diameter of the circular pulley cap 40 is of sufficient dimension to cover the pulley 36 and wire cable 26 assembly with minimal clearance. The vertical side of the pulley cap 40 has first and second openings 41 spaced to allow the cable wire 26 to pass into the pulley cap 40 and around the pulley 36 . In the preferred embodiment of this invention, the segments of the cable wire 26 on opposite sides of the pulley 36 between the pulley 36 and mounting bracket 32 are parallel. Both segments of the cable wire 26 are perpendicular to the vertical side of the mounting bracket 32 .
The pulley cap 40 , pulley 36 , and wire cable 26 are connected to an actuator rod 42 of a DC linear actuator 50 (See FIG. 3 ) by means of a coupling bracket 44 . The pulley cap 40 , pulley 36 , and wire cable 26 are connected to the coupling bracket 44 by a bolt and nut combination 46 passing through holes vertically aligned with the axis of the pulley cap 40 and pulley 36 . The actuator rod 42 is connected to the coupling bracket 44 by a bolt and nut combination 48 passing through holes horizontally aligned through the coupling bracket 44 and through the center of the outer end of the actuator rod 42 .
The DC linear actuator 50 , as shown in FIG. 3 , is mounted to the solid seat base 11 by means of a mounting flange 56 and an actuator mounting piece 52 . The actuator mounting piece 52 is mounted to the solid seat base 11 by two nut and bolt combinations. The mounting flange 56 is mounted to the actuator mounting piece 52 by a nut and bolt combination passing through horizontally aligned holes in the mounting flange 56 and first and second vertical portions 54 of the actuator mounting piece 52 . The DC linear actuator is positioned so that displacement of the actuator rod 42 is in a direction perpendicular to the vertical portion of the mounting bracket 32 and centered between the first and second circular openings (not shown) in the vertical portion of the mounting bracket 32 . In the preferred embodiment, the DC linear actuator 50 is manufactured by Warner Electric, model number DE12Q17W41-02FHM3HN.
The DC linear actuator 50 is powered by a twelve-volt rechargeable battery 58 mounted to the bottom of the solid seat base 11 . In the preferred embodiment of this invention, the twelve volt rechargeable battery 58 is mounted to the solid seat base 11 by first and second Velcro straps 59 . Each of the first and second Velcro straps 59 pass through two slits (not shown) in the solid seat base 11 such that each of the first and second Velcro straps 59 pass through the first slit (not shown) to the top of the solid seat base 11 and back through the second slit (not shown) and around the twelve volt rechargeable battery 58 . In the preferred embodiment of this invention, the twelve volt rechargeable battery 58 is a sealed, non-spillable, lead battery manufactured by CSB Battery Company, Ltd.
A recharger outlet 68 is mounted to the frame 14 and is wired across the positive and negative leads of the twelve volt rechargeable battery 58 . In the preferred embodiment of this invention, the recharger outlet 68 is mounted to the rear of the solid seat base 11 . However, the recharger outlet 68 can be mounted generally to any part of the frame 14 where it is convenient and accessible.
As shown in FIGS. 3 and 8 , the battery power is controlled by a double throw toggle switch 60 which is mounted to the frame 14 . In the preferred embodiment of this invention, the double throw toggle switch 60 is mounted to vertical component 15 of the frame 14 . (See FIG. 1 .) However, the double throw toggle switch 60 can be mounted generally to any part of the frame 14 where it is convenient and accessible to the wheelchair user. The double throw toggle switch 60 is wired into the electrical circuit, as shown in FIG. 7 , across the positive and negative leads of the twelve volt rechargeable battery 58 . The double throw toggle switch 60 can be thrown in a first direction 74 or a second direction 76 . If the double throw toggle switch 60 is thrown in the first direction 74 , it closes the circuit and powers the motion of DC linear actuator 50 and causes the actuator rod 42 to retract. The retraction of the actuator rod 42 pulls the pulley 36 and cable wire 26 assembly causing the displacement of the cable wire 26 within the cable wire housing 28 in a direction away from the first and second caliper brakes 18 (See FIGS. 4 , 5 , and 6 in combination). The displacement of the cable wire 26 away from the first and second caliper brakes 18 causes equal tension in the cable wire 26 on opposite sides of the pulley 36 and activates the first and second caliper brakes 18 with equal braking force.
If the double throw toggle switch 60 is thrown in the second direction 76 , it closes the circuit and the polarity and direction of current flow through the DC linear actuator 50 is reversed. This powers the motor of the DC linear actuator 50 in the reverse direction and causes the actuator rod 42 to extend. The extension of the actuator rod 42 displaces the pulley 36 and causes the cable wire 26 to move within the cable wire housing 28 toward the first and second caliper brakes 18 . This in turn releases the tension in the cable wire 26 created by retracting the activator rod and deactivates the first and second caliper brakes 18 . The first and second caliper brakes 18 are spring biased (not shown) toward the deactivated position which retains tension in the cable wire 26 while the actuator rod 42 is extending and prevents bunching of the cable wire 26 .
In order to control the tension in the cable wire 26 when the actuator rod 42 is retracting, a motion limit switch 62 is placed in the electrical circuit, as shown in FIG. 7 , between the positive lead of double throw toggle switch 60 . When the double throw toggle switch 60 is thrown in the first direction 74 , the motion limit switch 62 limits movement of the DC linear actuator 50 . The motion limit switch 62 is equipped with a motion arm 64 as shown in FIGS. 3 , 6 , 7 , and 8 . The motion arm 64 is spring biased to contact and press against an actuating pin 66 as shown in FIGS. 3 , 6 , 7 , and 8 . The actuating pin 66 extends from, and is a part of, the coupling bracket 44 as more clearly illustrated in FIG. 6 . The motion limit switch 62 is normally closed. Retraction of the actuator rod 42 causes displacement of the coupling bracket 44 and actuating pin 66 , which in turn displaces the motion arm 64 . Sufficient displacement of the motion arm 64 throws the motion limit switch 62 opening the circuit and preventing further retraction of the actuator rod 42 . The displacement of the motion arm 64 required to throw the motion limit switch 62 is adjustable to allow for control and selection of the tension in the cable wire 26 and the resulting braking force.
In the normal operation of the wheelchair 10 , it is desirable to have brakes activated during the transfer in and out of the wheelchair 10 . If the wheelchair user intends to transfer out of the wheelchair, he will throw the toggle switch 60 in the first direction 74 which causes the actuator rod 42 to retract and activates the first and second caliper brakes 18 . The wheelchair user should hold the toggle switch 60 in the first direction 74 , thereby increasing the braking force applied by the first and second caliper brakes 18 until the motion limit switch 62 is thrown and opens the circuit which stops the retraction of the actuator rod 42 . The user should then release the toggle switch 60 which is spring biased to the center, OFF position. The motor of the DC linear actuator 50 locks the actuator rod 42 in position when there is no power to the DC linear actuator 50 . Thus, the first and second caliper brakes 18 will remain activated and hold the wheelchair 10 in position while the wheelchair user transfers out of the chair. The first and second caliper brakes 18 will remain activated until the toggle switch 60 is thrown and held in the second direction 76 and thereby allowing the actuator rod 42 to extend a sufficient amount to deactivate the first and second caliper brakes 18 and allow the first and second wheelchair wheels 24 to rotate freely. The toggle switch 60 is then released allowing it to spring back to the center OFF position which opens the circuit and stops the flow of power to the DC linear actuator 50 .
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the inventions will become apparent to persons skilled in the art upon the reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention.
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A quick release detachable wheel hub assembly is shown for a lightweight manual wheelchair. The wheelchair wheels mount on exterior hubs and rotate therewith. The inner face out of each of the exterior hubs mates with an opposing outer face of interior hubs. One of the opposing faces on the hubs has a projection or a plurality of projections which fit snugly into corresponding openings on the opposing face of the other hub when the opposing faces of the hubs are mated. The interior hubs are mounted and rotate on detachable axles which screw into the wheelchair frame. A quick release, removable locking pin is inserted through the center of the hubs and into detachable axle and locked in place and thereby causing the hubs to be locked and rotate together. The wheels are quickly detached by simply removing the locking pins and pulling apart the hubs.
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[0001] This application is a division of application Ser. No. 08/865,419 filed May 28, 1997.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a water-based mineral stain for wood and other substrates. More specifically, the invention relates to a process in which a metal salt and an oxygen source react with the substrate to provide a stable color or other desired effect such as preserving the substrate.
[0003] Many commercial stains readily available on the market are oil or solvent-based and/or contain hazardous chemicals subject to increasing environmental regulation and health concerns. There is a growing need for water-based colorants and finishes that contain no hazardous chemicals. Federal and state initiatives are leading to bans on stains using volatile organic compounds (e.g. petroleum, mineral spirits, toluene, or benzene).
[0004] Most water-based products for coloring and finishing wood and other materials are primarily based upon a pigment or dye suspended in a binder such as acrylic resin, which is spread onto the wood surface and held in place by the binder. Such products, although less toxic, exacerbate a problem of all conventional stains, namely that while coloring a wood such as pine they sink in more deeply into the soft pulp and are repelled by the harder wood around the annual growth rings formed during the dormant period in a tree's growing season. For example, stains such as Minwax™ can color pine to a maple-like general color, but in doing so emphasize the distinctive grain-markings characteristic of pine. Such products tend to produce marginal results and an un-even staining pattern. There would be great advantages for a stain capable of coloring both had and soft woods evenly allowing for a maple-like overall color with a much more subtle grain pattern, thereby allowing a soft wood to mimic the appearance of a hard wood more effectively. Also, water-based stains tend to raise wood grain, requiring additional sanding.
[0005] There is a need for a coloring process having the environmental benefit of allowing rapidly growing, sustainably harvestable woods such as pine and other fast-growing and therefore “renewable” wood resources to give the visual appearance of endangered hardwoods such as mahogany, ebony, redwood, and other species that are increasingly rare and expensive.
[0006] The construction, furniture, and woodworking industries need new improved water-based stains effective for soft woods. Likewise, there is a need for environmentally beneficial coloring processes for wood products such as paper and cardboard, for fabrics for clothing and upholstery, and for manufactured polymer products.
[0007] Conventional stains take a relatively long time to dry and can only be applied in temperatures at or above 55 degrees F. There is a need for a stain that can be applied outside this range, for example, for exterior woodwork in a colder climate.
[0008] Conventional stains are made up of a binder and a pigment or dye. Many of these coloring agents are “fugitive,” fading over time, especially in exterior settings. A stable coloring agent that is permanent and does not fade over time and even becomes richer and slightly darker would be an improvement over conventional stains.
[0009] Conventional stains can be used on dry, cured wood only. There is a need for stains that can be applied to damp or “green” un-cured wood. Conventional stains coat the surface of aromatic woods such as cedar, preventing the natural aroma from being released by the wood. There are advantages to stains that leave a wood fully aromatic. Oil-based conventional stains can be difficult to over-coat with water-based acrylic finishes. A stain that can be over-coated with any type of oil or water-based finish would have pronounced advantages.
[0010] Stains used to simulate wood aging, such as Cabot Stains Bleaching Oil™ can only be used for exterior use and the appearance of aging of the wood takes many months from application. An aging treatment that can be used indoors and occurs immediately has clear advantages. Other aging processes require the use of harsh acids, bleaches and other toxic chemicals and require complex manual wood-distressing techniques such as multiple layering of different stains to mimic grain patterns of aged wood. Preferable would be an aging treatment that is non-toxic and can be applied easily by a layman.
[0011] Some coloring processes have been developed to compensate for the unattractive green color of CCA (copper-chromium-arsenic) pressure-treated preserved lumber, such as Leach, U.S. Pat. Nos. 4,752,297 and 4,313,976. These processes rely on organic acids and other organic compounds. They are concerned primarily with preservation of wood, are able to produce only a limited color palate, and are not of general applicability.
[0012] A process of using an aqueous solution of an alkaline earth metal base to treat wood is described in Gaines et al. U.S. Pat. No. 4,757,154. This method requires immersing wood at high temperature and pressure and sanding to remove an unattractive deposit, so it is not a viable method for staining wood. Some woodworkers soak wood in a solution of iron-rich fertilizer to produce a dusty gray tone. The coloring is unstable, uneven, fades over time, leaches out if exposed to moisture, and if overcoated creates an unattractive residue, so it is not in regular use.
SUMMARY OF THE INVENTION
[0013] According to the invention, a metal salt and an oxygen source are applied to penetrate or impregnate a suitable substrate sequentially in effective amounts so as to react in contact with the substrate and produce a mineral compound fixed within the surface of the substrate. The inventive combination of a mutually compatible metal salt, oxygen source, and substrate brings about an in situ reaction, and modifies the substrate to bring about a lasting desired effect. The mineral compound that is produced according to the invention is linked to the substrate, is stable and long-lasting or permanent, and is immobilized or insolubilized in the substrate. The mineral compound is bound or contained within and on the surface of the substrate, so it may be said to be ingrained in the fibers or matrix of the substrate, or incorporated or embedded within the substrate. The desired effect is preferably a color. A wide variety of metal salts may be used depending on the desired effect. The oxygen source is preferably a peroxide, and the substrate is preferably a cellulose product such as wood, cotton, or paper; leather; or masonry. The invention contemplates methods of treating substrates, treatment kits, and treated products.
[0014] This invention satisfies a long felt need for a water-based, non-toxic stain for woods and other substrates that provides a permanent even coloring effect. The invention is in the crowded and mature art, of colorants, preservatives, and finishes for wood and other substrates, yet it has not previously been discovered or used.
[0015] The wood-stain industry has been searching for ways to reduce toxic chemical use, to more effectively stain woods such as pine that are difficult to work with and relatively inexpensive, and to simulate the appearance of aging. The demand is such that any feasible process tends to be put into use.
[0016] This invention succeeds where previous efforts have failed. It avoids the need for volatile organic solvents and toxic compounds, heat, or pressure—elements employed in the prior art—without loss of ability, and indeed with improved results. It can be applied to a wide variety of woods and other substrates with excellent, permanent results. It works quickly in environments and temperatures inappropriate for conventional treatments, and is simple enough to be used by an amateur.
[0017] This invention solves previously unrecognized problems, including how to react a substrate with a soluble mineral salt and an oxygen source to color the substrate; how to satisfy consumer aesthetics limiting the substitutability of sustainable woods for endangered species; and how to use a single staining system for a wide variety of wood and non-wood substrates. This invention also solves the problem of evenly staining and rapidly aging soft woods and green woods and related materials, which was generally thought to be insoluble. The advantages provided by the invention could not previously have been appreciated, such as its adaptability to a variety of overcoat finishes, the ability to stain without appreciably raising wood grain, and its retention of the aromatic quality of the substrate.
[0018] This invention differs from the prior art in modifications which were not previously known or suggested, such as using mineral salts and peroxide solutions to produce surprising coloring effects. Indeed, this invention is contrary to the teachings of the prior art, which favors one step treatments using colored pigments, rather than two step processes whereby the color is developed and stabilized during the process.
[0019] The inventive approach to the coloring and preserving of cellulose and other materials is a process whereby a water-soluble mineral salt is saturated into the substrate material and subsequently oxidized and somehow linked or bonded to that material. This process has no precedent in the marketplace and provides important advantages in both the commercial and consumer markets. In a preferred embodiment, the inventive stains are completely water-based. The process does not require a binder of any kind, petroleum products, organic solvents, acrylic resins, dyes, or other expensive or toxic materials. The component materials have low-impact on both the environment and human heath. The unique characteristics of the product, its permanence even in exterior applications, its ability to evenly stain extremely soft woods and penetrate extremely hard woods, its simulated aging of wood, and the richness of the colors achieved will appeal even to those completely unconcerned about its environmental and health advantages.
[0020] According to the invention, a method for coloring a substrate comprises:
[0021] (a) applying a preparation of a metal salt to the substrate, and
[0022] (b) separately applying a preparation of an oxygen source to the substrate, such that the metal salt and the oxygen source penetrate the substrate and react in contact with the substrate to produce a stable, water-insoluble stain or other fixed physical characteristic in the substrate.
[0023] Step (a) may be performed before or after step (b), and there may be a step of drying the substrate between the two steps. Preferably the preparations are aqueous solutions and are applied between the freezing point and boiling point of the solutions as determined under the particular process conditions selected for the method. The method may further comprise applying a sealing coat over the substrate surface.
[0024] In a preferred embodiment, the substrate is a sustainably harvested wood, the stain is relatively uniform, the metal salt is of low toxicity and not considered hazardous, the preparations of metal salt and oxygen source are water-based solutions, and the oxygen source leaves essentially no residue. Preferably, the metal salt preparation and the oxygen source preparation are aqueous solutions.
[0025] The metal salt may be any appropriate mineral salt and is preferably a salt of iron, silver, zinc, cerium, copper, magnesium, molybdenum, nickel, tin, chromium, aluminum, and titanium, or a salt of antimony, beryllium, bismuth, cadmium, cobalt, gold, iridium, lead, manganese, mercury, niobium, osmium, platinum, plutonium, potassium, rhodium, selenium, silicon, sodium, tantalum, thorium, tungsten, uranium, vanadium, or a combination. The principal purpose of staining with the mineral may be to impart a desirable color to the substrate, to preserve the substrate, or both.
[0026] The metal salt is preferably selected from sulfates, chlorides, perchlorates, permanganates, thiosulfates, acetates, nitrates, as well as oxides that are subject to reduction to release a metal ion capable of reacting with the oxygen source in the presence of the substrate to produce a color. Other salts that may be suitable include halides, phosphates, carbonates, nitrates, oxalates, silicates, tartrates, formates, chromates, organic salts, and the like, so long as the metal ion or compound is sufficiently soluble to penetrate the substrate and is able to react with the oxygen source preparation to produce the desired color or other desired fixed quality in the substrate.
[0027] Preferred metal salts are silver sulfate, iron (II) chloride, zinc perchlorate, cerium (III) perchlorate, iron (II) perchlorate, iron (II) sulfate, silver perchlorate, copper acetate, magnesium nitrate, and cerium nitrate. Other preferred metal salts are molybdenum (VI) oxide, zinc sulfate, copper (II) chloride, nickel perchlorate, nickel sulfate, copper (II) perchlorate, tin (III) sulfate, tin (I) chloride, chromium (III) sulfate, aluminum sulfate, cerium (III) perchlorate, zinc peroxide, titanium hydride, chromium (III) perchlorate, zinc powder in combination with titanium salts, manganese (II) chloride, aluminum chloride, titanium (IV) chloride, silver chloride, and titanium (II) sulfate.
[0028] Preferably the oxygen source is a peroxide. It may be hydrogen peroxide, sodium peroxide, zinc peroxide, barium peroxide, calcium peroxide, or lithium peroxide. The oxygen source may include a hydroxide such as sodium hydroxide. The oxygen source is capable of penetrating the substrate and reacting with the metal salt to impart a stable color or other physical characteristic to the substrate.
[0029] The substrate is preferably a building material or textile and is preferably a cellulosic material such as a soft wood, hard wood, bamboo, rattan, or other cellulose product, such as cotton, paper, cardboard, or the like. The substrate may be previously coated, such as a latex painted surface. The substrate may be leather, fabric, or porous plastic; or it may be a masonry material such as ceramic, plaster, cement, concrete, stone, brick, or a combination. Preferably the effect achieved in the substrate is a color, typically an earth tone. The substrate is one which can be penetrated and contacted sequentially with the metal salt preparation and the oxygen source preparation so as to produce the desired color or other effect bound stably within the substrate. Preferably the substrate is wood or is a wood-like product, meaning a hard fibrous, cellulose-based product from trees, bamboo, reeds or other agricultural sources, including fiber board, plywood, and veneer.
[0030] The metal salt preparation and/or oxygen source preparation may further comprise a compatible additive selected from the group consisting of thickener, alcohol, emulsifier, coloring agent, pigment, dye, bleach, sealer, finishing agent, tint, acrylic finish, latex finish, polyurethane, alcohol, gelling agent, tabletting agent, surfactant, buffer, citric acid, tannic acid, acetic acid, other acid, base, color, salt, stabilizer, antimicrobial, antifungal, insecticide, insect repellant, ultraviolet protectant, and fire retardant. Other additives now known or hereafter available to a person of skill in the art may be employed so long as they do not interfere with the operation of the components of the invention and have suitable shelf life and other characteristics.
[0031] The invention contemplates a colored or otherwise altered substrate produced by the method of the invention. The colored or altered substrate, at its surface or within, has a stable manufactured composition that imparts color or other desirable characteristics, the composition comprising the products of a chemical reaction in contact with the substrate, between a metal salt, and an oxygen source.
[0032] The invention further contemplates a kit for treating a substrate, comprising (a) a metal salt preparation, and (b) an oxygen source preparation, the preparations being adapted to penetrate the substrate when applied, and both preparations, when applied sequentially in effective amounts, being adapted to react with each other to produce a compound fixed on or in the substrate that is stable, and water-insoluble and imparts a color or other desirable characteristic.
[0033] The metal salt preparation is preferably an aqueous solution comprising between about 0.001% and about 20% (w/v) more preferably about 0.025% to about 8% metal salt. The oxygen source preparation is preferably an aqueous solution comprising between about 0.1% and about 50% (w/v) peroxide, more preferably between about 0.3% and about 15%. The concentration of either component may be the point of saturation of a solution or a higher concentration of an appropriate suspension.
[0034] Further details, objectives, and advantages will become apparent from a consideration of the following description.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] In describing preferred embodiments of the present invention, specific terminology is employed for the sake of clarity. However, the invention is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. For the sake of simplicity, this description principally addresses application to wood products. In most cases, however, processes and compositions discussed are also applicable to a wide variety of non-wood products.
[0036] The inventive process is a two-step process preferably involving a non-toxic, water-based mineral solution and a low toxicity water-based oxidizing solution applied sequentially to unfinished wood products. The process may be adapted for the coloring and finishing of wood-like products such as bamboo or rattan paper, recycled cellulose products, cotton and other cloths, leather, certain porous plastics, tile, cement, and other masonry, and other substrate substances.
[0037] The user first brushes, sprays, or otherwise applies a water-based solution “A” onto a wood or other product, lets the product dry for about 5-30 minutes, depending on temperature and humidity, then applies a second water-based solution “B”. Color change begins immediately and when the B solution dries, in another approximately 5-30 minutes, the product is permanently stained. The solutions may also be applied by soaking the substrate in the solution, at standard temperature and pressure or at either extreme or combinations as with typical pressure treatments for lumber to ensure thorough penetration of thicker substrates.
[0038] The inventive process can simulate the look of other, generally more expensive woods (i.e. making pine look like maple, alder look like walnut, or bamboo plywood look like oak). In particular, the coloring process can provide stains that simulate increasingly endangered woods such as mahogany, ebony, and redwood.
[0039] In another application, the process can be used to give new wood an aged appearance for aesthetic reasons, or to allow the unobtrusive introduction of new wood into antique furniture, architectural antiques, fences or shingles that are in need of refurbishment. In such applications, it may be advantageous to distress the surface with rough sanding, sand blasting, chiselling, saw marks, and so on, to allow the minerals to soak in and provide irregular staining. In other applications, it is preferable to maximize the uniformity of the staining, although the stain tends to be somewhat darker around knots and ring areas even with a smooth surface. Nonetheless, staining according to the invention may be uniform, in the sense that it is more even than conventional water-based stains.
[0040] The A solutions contain a variety of mineral salts (such as a variant of the iron-rich compounds found in nutritional supplements) and other natural compounds that soak into the wood surface readily. The B solutions contain an oxidizing agent, such as dilute peroxides similar to the hydrogen peroxide found in many medicine cabinets. Preferred B solutions are somewhat more concentrated.
[0041] Although the invention is not intended to be limited to the mechanism of action, it is believed that the oxygen source causes an oxidation reaction, bonding the minerals in solution A to or among the cellulose fibers in the wood, or other matrix material of a substrate, a process referred to here as “crosslinking.” The chemical nature of the crosslinking reaction is suggested by the fact that a color change results from the combination of solution A, solution B, and the substrate. The resulting color, unlike the clear solutions and their components, is not water-soluble. Also, typically if solutions A and B are mixed without first applying them to the substrate, they throw an unattractive gray-black or gray-brown sediment which is not useful for staining according to the invention. At high strengths and with peroxides, such a reaction is accompanied by bubbling as oxygen is released from the peroxide.
[0042] The process involves saturating the fibers of a wood or other product matrix with a solution of minerals in a water-soluble form and then oxidizing said minerals in the fibers or matrix to change the color, texture, and general appearance of the wood or other properties. It is believed that the coloring process of the invention renders mineral salts into a stable, insoluble form, perhaps an oxide, coordination compound, or other water-insoluble compound or complex, referred to here as a cross linked compound.
[0043] The metal salt formulation soaks into the substrate, impregnating it with mineral ions, which are then converted by the oxygen source into an insoluble coloring compound. Thus, a metal oxide may serve as a metal salt according to the invention, and is contemplated within that definition, if it is solubilized with an acid, applied so as to penetrate into a substrate, and then reacted with an appropriate oxygen source to generate the desired color or other effect. With soluble oxides such as molybdenum IV oxide, the metal oxide may be soaked into the substrate directly, and then reacted to produce a color. Also, solution A may include a combination of a salt of one metal such as titanium chlorate and an elemental metal, such as zinc powder, such that the elemental metal is oxidized by the salt to produce a metal salt which then reacts according to the invention.
[0044] The coloring agent according to the invention may associate physically or chemically with the substrate, via absorption, mechanical admixture, entrapment, polar attraction, or covalent bonding. With cellulosic and leather products, it is assumed that the reaction involves the cellulose or collagen matrix of the substrate article, although it would not affect the scope of the invention if the colored compound remains physically trapped in the matrix of such substrates, without reacting chemically with them. With masonry, the substrate may or may not react with the metal salt and oxygen source, so long as the colored compound is fixed insolubly within the substrate. The scope of the invention is not intended to be limited to any of these supposed mechanisms of action, however.
[0045] The invention also encompasses methods and compositions for imparting other desired stable physical effects to a substrate, where color may be a secondary factor. For example, with certain combinations of metal salts and oxygen sources, the substrate may have an improved texture, conductivity, photosensitivity, anti-fungal, antimicrobial, insect repellant, or fire retardant quality, as a result of treatment according to the invention. Thus the scope of the intention may encompass a method for imparting a desirable stable physical change by sequentially applying preparations A and B to the substrate and allowing them to react so as to fix or bond the reaction product to or within the substrate.
[0046] In some cases, the B solution is applied before the A solution in order to obtain a different effect. Different mineral solutions and different oxidizing agents create markedly different effects on wood, and these finishes can be customized for specific application to a wide variety of materials.
[0047] The invention relates to compositions and kits comprising the various A and B solutions prepared by combining water soluble or other mineral salts, oxidizing agents, and other substances into an aqueous solution.
[0048] The product has a variety of commercial applications including: wood stain, as an alternative to petroleum, acrylic, and latex wood finishes; a wood aging system, to make new wood take on the appearance of old wood; stain for wood-like products, to color and preserve wood-like products such as bamboo; cloth stain, to color cloth, hemp, flax, textiles, leather, and other similar products; wood or other substrate preservation through anti-microbial or anti-fungicidal effects; and masonry stain: to color tile, cement, concrete, brick, stone, and other similar products. The invention can be used both indoors and outdoors, for wood and non-wood products. As can be appreciated, the metal salt can be selected to provide desirable preservative, antifungal, and/or insecticidal properties in addition to a color effect, or can be combined with known preservative treatments. In some applications, the color may be secondary to the ability of the oxygen source to bind or link the metal ion into the substrate according to the two step process of the invention.
[0049] A kit according to the invention can be distributed in two containers such as plastic bottles, one for the A solution and one for the B solution. Bottles A and B can preferably contain a concentrated solution of key mineral salts or oxidizing agents dissolved in water, which the end-user will dilute in a gallon or other volume of water. Alternatively, the product may be distributed in powder or tablet form, requiring the end-user to dilute fully with water. The product can be distributed in fully diluted liquid form, ready to use, which increases shipping costs but reduces variability due to the type of water used and dilution techniques. These decisions can readily be made by a person of ordinary skill depending on acceptance of the various techniques among consumers (such as professional or amateur markets) and the relative difficulty of maintaining certain chemicals' shelf lives in aqueous versus dry conditions. Preferred formulas make use of only non-toxic substances such as iron and silver sulfates and avoid toxic heavy metals such as chromium, cobalt, and lead, which minimize regulatory oversight, and shipping, labelling, and disposal requirements.
[0050] Preferred applications involve water-soluble solutions of minerals of low toxicity, usually in the form of mineral salts such as iron chloride in the A solution, and sodium peroxide or hydrogen peroxide as the oxygen source in the B solution. More toxic metals may also be used for an appropriate result, although they require additional precautions in handling and disposal. Other oxygen sources may be used, and the invention may be carried out in preparations other than water or aqueous solutions. For example, a gel, paste, emulsion, or other thick preparation may be used for either or both components, so long as such a formulation is able to deliver the metal salt and oxygen source into the substrate in a reactive form. Typically, such a thick preparation would be an aqueous solution, although an emulsion with an oil or a suspension may be appropriate in certain applications.
[0051] In a preferred embodiment, to form the various preparations of Solution A, a measured weight of the mineral or minerals is mixed in a volume of purified water. To form the iterations of Solution B, liquid hydrogen peroxide or powdered sodium peroxide are mixed in a volume of water. Alternatively, sodium hydroxide is added to a hydrogen peroxide solution and may be neutralized or buffered if desired. Certain other compounds may serve as an oxygen source according to the invention, such as citric acid on other organic and inorganic acids, provided that they react with an appropriate metal salt according to the invention in contact with the substrate to produce the desired effect.
[0052] The first step in applying the mineral stain is to apply a sufficient amount of Solution A onto the wood or other substrate so that it penetrates, using a brush, pad, roller, spraying device or other suitable method. The solution is generally clear, translucent or slightly cloudy, and alters the color of wood much the same way the application of water would. Some of the A solutions are orange or pink, some milky, some gray. When applied, however, in thin coatings, there is no appreciable color until the oxygen source is applied. Optionally colorants, thickeners, surfactants, and other additives may modify the appearance of the A solution. When the Solution A dries, in 5-30 minutes depending on temperature and humidity etc., the wood looks much as it did before anything was applied to it. A slight graying may be apparent.
[0053] The next step is to apply Solution B to the wood or substrate in much the same manner as Solution A. With a strong Solution B, the color in the wood changes immediately. With weaker solutions, the color comes on slowly, over five minutes or so. The process is reminiscent of making photographic film prints, or watching an instant photograph develop, or making invisible ink become visible. Strong iterations of Solution B have a greater tendency to show brush marks, which can be a negative or positive, depending on the effect desired. The final depth of color in the stained wood is more dependent on the concentration of minerals in Solution A.
[0054] It is possible, in addition to mixing two or more mineral salts in an A solution or two peroxides in the B, to apply first one and then another A, or first a hydrogen peroxide-based and then a sodium peroxide-based B solution. Thus two basic steps of the process might, for certain effects, such as highlighting raised areas with a different color, etc. involve more than two steps.
[0055] The color and tone of the varying wood samples discussed below are described in words but the visual impression of two different samples of wood treated with two different formulas might both be described as “gray brown” though they actually create quite different nuances of visual impression. The colors produced according to the invention are generally earth tones, by which is meant the palate relating to brown, including gray, orange, yellow, red, green and blue variants, ranging from light to virtually black. Opalescent or iridescent effects may be achieved. Brighter coloring effects may also be achieved, as with aluminum oxides. Gray is a preferred effect for simulated aging. The effects may be modified by distressing the surface of the wood to simulate an aged appearance, or by adding pigments and other coloring agents.
[0056] The following mineral salts and oxides have been used according to the invention to stain wood: barium sulfate, calcium sulfate, cerium III nitrate, cerium III perchlorate, copper II nitrate, copper II acetate, copper II carbonate dihydroxide, copper sulfate, iron II sulfate, iron II perchlorate, iron II chloride, sodium thiosulfate, magnesium thiosulfate, potassium thiosulfate, potassium nitrate, potassium permanganate, silver sulfate, silver perchlorate, silver nitrate, titanium III sulfate, and zinc perchlorate.
[0057] Other mineral salts that may be used according to the invention include: aluminum potassium sulfate, molybdenum (VI) oxide, zinc sulfate, copper (II) chloride, nickel perchlorate, nickel sulfate, copper (II) perchlorate, tin (II) sulfate, tin (I) chloride, chromium (III) sulfate, aluminum sulfate, titanium hydride, chromium (III) perchlorate, zinc powder, manganese (II) chloride, aluminum chloride, titanium (IV) chloride, silver chloride, and titanium (II) sulfate.
[0058] Other minerals capable of reacting with an oxygen source in contact with a substrate to color the substrate or provide other effects according to the invention may be selected from salts of elements of columns 2 through 6 of the Periodic Table of the Elements, including the transition elements, Lanthanides, and Actinides. Preferably, the metal is selected from aluminum, antimony, beryllium, bismuth, cadmium, chromium, cobalt, copper, gold, iridium, lead, magnesium, manganese, mercury, molybdenum, nickel, niobium, osmium, platinum, plutonium, potassium, rhodium, selenium, silicon, silver, sodium, tantalum, thorium, tin, titanium, tungsten, uranium, vanadium, and zinc.
[0059] As applied to wood and other substrates, the invention may employ any water-soluble mineral salt or oxidized mineral compound soluble in solvents such as acids, alcohols, or other aqueous substances. It may employ any oxidized mineral compounds capable of reacting with an oxygen source and a substrate to form a colored compound linked to the substrate. Such compounds are referred to here collectively for convenience as metal salts, although some of the mineral elements are not metal, and some of the compounds are oxides, not salts.
[0060] The oxygen source may be any oxidizing agent capable of oxidizing mineral salts according to the invention in the presence of a substrate of wood, bamboo, leather, cellulose, and other suitable substrates. Preferred oxygen sources are peroxides, compounds that include the peroxy (—O—O—) group. Peroxides form hydrogen peroxide upon solution in water. The invention may employ any inorganic or organic peroxide, including those described in Kirk Othmer, Concise Encyclopedia of Chemical Technology , pp. 845-850 (1985), which is incorporated herein by reference. Thus, the oxygen source may be a superoxide or ozonide, or a peroxyacid. It may also be a hypochlorite or chlorine dioxide, although these are relatively toxic and unstable.
[0061] A person of ordinary skill may vary and control for the following parameters to obtain a desired result. The color-producing reactions and resultant color and textural appearance of the wood varies widely with the different minerals used in Solution A. They are reproducible, however, and may be selected as desired to provide a particular appearance. The effect may vary with the purity of the minerals used in Solution A. The examples below used Reagent Grade but Technical Grade or lower grades are suitable for a commercial application.
[0062] The effect varies with the oxygen sources in solution B. Sodium peroxide and hydrogen peroxide and combinations give desirable effects. Other inorganic and organic peroxides and oxygen sources are suitable.
[0063] The effect may vary with the source of water. The examples use purified water. Distilled water versus mineral-rich well water may result in slightly different effects. In general, however, the use of tap water or deionized water gives adequate results. In other cases, modifying the pH or ionic strength with additives may be desirable.
[0064] The effect may vary with the solution in which the minerals or peroxides are dissolved or suspended. In the examples below, water is used, but other liquids could be used, some with non-water-soluble minerals. Instead of a solution, the minerals could be dissolved or suspended in a gel, wax, lotion, or cream and rubbed into the wood or substrate, so long as adequate penetration results. The wood or substrate must also be susceptible to penetration by an appropriate oxygen source, and the vehicle must be compatible in that it does not interfere with the color-producing reaction.
[0065] The effect may vary with the concentrations of the solutions. Generally, more dilute solutions create lighter color density but in some cases they actually give the appearance of a different color.
[0066] The effects produced do not vary appreciably with the ambient temperature at which the solutions are applied. The process can be followed at any temperature above or even slightly below 32° F. or the freezing point, and the stained-wood is dry and ready to be top-coated (if desired) in less than an hour, depending on humidity and temperature conditions. For extremely low-temperature applications, minerals and/or oxidizing agents can be dissolved in alcohol or other non-water solutions. In the examples below, the tests took place at room temperature, but experiments at near-freezing temperatures seemed to create the same result. The invention can also be applied at upper extremes of temperature or high or low pressure, if appropriate.
[0067] Reactions and resultant color and textural appearance of the substrate vary with the substrate material. In the examples below, sugar pine was used but the method of the invention has been successfully applied to northern pine, ponderosa pine, alder, poplar, maple, oak, ash, cedar, cherry, walnut, obinji and other woods and, of course, the results vary widely with the color, tone, and character of each type of wood. Successful demonstrations have also been done on ply bamboo, cotton, leather, and masonry. Ply bamboo is a very hard wood product, does not stain well with conventional products but is susceptible to coloring according to the invention. Other substrates are suitable so long as they are made of a material capable of binding the mineral salt in the presence of the oxygen source according to the invention.
[0068] Effects may vary with the order of application of solutions A and B. In general, starting with B and finishing with A yields a similar color but less nuances of wood grain, which could be preferable in certain applications. In simulating aged wood, for example, the A solution should be applied first. For a non-aged appearance and an even color, the B solution can be applied first. It may be that applying B first makes for a more superficial penetration of the linked color in the wood, but this may be appropriate for thin substrates. With porous substrates, such as fabric or leather, it is preferable to soak the substrate in the solutions to ensure even staining.
[0069] The results also vary with the additives included in solutions A or B such as pigments or dyes, citric acid, bleaches, alcohols, solvents, thickeners, tableting agents, finishing agents such as an appropriate overcoat of acrylic and other resins or polyurethanes that might oxidize and seal the wood simultaneously. Alternatively, an over coat sealer may be applied over the stain. An overcoat may optionally be included into Solution B (or solution A if that is applied last).
[0070] Stained wood according to the invention has been subjected to accelerated weathering situations, exposure to sun, hot water, freezing temperatures, and submersion in water. It is resistant to fading and actually is made slightly darker or warmer in tone on exposure. These tests show that the product produces a remarkably permanent stain suitable for use by professionals and amateurs, for interior and exterior application.
EXAMPLES
[0071] In all the formulas below, Solution A is made up as a solution of mineral in water. Concentrations are given as percent (weight/volume), or the number of grams of mineral and the volume of water is given. Solution B is made up of a 15% (v/v) solution hydrogen peroxide or a 0.3% sodium peroxide solution (made from 3.0 grams per liter of water). In all these cases, the substrate is Sugar Pine unless specifically mentioned otherwise. Different woods or other substrates work equally well, but the colors are somewhat different. These experiments were conducted with an ambient temperature around 65-75 degrees F. Upon application of the B solution, color appeared in from less than one second to up to one minute. Experiments at different temperatures have only marginally different results. Different strengths of Solution B speed or slow the reaction, but result in similar end colors. The key variable determining the color is the mineral or minerals in Solution A.
[0072] In Examples 1-10, the given mass of mineral was dissolved in 1 liter water.
[0000] Example 1 Solution A: 0.25 g Silver Sulfate (Ag 2 SO 4 ) Solution B: Sodium Peroxide Result: Medium density golden-brown Example 2 Solution A: 2.0 g Iron (II) Chloride (FeCl 2 •XH 2 O) + 0.5 g Silver Sulfate (Ag 2 SO 4 ) Solution B: Sodium Peroxide Result: Medium density gray-brown, aged appearance Solution B: Hydrogen Peroxide Result: Medium density warm yellow-brown Example 3 Solution A: 1.5 g Iron (II) Chloride Solution B: Hydrogen Peroxide Result: Light density warm brown with reddish tone Example 4 Solution A: 1.5 g Iron (II) Chloride + 1.0 g Zinc Perchlorate (Zn(ClO 4 ) 2 •6H 2 O) Solution B: Hydrogen Peroxide Result: Medium density orange-brown with dark brown to black highlights in the crossgrain Solution B: Sodium Peroxide Result: Medium density gray with black in the crossgrain Example 5 Solution A: 1.5 g Cerium III Perchlorate (Ce(ClO 4 ) 3 •6H 2 O) Solution B: Hydrogen Peroxide Result: Light to medium density yellow-brown Example 6 Solution A: 2.0 g Iron (II) Perchlorate (Fe(ClO 4 ) 2 •6H 2 O) Solution B: Hydrogen Peroxide Result: Light to medium density warm brown, aged appearance Example 7 Solution A: 2.0 g Iron (II) Perchlorate (Fe(ClO 4 ) 2 •6H 2 O) + 0.25 g Silver Sulfate (Ag 2 SO 4 ) Solution B: Hydrogen Peroxide Result: Medium density warm brown aged appearance Solution B: Sodium Peroxide Result: Medium density gray brown aged appearance Example 8 Solution A: 1.5 g Iron (II) Sulfate (FeSO 4 •7H 2 O) Solution B: Hydrogen Peroxide Result: Medium density warm brown, aged appearance Solution B: Sodium Peroxide Result: Medium density warm gray Example 9 Solution A: 0.5 g Silver Perchlorate (AgClO 4 •H 2 O) Solution B: Sodium Peroxide Result: Medium density warm brown, aged appearance Example 10 Solution A: 1.0 g Iron (II) Sulfate + 0.5 g Silver Perchlorate Solution B: Hydrogen Peroxide Result: Medium density warm brown, aged appearance Solution B: Sodium Peroxide Result: Medium density gray brown aged appearance Example 11 Solution A: Copper Acetate, 1 gram diluted in 50 ml of H 2 O With Hydrogen Peroxide: warm orange-brown, medium density With Sodium Peroxide: no reaction Example 12 Solution A: Iron(II) Chloride: 0.5 grams and Silver Sulfate 0.5 grams in 50 ml H 2 O With Hydrogen Peroxide: gray-brown, medium density With Sodium Peroxide: orange brown, dark density Example 13 Solution A: Iron (II) Perchlorate: 8 grams and Silver Sulfate 0.25 grams in 100 ml H 2 O With Hydrogen Peroxide: dark aged appearance With Sodium Peroxide: nearly black, ebony-like appearance Example 14 Solution A: Iron (II) Perchlorate: 4 grams and Silver Sulfate 0.1 grams in 100 ml H 2 O With Hydrogen Peroxide: warm orange brown, medium density With Sodium Peroxide: warm reddish brown, medium density Example 15 Solution A: Iron (II) Perchlorate 4 grams and Silver Sulfate 0.1 grams in 200 ml H 2 O With Hydrogen-Peroxide: warm gray aged appearance, light density With Sodium Peroxide: reddish gray aged appearance, light density Example 16 Solution A: Iron (II) Chloride 2.5 grams and Silver Sulfate 0.5 grams in 150 ml H 2 0 With Hydrogen Peroxide: minimal reaction With Sodium Peroxide: gray-black with silvery sheen, dark density With Sodium Peroxide and Hydrogen warmer gray-black with reddish tinge, dark Peroxide mixed together: density Example 17 Solution A: Iron (II) Perchlorate 1 gram in 200 ml H 2 O With Hydrogen Peroxide: gray brown aged appearance, light density With Sodium Peroxide: orange brown aged appearance, light density Example 18 Solution A: Iron (II) Chloride 1 gram in 200 ml H 2 O With Hydrogen Peroxide: gray brown aged appearance, light to medium density With Sodium Peroxide: richer brown aged appearance, light to medium density Example 19 Solution A: Iron (II) Chloride 1 gram in 400 ml H 2 O With Hydrogen Peroxide: gray brown aged appearance, light density With Sodium Peroxide: warm brown aged appearance, light density Example 20 Solution A. Magnesium Nitrate 1 gram in 250 ml H 2 O With Hydrogen Peroxide: minimal result With Sodium Peroxide: yellow appearance, medium density Example 21 Solution A: Cerium Nitrate 1 gram in 250 ml H 2 O With Hydrogen Peroxide: minimal result With Sodium Peroxide: yellow appearance, medium density
In all of the examples below the hydrogen peroxide is in a 15% solution and the Sodium Peroxide is made with 2 grams diluted in one liter H 2 O.
[0000]
Example 22
Silver Perchlorate:
1.5 grams per liter H 2 O
Result on concrete:
With Hydrogen Peroxide:
no effect
With Sodium Peroxide:
gun metal gray to black
Example 23
Iron (II) Chloride:
2 grams per liter H 2 O
result with cotton cloth:
With Hydrogen Peroxide:
light gray
With Sodium Peroxide:
orange brown
Example 24
Iron (II) Chloride:
2 grams per liter H 2 O
result on pale unfinished leather:
With Hydrogen Peroxide:
warm golden brown
With Sodium Peroxide:
grayish tan
Example 25
Iron (II) Chloride:
2 grams per liter H 2 O
result on paper:
With Hydrogen Peroxide:
light gray
With Sodium Peroxide:
rich sepia
[0073] The embodiments illustrated and discussed in this specification are intended only to teach those skilled in the art the best way known to the inventors to make and use the invention. Nothing in this specification should be considered as limiting the scope of the present invention. Modifications and variations of the above-described embodiments of the invention are possible without departing from the invention, as appreciated by those skilled in the art in light of the above teachings. It is therefore to be understood that, within the scope of the claims and their equivalents, the invention may be practiced otherwise than as specifically described.
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According to the invention, a metal salt and an oxygen source are applied to penetrate or impregnate a suitable substrate sequentially in effective amounts so as to react in contact with the substrate and produce a mineral compound fixed within the surface of the substrate. The inventive combination of a mutually compatible metal salt, oxygen source, and substrate brings about an in situ reaction, and modifies the substrate to bring about a lasting desired effect. The mineral compound that is produced according to the invention is linked to the substrate, is stable and long-lasting or permanent, and is immobilized or insolubilized in the substrate. The mineral compound is bound or contained within and on the surface of the substrate, so it may be said to be ingrained in the fibers or matrix of the substrate, or embedded within the substrate. The desired effect is preferably a color. A wide variety of metal salts may be used depending on the desired effect. The oxygen source is preferably a peroxide, and the substrate is preferably a cellulose product such as wood, cotton, or paper; leather; or masonry. The invention contemplates methods of treating substrates, treatment kits, and treated products. With wood products, the invention provides a water-based stain of low toxicity useful for soft woods.
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This nonprovisional is a divisional application of U.S. application Ser. No. 12/625,032, which is a continuation of International Application No. PCT/DE2008/000663, which was filed on Apr. 15, 2008, and which claims priority to German Patent Application No. 10 2007 024 350.4, which was filed in Germany on May 24, 2007, and which are both herein incorporated by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a method and a device for operating a drawing line or drawing unit.
Description of the Background Art
DE 21 48 619, which is incorporated herein by reference, illustrates a device for drawing of tows having high polymer synthetic filaments in drawing units with intake units and drawing units where the tow mass is divided into several individual tows.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method and a device for driving a drawing unit in line.
In an embodiment, each drawing roller can be driven by a separate drive unit that can be controlled by an actuator to operate at a specified speed or with the torque required for driving the relevant drawing roller. Different speeds (rotational speeds) of two drawing units allow the tows or filaments passing round the drawing rollers to be drawn by a certain amount. The accumulated speed ratio from the first intake drawing roller to the last discharge drawing roller can range, for example, from 1:3 to 1:4. Since the individual drawing rollers or godets are not driven centrally by one drive unit, but each godet instead is driven individually, the drawing unit can be operated more precisely. It is also an advantage that the drives within one drawing unit are nearly identical and that the load can be distributed evenly. Slip can be considerably reduced by the individual drives.
In an embodiment, the required torque of the drive unit can be set or the drives of the individual godets can be operated through a control unit.
In another embodiment, the motors can be designed as asynchronous drives and the control unit can contain a frequency converter including a tacho-generator connectable to the motor. The frequency converter can be used to set the required rotational speed and thus also the torque of one godet each. The frequency converter allows the required optimum speed to be adjusted for each individual motor. For more complex control requirements, field-oriented converters can be used. These can include a speed controller based on a secondary current controller. The motor characteristics are saved or possibly even automatically determined and adapted in an electronic motor model stored in the converter. This offers the advantage that there has to be no separate speed measurement and feedback for controlling speed and torque. The only feedback used for control is the instantaneous current. Based on current level and phase relation to voltage, all required motor conditions (speed, slip, torque and even heat loss) can be established.
If a disturbance occurs, such as tow rupture during drawing, this disturbance is also registered by a speed sensor and/or by means of the frequency converter, a fault signal is generated and the line can immediately be switched off automatically. For this purpose, the speed and/or the torque of each motor is registered and compared to a given value which can exclusively occur in the event of fault (sudden speed increase). These values are established and saved. By specific adjustment of speeds the respective motors can be designed in an optimum manner, the motor rating can be fully used and costs can consequently be reduced. Moreover, the range of applications of such a line will expand and frequent malfunctions will be avoided.
It is also an advantage that the frequency converter assigned to a motor compares the actual torque with the setpoint torque and then adapts the drive speed of the appertaining motor.
It is beneficial that the surfaces of the godets are chromium-plated or provided with ceramic coating in order to generate higher adhesion.
In an embodiment, the first godet can be driven at a fixed speed which is not changed by the open-loop or closed-loop control system; the speed of the last godet is also fixed, thus determining the drawing ratio. The line is started according to the dotted line ( FIG. 7 ) with a freely selectable starting draw ratio, while the speed increase is distributed among the individual godets either in a linear or freely selectable manner. The tow can be placed on the godets and speed optimization is started. The drives of the individual godets are constantly monitored by means of frequency converters and the actual torque is compared with the calculated average setpoint torque, the speed is thus controlled accordingly while the line is accelerated to maximum speed. Also, the speeds can be saved in a setpoint curve and can be used during the next starting procedure to quicken the starting cycle.
It is also an advantage that optimum drive adjustment of all motors or setting of the desired driving torque for each motor is done automatically through gradual approximation or iteration toward a setpoint torque curve or setpoint torque characteristic.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limitive of the present invention, and wherein:
FIG. 1 is a schematic representation of a drawing line with two drawing units;
FIG. 2 is a top view of the drawing line with two drawing units and one joint drive each;
FIG. 3 is a schematic representation as a top view of an individual motor arrangement for individually and separately driving the godets of a drawing unit;
FIG. 4 is a process speed diagram of the godets in a drawing line with two drawing units according to FIG. 2 ;
FIG. 5 is a torque diagram of the individual godets of the drawing line according to FIG. 2 ;
FIG. 6 is a torque diagram of the individual godets in a drawing line with two drawing units according to FIG. 2 with a second speed or drawing profile;
FIG. 7 is a diagram with rising speed curve for adapted torques of a godet arrangement in line with FIG. 3 ; and
FIG. 8 is a torque diagram for the individual godets of an adjusted machine in line with FIG. 3 .
DETAILED DESCRIPTION
FIG. 1 shows a layout of a drawing line 1 known as such with drawing rollers or godets 2 which are arranged in two drawing units 1 . 1 , 1 . 2 . The two drawing units 1 . 1 and 1 . 2 contain arrangements of seven godets 2 each. In a drawing line 1 to the state of the art, as illustrated in FIG. 2 , the godets 2 of drawing units 1 . 1 and 1 . 2 are driven by a central driving unit or through one assigned motor 3 . 1 , 3 . 2 each and a gearbox symbolized in the respective frame 4 . 1 , 4 . 2 .
FIG. 3 shows the drawing line 1 according to the invention with a total of fourteen godets 2 . The drawing line 1 according to this embodiment includes a first drawing unit 1 . 1 and a second drawing unit 1 . 2 .
According to FIG. 3 , individual motors 31 . 1 , 31 . 2 , . . . 32 . 14 are mounted in the drawing units 1 . 1 , 1 . 2 in one support 5 . 1 , 5 . 2 each, which also contain the bearings for rotation of the godets 2 . The supports 5 . 1 , 5 . 2 are shown only schematically. The sheet with FIG. 3 and the sheet with FIG. 2 both show the overall layout of drawing line 1 as FIG. 1 so that the assignment of drives 31 . 1 , 31 . 2 , . . . 32 . 14 to the fourteen godets in all of the two drawing units 1 . 1 , 1 . 2 becomes clear.
Each motor 31 . 1 , 31 . 2 , . . . 32 . 14 , which can be designed as a water-cooled motor, is used for direct drive of an individual godet 2 . Inserted between the drive shaft of the motor 3 and the drive shaft of the godet 2 is a joint, a joint shaft or a self-aligning bearing so that lateral offset or effects caused by bending moments can be compensated.
FIG. 4 shows a speed diagram with two different speeds V of a first and second drawing unit 1 . 1 and 1 . 2 driven by one motor 3 . 1 and 3 . 2 each, where V 1 is the speed (circumferential speed=rotational speed of godet times radius of godet surface; the circumferential speed corresponds to the speed of the tow 6 ; this description always talks of speed while the value of rotational godet speed results from the above relationship) of the godets 2 of the first drawing unit 1 . 1 and V 2 is the speed of the godets 2 of the second drawing unit 1 . 2 (see also FIG. 1 and FIG. 2 ). The continuous line shows a higher drawing ratio, the dashed line a lower one. The course of the torques M exerted on the godets 2 by the tow 6 (starting from an average torque) is illustrated in the diagrams of FIGS. 5 and 6 . The bars shown in continuous outlines in FIG. 5 correspond to a higher drawing ratio and the bars shown in dashed outlines in FIG. 6 to a lower one—see also the speeds represented as continuous and dashed lines in FIG. 4 .
FIG. 4 makes it clear that the first drawing unit 1 . 1 is driven more slowly than the second drawing unit 1 . 2 so that the tows 6 schematically illustrated in FIG. 1 are drawn. As a result, the total torque taken up by the second drawing unit 1 . 2 is higher than the torque taken up by the first drawing unit 1 . 1 . The difference in torques between the first and second drawing units 1 . 1 and 1 . 2 represents the frictional heat or drawing force, respectively, which is required for drawing the tow or filaments 6 . Drawing the molecules of a filament requires a certain drawing force. By drawing the molecule of a filament a certain friction is generated between the individual molecules so that the filaments or the tow can heat up to about 100° C.
FIG. 5 shows the distribution of torques M among the altogether fourteen godets 2 in the two drawing units 1 . 1 , 1 . 2 (see FIG. 4 —continuous line). FIG. 6 shows the distribution of torques for a smaller drawing ratio ( FIG. 4 —dashed line). The maximum and minimum torques are identified by M 1mx , M 2max , M 2min etc.
As suggested in FIG. 1 , the last drive roller of the last godet 2 in the first drawing unit 1 . 1 and the first drive roller of the first godet 2 in the second drawing unit 1 . 2 are wrapped by the tow 6 only by 90° so that at these points not the full torque is transferred. As a result a higher slip occurs at these points. Since the tow 6 can slide over the surface of the godet 2 at these points, the godet is more strongly worn at and does not transfer the full torque either. The drawing forces on the last godet 2 of the first drawing unit 1 . 1 and on the first godet 2 of the second drawing unit 1 . 2 mostly are therefore somewhat lower than those on the neighboring godets 2 . It is an advantage here that the surfaces of these godets are chromium-plated or have a ceramic coating in order to produce better adhesion.
When calculating the driving force based on the example of FIGS. 1 and 2 (state of the art), the selection of a drive motor is determined by the maximum torque M 2max ( FIG. 5 or FIG. 6 ), i.e. the driving unit is oversized. Consequently, larger gears are required so that modifications of customary lines according to FIG. 1 are costly and time-consuming.
With a driving unit according to FIG. 3 , the energy consumption can be reduced. Here the drives are laid out individually for the maximum demand of the respective godets 2 by grading the specific drive speeds and thus make available for each individual godet 2 a specific ideal driving torque. A total torque M d =M/N must be made available for this purpose, M d being the average torque, M the motor torque and N the number of drive for driving a single godet 2 .
The individual motors 31 . 1 .- 32 . 14 are designed for the specific maximum torque of a godet 2 . With the use of a frequency converter, the required speeds V 1 and V 2 can be monitored and adjusted in such a way that the desired drawing effect is achieved for the tow 6 . For this purpose, a torque control system is used for driving all motors 31 . 1 - 32 . 14 . The previously established M d is the setpoint torque for driving all motors. See also FIGS. 7 and 8 .
V 1 is the initial speed which is gradually increased according to the desired drawing effect on the tow 6 to the subsequent values according to FIG. 7 so that the desired drawing effect is achieved. If the actual torque differs from the setpoint torque, the current speed is adapted to the setpoint speed by iteration using the control system.
As shown by FIG. 7 , the tow 6 can be easily drawn at the beginning as it still can be strongly elongated. The more the tow 6 has been elongated, the higher the required torque for driving the respective motor 3 , as the drawing forces increase with increasing elongation. The speed increments for godets one to seven are much higher than the speed increments of the subsequent godets.
The torques of the godets 2 are sampled several times per time unit so that the drive speed of the individual godets 2 can be adapted. The signal sampled by the control system represents the controlled variable used to determine the required drive speed and thus to determine the required torque of the godets 2 .
By continually monitoring the torque and adjusting the required torque, the drive system after a short run-in time is continuously optimized for the required conditions. As a consequence, only the amount of drive energy required for driving each individual motor 3 is made available. Oversizing of the drive unit can be avoided by the control system in line with the invention using the control curve according to FIG. 7 .
The drive of a drawing line during the optimization stage is effected by the following process steps:
a) The first godet 2 ( FIGS. 7 —N=1) is driven at a pre-determined speed V 1 (which is not changed by the control system, thus remains constant and is selected to match the speed, for example, at which the tow 6 arriving from the spinning plant is supplied). Another given speed is the operating speed V 2 of the last godet (according to FIG. 3 —driven by motor 32 . 14 ). This determines the drawing ratio. This ratio also depends on how the drawn tow 6 shall be further processed.
b) The line is started according to the dashed line ( FIG. 7 ) with a freely selectable starting draw ratio with the speed increase being distributed either in a linear manner (or freely selectable) among the individual godets. This means that the godets ( FIGS. 7 —N=2, 3, 4 . . . . ) following the first godet ( FIG. 7 —left end, N=1) are driven at a speed increased in a linear manner (or by a freely selectable function). This means that the initial speed distribution is determined, which is identified by K A in FIG. 7 . The speed of the last godet ( FIGS. 7 —N=14) is preferably smaller than the intended final speed V 2 . In FIG. 7 , V A is the speed of the initial drawing stage, so that in this case V A <V E .
c) The tow 6 is placed on the godets and the torque optimization process is started.
d) The drives 31 . 1 , 31 . 2 . . . 32 . 14 of the individual godets 2 are continually monitored by means of the control system and the actual torques compared to the specified setpoint torques. The speeds of the individual godets are controlled accordingly. Based on an initial speed distribution ( FIG. 7 —curve K A ), the drives 31 . 2 . . . 32 . 14 of the godets are accelerated—resulting during the individual iterations in the speed distributions suggested by the dashed lines above the starting curve K A in FIG. 7 . This optimization process continues until the torques of the individual drives 31 . 1 , 31 . 2 . . . 32 . 14 meet the specified setpoints and the torque of the last godet ( FIGS. 7 —N=14) reaches the specified final speed V 2 which defines the draw ratio. The torques of the individual drives 31 . 1 , 31 . 2 . . . 32 . 14 are preferably controlled until the situation represented in FIG. 8 is given, namely that the same torque is given throughout.
e) The speeds of the godets of the final curve K E thus obtained are saved and can be used as setpoint values during the next starting procedure to accelerate the start-up process.
As mentioned above, it is possible to drive the last godet (N=14) right from the beginning at the speed V 2 (required speed) defining the draw ratio (V A =V E ). Preferably, however, the starting torque is selected according to the formula V A <V E so that unfavorable situations during the optimization stage can absolutely be avoided.
Speed changes (V 1 and/or V 2 ) during operation of the drawing line in conformity with the invention are carried out analogously. Here also the speeds of the individual godets are optimized in such a way that the specified setpoint torques are reached.
The invention being thus described, it will be obvious that the same 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 to be included within the scope of the following claims.
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A method and device for operating a drawing line or drawing unit for drawing cables from polymer threads using a plurality of driven drawing rollers. According to the invention, each drawing roller is controlled to a prescribed motion value. To this end, each drawing roller is associated with a separately controllable drive device.
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BACKGROUND OF THE INVENTION
This invention has to do with a measuring tool for use in the construction profession with particular applicability to finish carpentry, framing carpentry, wall layout, drywall installation, fitting countertops, piping layouts, floor and ceiling installations and cabinetry. It also has direct applications in the graphic arts field, the engineering and drafting fields and other manufacturing situations where angle measurements are performed. This invention has direct applications in virtually every situation requiring an angle measurement, and it has a multitude of professional and household applications, providing precise angle readings for any carpentry project and any other project that requires angle measurement, angle copying, angle transferring, and/or angle projection. Such projection of an angle may be accomplished with a laser, scope or other means of projecting or sighting to a distant point, line, plane or planes.
This invention is used in the fitting of trim and decorative pieces, or any material, to the surface of wall surfaces, or any surfaces, which meet at an angular junction. This angular junction is commonly referred to as a miter joint. A miter saw/miter box is used to cut the trim and decorative pieces, or any material, in a precise manner so that a clean and accurate miter joint is established.
The invention is also used for fitting single pieces of trim, or any material, into any angle that is encountered. A miter saw/miter box is used to cut the material in a precise manner so that a clean and accurate fit is established between the freshly cut piece and the work surface(s).
In addition to the above-mentioned functions, which are specific to the angle scale that is virtually universal to the miter saw/miter box, this invention also has scales for determining the actual angle, or any interpretation of the actual angle, throughout an entire revolution (zero degrees through 360 degrees).
This invention has additional scales for determining, transferring and laying out the angles for common roof pitches. In the preferred embodiment, these scales are laid out in the standard “inches of rise per lineal foot.” The indicated roof pitch is simultaneously converted to a protractor or miter saw/miter box setting.
This invention also has scales for determining, transferring and laying out gradients. In the preferred embodiment, the slopes (grades) are presented for reading in percentages wherein 0% slope is horizontal and 100% slope is a 45° angle with respect to horizontal.
While a miter saw/miter box is the preferred and generally most accurate way to achieve the angled cuts determined by the invention, other means such as a hand saw, hand-held circular saw, radial arm saw, table saw, jig saw and any other means for achieving the determined cuts are contemplated by the inventor.
This invention has a laser/scope accessory and provision is made for said laser/scope accessory to be attached to the invention. The union of this invention with the laser/scope accessory provides a means for projecting any angle setting from a chosen point of origin along the angle chosen and out to a distance limited only by the power of the laser/scope. Such a laser/scope projection is useful in the layout of walls and construction angles, regardless of what plane they are in. Such a laser/scope projection is also useful in the electrical, plumbing, drywall and landscaping fields, as well as any trade or endeavor that requires the accurate determination, and/or projection, of any angle. It should be understood that a laser/scope, or lasers/scopes, might also be incorporated in the body of the tool as a permanent fixture(s). All such alternative means for employing a laser(s), scope(s) or other means of projecting or sighting on the measuring tool are contemplated by the inventor.
BRIEF SUMMARY OF THE INVENTION
It is an object of this invention to provide an easy to use tool to transfer angle readings from a work place surface(s) to a miter saw/miter box, to any other cutting device, or directly to any work piece, in a one-step operation.
It is a further object of this invention to measure and/or project with a laser, scope or other means, an angle, its complementary angle, its supplementary angle, common roof pitch angles, gradients and/or any angle measurement to which the several scales might be adapted. In the preferred embodiment all of these angle measurements are measured and projected simultaneously.
In the preferred embodiment of the invention an angle measurement tool is provided that in its final form has two interacting legs and a plurality of interacting gears. The first of the two legs has a fixed gear assembly at the axis of the two interacting legs. The second leg has one or more gears which are driven by the aforementioned fixed gear assembly on the first leg. One or more of these gears serve as dials for the purpose of displaying and reading a variety of angle measurements. Both of the legs and those gears employed as dials have a plurality of scale measurements scribed upon them. The tool is so constructed that the movement of the two legs relative to each other will result in an angle being formed there between that will be measured by referring to a setting on the scales so provided for the gears and the legs.
The tool can be utilized to measure the miter joint angle, bevel and miter settings for compound angles, the actual angle made by the legs of the tool, the complementary angle of the actual angle, the supplementary angle of the actual angle, the common roof pitch angle, gradients, and/or any angle measurement to which the several scales might be adapted. In the preferred embodiment, all of these angle measurements are measured simultaneously. The tool can also be utilized with its laser/scope accessory (or integral laser[s] and/or scope[s]) to measure, layout and project wall angles, construction angles and any angle encountered or required. This improvement is accomplished by attaching the twin-beamed laser/scope to the invention and projecting/sighting a line along a chosen angle from a known point to any other point along the laser beam(s) or sighted line(s). Said point, or points, along the projected laser beam(s), or sighted line(s), must be located in order to achieve a proper rendition of the angle required, and the laser/scope accessory achieves that purpose in a one-step operation. It should be understood by those practiced in the art that many additional deployments of lasers or scopes might be employed for a variety of angle projections that are calculated by the measuring tool. The laser, or lasers, can be used to project planes as well as points along a line. These lasers can be deployed in many useful layouts that are directly related to any of the many angle functions to which the tool can be calibrated. It should be further understood that said laser(s), or scope(s), might also be integrated into the measuring tool, in addition to, or as an alternative to the laser (or scope) accessory.
A first alternate embodiment is presented in which both legs are provided with a fixed gear assembly at the axis of the two interacting legs. Both legs are similarly fit with one or more gears which are driven by the aforementioned fixed gear of the respective opposite leg. This improvement provides the ability to have additional indicia bearing gears and thus the ability to provide additional angle measurements.
In addition, a second alternate embodiment is presented which improves on the gear trains in both the preferred embodiment and the first alternate embodiment. As will be evident in the descriptions and drawings to follow, this second alternate embodiment employs compound gears on either or both legs of the tool to provide angle measurements to a still greater degree of precision as compared to those measurements provided by a non-compound gear train.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of all of the components of tool 10 as assembled with the legs forming an acute angle.
FIGS. 2A , 2 B, and 2 C are orthographic views of bottom leg 18 .
FIGS. 3A , 3 B, 3 C and 3 D are orthographic views of top leg 14 .
FIG. 4 is a section view of top leg 14 .
FIG. 5 is a section view of top leg 14 .
FIGS. 6A , 6 B and 6 C are orthographic views of gear cover 22 .
FIGS. 7A , 7 B, 7 C and 7 D are orthographic views of gears 26 , 30 , 34 , 38 and 42 .
FIGS. 8A , 8 B and 8 C are orthographic views of ‘O’ ring 46 .
FIGS. 9A , 9 B and 9 C are orthographic views of bolt 50 .
FIG. 10 is an exploded view of tool 10 .
FIG.11 is a plan view of tool 10 as assembled in a closed position. Direction of movement is shown by arrows. Gear cover 22 is not shown.
FIG. 12 is a section view of tool 10 as assembled in a closed position.
FIGS. 13A , 13 B, 13 C and 13 D are orthographic views of the laser device 54 .
FIG. 14 is a perspective view of laser device 54 .
FIG. 15 is a perspective view of laser device 54 .
FIG. 16 is a perspective view of all of the components of tool 11 as assembled with the legs forming an acute angle.
FIGS. 17A , 17 B, 17 C and 17 D are orthographic views of bottom leg 19 .
FIG. 18 is a section view of bottom leg 19 .
FIG. 19 is a section view of bottom leg 19 .
FIGS. 20A , 20 B, 20 C and 20 D are orthographic views of top leg 15 .
FIG. 21 is a section view of top leg 15 .
FIG. 22 is a section view of top leg 15 .
FIGS. 23A , 23 B and 23 C are orthographic views of gear cover 22 of tool 11 .
FIGS. 24A , 24 B, 24 C and 24 D are orthographic views of fixed gear assembly 78 .
FIGS. 25A and 25B are, respectively, elevation and plan views of assembly washer 70 .
FIGS. 26A , 26 B, 26 C and 26 D are orthographic views of gears 86 , 90 , 94 , 98 and 102 .
FIGS. 27A , 27 B and 27 C are orthographic views of ‘O’ ring 47 .
FIGS. 28A , 28 B and 28 C are orthographic views of bolt 51 .
FIG. 29 is an exploded view of tool 11 .
FIG.30 is a plan view of tool 11 as assembled in a closed position. Direction of movement is shown by arrows. Gear cover 22 is not shown.
FIG. 31 is a section view of tool 11 as assembled in a closed position.
FIG. 32 is a plan view of tool 10 as assembled in a closed position. Direction of movement is shown by arrows. Gear cover 22 is not shown.
FIG. 33 is an exploded view of the components shown in section view 34 . Gear cover 22 is not shown.
FIG. 34 is a section view which applies universally to leg 14 of tool 10 and to legs 15 and 19 of tool 11 .
DETAILED DESCRIPTION OF THE INVENTION
As can be seen in the FIGS. 1-12 the preferred embodiment of angle measurement tool 10 is constructed from several components including top leg 14 , bottom leg 18 , bolt 50 and a plurality of interacting gears. Legs 14 and 18 are the same width and both have a circular shaped end 20 . It should be understood that circular shaped end 20 of both leg 14 and leg 18 is a semicircle of a circle having a diameter equal to the width of leg 14 and leg 18 . It should be further understood that leg 14 and leg 18 might be wider or narrower than circular shaped end 20 where the legs extend beyond the circle described by circular shaped end 20 . It should also be understood that leg 14 and leg 18 might have non-parallel edges and tool 10 will still function as intended. Leg 14 is provided with projected axis spindle 12 at the center of the circle of which circular shaped end 20 is a part. Axis spindle socket 16 of bottom leg 18 is provided at the center of the fixed gear assembly 24 which is at the center of the circle of which circular shaped end 20 is a part. In the preferred embodiment, projected axis spindle 12 is circular in shape and has a diameter equal to or less than the diameter of axis spindle socket 16 , as shown in the figures. It should be understood that projected axis spindle 12 has a diameter equal to or less than the diameter of the axis spindle socket 16 as a function of the assembly of tool 10 and thus to facilitate precisely pivoting legs 14 and 18 secured by bolt 50 . It should be further understood that projected axis spindle 12 does not have to be in the shape of a circle in order for tool 10 to operate in the fashion described. Variable friction adjustment for the pivoting legs 14 and 18 is provided when ‘O’ ring 46 is compressed by projected axis spindle 12 into axis spindle socket 16 when bolt 50 is tightened through bolt hole 32 in leg 18 and into threaded bolt hole 36 in leg 14 , as shown in the figures. Bolt hole 32 and threaded bolt hole 36 are at the center of the circle of which circular shaped end 20 is a part. With legs 14 and 18 so engaged, fixed gear assembly 24 meshes with gear 26 in a secure and rotationally precise manner. Fixed gear assembly 24 of leg 18 is housed within fixed gear cavity 53 in leg 14 in the assembled tool 10 . When the legs 14 and 18 are pivoted around their common axis as defined by projected axis spindle 12 and axis spindle socket 16 , fixed gear assembly 24 meshes with and turns gear 26 , which in turn meshes with and turns gear 30 , which meshes with and turns gear 34 , which meshes with and turns gear 38 , which meshes with and turns gear 42 . Gears 26 , 30 , 34 , 38 and 42 are each precisely located for accurate meshing and rotation by axis pivots 40 located in close tolerance within gear center holes 44 as shown in the figures. Any or all of the gears may include dial indicia 43 for the purpose of measuring any angle reading throughout a full revolution of either leg 14 or leg 18 . As indicated in FIG. 11 , each of the gears 24 , 26 , 30 , 34 , 38 and 42 is supplied with dial indicia 43 which are comprised of straight lines radiating outward from the rotational center of these gears. The purpose of these several gears is to simultaneously provide a variety of useful angle measurements on scales specifically suited to the work at hand. For example, the indicia on fixed gear assembly 24 would be marked with a protractor scale, in a 0°-180°-0° format, providing the actual angle determined by the relative positions of leg 14 and leg 18 ; in turn, gear 26 would provide the protractor scale in a 180°-0°-180° format, gear 30 would provide a scale for the miter saw setting for miter joints, gear 34 would provide a scale for the miter saw setting for butt joints, gear 38 would provide a scale for the roof pitch reading in ‘inches of rise per lineal foot’, gear 42 would provide a scale for gradients expressed as a percentage. This example is one of many configurations possible, dependent only on the angle measurements chosen for the several gears and the relative positions of these several interchangeable gears, whose interchangeability is described below. In the preferred embodiment, fixed gear assembly 24 and gears 26 , 30 , 34 , 38 and 42 are the same diameter and have the same number of gear teeth, thus gears 26 , 30 , 34 , 38 and 42 are interchangeable to suit the user's preference. Gears 26 , 30 , 34 , 38 and 42 may also be reversible, thus providing their reverse side for additional angle measurements. Further, the interchangeable design of the gears provides the opportunity to substitute additional gears provided with specialized scales for use in any field of endeavor requiring precise measurement and layout of particular angles for particular purposes. The various gears would be so marked, or colored, as to provide immediate identification and differentiation of the various scales. It should be apparent to those practiced in the art that interchangeability and reversibility of the gears is not a necessary component of the invention and that the various gears need not be identical in shape, interchangeable or reversible for the invention to function as intended; all such non-interchangeable and non-reversible configurations are contemplated by the inventor. A means for accurately reading these several angle measurements is provided by indicator line 28 placed along the center of gear cover 22 as shown in the figures. It should be understood that many other locations for indicator line(s) 28 on gear cover 22 and/or leg 14 are possible and are contemplated by the inventor. In the preferred embodiment gear cover 22 is transparent and indicator line 28 is provided on the surface of gear cover 22 which is closest to gears 24 , 26 , 30 , 34 , 38 and 42 . In the preferred embodiment gear cover 22 is of a form that provides beveled edges 48 which securely mate with dovetail channel 52 providing a secure location for gear cover 22 . Gear cover 22 is retained by friction, ball catch, screw(s), latch(es), magnet(s) or any of the many suitable means that should be apparent to those skilled in the art. The inventor contemplates all such means of securing gear cover 22 in its assembled location within dovetail channel 52 . So located, gear cover 22 retains gears 26 , 30 , 34 , 38 and 42 securely in their proper working locations with their respective gear center holes 44 engaged with their respective axis pivots 40 . Areas of the surfaces of gear cover 22 which are not necessary areas for viewing angle readings determined by indicator line 28 may be masked so as to provide a well delineated reading environment for the several angle readings so provided. It should be understood by those practiced in the art that gear cover 22 may be opaque and readings can be accomplished through openings and/or lenses in its surface; further, it should be understood that many variations of gear retention and reading means for the various scales and indicia are possible and that all such alternatives are contemplated by the inventor. It should be understood that fixed gear assembly 24 may or may not be constructed in union with leg 18 , but in its final form tool 10 comprises a bottom leg 18 that is in fixed union with fixed gear assembly 24 , such that, in operation, leg 18 is a single piece rigidly attached to, or constructed with, fixed gear assembly 24 . In operation tool 10 simultaneously provides the miter joint angle measurement, the actual angle made by the legs 14 and 18 , the complementary angle measurement of the actual angle, the supplementary angle measurement of the actual angle, roof pitch angles, gradients and/or any angle measurement to which the several scales are adapted. It should be understood by those practiced in the art that any number and any size or variety of gears can be employed in infinite configurations and that all such alternate deployments of gears driven by fixed gear assembly 24 are contemplated by the inventor. It should be further understood by those practiced in the art that, as an alternative, supplement, or addition to the preferred embodiment in which the various gears mesh directly with one another, that a gear-toothed belt drive, friction belt drive, or similar means might be employed as an alternative, supplementary or additional means of rotating all, or some, of the various gears and/or dials and that the inventor contemplates all such variations. Further, the inventor wishes it to be understood that various other friction inducing means other than ‘O’ ring 46 should be apparent to those practiced in the art and that the inventor contemplates all such friction inducing means including the substitution of a suitable magnet for ‘O’ ring 46 and bolt 50 , said magnet located in the bottom of the axis spindle socket 16 and magnetically engaging a magnetized projected axis spindle 12 . Alternate embodiments are contemplated by the inventor in which a wide variety of angle readings may be accomplished on the top surfaces, bottom surfaces and edges of either or both of legs 14 and 18 in which leg indicia 45 and certain scales are employed at various significant intersections of legs 14 and 18 as they bypass each other while being adjusted to the work surfaces which are being measured.
As can be seen in FIGS. 3A , 3 B, 3 C and 3 D, leg 14 is provided with three peg holes 58 , 59 and 60 . In the preferred embodiment peg holes 58 , 59 and 60 are flush and perpendicular with the top surface of leg 14 . Peg holes 58 , 59 and 60 are entirely contained between the bottom and top surfaces of leg 14 . Peg holes 58 , 59 and 60 may be similarly placed in leg 18 . Peg holes 58 , 59 and 60 may be of the same shape as each other or they may be unique shapes. FIGS. 13A , 13 B, 13 C, 13 D, 14 and 15 illustrate laser device 54 . Laser device 54 is intended for projecting diametrically opposed laser beams 64 and 65 in diametrically opposite directions from each other. Laser device 54 is fitted with three pegs 67 , 68 and 69 that precisely match the shape or shapes of peg holes 58 , 59 and 60 . Pegs 67 , 68 and 69 may be of the same shape as each other or they may be unique shapes. Pegs 67 , 68 and 69 are fit perpendicular to the bottom surface 62 of laser device 54 . Bottom surface 62 is in a single plane. Bottom surface 62 is parallel with laser beams 64 and 65 . The relative positions of pegs 67 , 68 and 69 are such that they fit respectively in peg holes 58 , 59 and 60 and in so doing they attach laser device 54 to leg 14 or leg 18 such that laser beams 64 and 65 are parallel to the angle chosen on leg 14 or leg 18 , according to the application chosen. In the preferred embodiment pegs 67 , 68 and 69 are circular and made of steel, either magnetized or not magnetized. It should be understood that other shapes and materials are contemplated for pegs 67 , 68 and 69 . It should also be understood that magnetic attachment is one of many means contemplated for attaching laser device 54 to leg 14 and/or leg 18 . Laser beams 64 and 65 are energized from a battery(ies) contained within laser device 54 . Laser beams 64 and 65 may be generated from a single source and redirected on diametrically opposite paths. Laser beams 64 and 65 may also be generated separately. Laser beams 64 and 65 may be generated not only as single lines, but might also be projected as planes or any number of planes. In operation laser device 54 is affixed to tool 10 by placing pegs 67 , 68 and 69 in peg holes 58 , 59 and 60 . It should be recognized by those practiced in the art that various other means of attaching laser device 54 to tool 10 are possible and those ways are contemplated by the inventor. Laser beams 64 and 65 are employed to project angles. In the preferred embodiment, the union of tool 10 and laser device 54 projects laser beams 64 and 65 along one side of the angle made by the legs 14 and 18 . The other side of the angle made by the legs 14 and 18 represents the base line from which the particular angle is being calculated and projected. Whichever of the legs 14 and 18 that does not have the laser device 54 mounted on it is the leg that is set parallel to the base line. Laser beams 64 and 65 are by design always parallel to one side of the angle being measured and projected. Laser beam 64 is aimed at the spring point of the angle that is to be projected. Laser beam 65 projects the chosen angle along and beyond the angle made by the legs 14 and 18 . It should be understood by those practiced in the art that there are alternate embodiments for a laser, or lasers, in which the laser function(s) are an integral part of tool 10 in addition to laser device 54 , or in place of laser device 54 . All such alternate embodiments are contemplated by the inventor. It should be understood that sighting scopes may be substituted for, or mounted in unison with, the laser beam in laser device 54 . Laser device 54 as herein described is also intended for use with tool 11 , described in the first alternate embodiment below. Additionally, laser device 54 is intended for all alternate embodiments described herein and those other embodiments contemplated by the inventor which should be apparent to those practiced in the art.
The following description of the first alternate embodiment of the invention utilizes the same reference numbers as those described in the preferred embodiment above in such cases where members are the same in both embodiments. New reference numerals have been assigned in cases where members are new or in some respects different when comparing the two embodiments. FIGS. 16-31 disclose the first alternate embodiment, tool 11 , in which leg 15 is provided with a projected axis spindle 13 at the center of the circle of which circular shaped end 20 is a part. The projected axis spindle 13 is provided with threaded bolt hole 37 at the center of the circle of which circular shaped end 20 is a part, as shown in the figures. Leg 19 is provided with axis spindle socket 84 at the center of the circle of which circular shaped end 20 is a part. Leg 19 securely houses assembly washer 70 which is so constructed as to provide a secure fit in recess 71 for rotatably engaging projected axis spindle 13 with bolt 51 as bolt 51 passes through bolt hole 33 which is provided in washer 70 at the center of the circle of which circular shaped end 20 is a part. A portion of projected axis spindle 13 is provided with projected axis spindle gear teeth 74 for reasons that will become apparent below. As shown in the figures, fixed gear assembly 25 is housed within fixed gear cavity 53 in order to drive the gear train of top leg 15 in the same fashion as fixed gear assembly 24 drives the gear train of top leg 14 of tool 10 in the preferred embodiment; the latter being illustrated in FIG. 11 . As tool 11 is assembled, bolt 51 passes through bolt hole 33 into threaded bolt hole 37 , so assembling leg 15 and leg 19 such that they rotate securely in relation to each other with an axis the center of which is located at the center of the circle of which circular shaped end 20 is a part. ‘O’ ring 47 is provided as a frictional interface between projected axis spindle 13 and washer 70 , with adjustable rotational friction for legs 15 and 19 provided as bolt 51 is tightened or loosened to the tool user's preference. In this first alternate embodiment ‘O’ ring 47 is located in ‘O’ ring channel 80 which is concentrically located on the end of projected axis spindle 13 which houses threaded bolt hole 37 at its center. Accurate rotation of legs 15 and 19 is ensured by the close-tolerance fit of projected axis spindle 13 as it revolves within axis spindle socket 84 . Projected axis spindle gear teeth 74 are fixedly engaged with fixed gear assembly 78 by meshing with the mating internal gear 82 contained at the center of fixed gear assembly 78 ; fixed gear assembly 78 then meshes with and turns gear 86 , which in turn meshes with and turns gear 90 , which meshes with and turns gear 94 , which meshes with and turns gear 98 , which meshes with and turns gear 102 . Gears 86 , 90 , 94 , 98 and 102 are each precisely located for accurate meshing and rotation by axis pivots 72 located in close tolerance within gear center holes 76 as shown in the figures. Any or all of the gears may be provided with dial indicia 43 for the purpose of determining any angle reading throughout a full revolution of either leg 15 or leg 19 . As indicated in FIG. 30 each of the gears 78 , 86 , 90 , 94 , 98 and 102 is provided with dial indicia 43 which are comprised of straight lines radiating outward from the rotational center of these gears. The purpose of these several gears is to simultaneously provide a variety of useful angle measurements on scales specifically suited to the work at hand. For example, the indicia on fixed gear assembly 78 would be marked with a protractor scale, in a 0°-180°-0° format, providing the actual angle determined by the relative positions of leg 15 and leg 19 ; in turn, gear 86 would provide the protractor scale in a 180°-0°-180° format, gear 90 would provide a scale for the explementary angle in a 0°-360° format, gear 94 would provide a scale for the explementary angle in a 360°-0° format, gear 98 would provide a scale for the miter saw settings for constructing equiangular polygons employing miter joints, gear 102 would provide a scale for the miter saw settings for constructing equiangular polygons employing butt joints. This example is one of many configurations possible, dependent only on the angle interpretations chosen for the several gears and the relative positions of these several interchangeable gears, whose interchangeability is described below. In the preferred embodiment, fixed gear assembly 78 and gears 86 , 90 , 94 , 98 and 102 are the same diameter and have the same number of gear teeth, thus gears 86 , 90 , 94 , 98 and 102 are interchangeable to suit the user's preference. Gears 86 , 90 , 94 , 98 and 102 may also be reversible, thus providing their reverse side for additional angle measurements. Further, the interchangeable design of the gears provides the opportunity to substitute additional gears provided with specialized scales for use in any field of endeavor requiring precise measurement and layout of particular angles for particular purposes. The various gears would be so marked, or colored, as to provide immediate identification and differentiation of the various scales. It should be apparent to those practiced in the art that interchangeability and reversibility of the gears is not a necessary component of the invention and that the various gears need not be identical in shape, interchangeable or reversible for the invention to function as intended; all such non-interchangeable and non-reversible configurations are contemplated by the inventor.
A means for accurately reading these several angle measurements is provided by indicator line 28 which is placed along the center of gear cover 22 as shown in the figures. It should be understood that many other locations for indicator line(s) 28 on gear cover 22 and/or legs 15 and 19 are possible and are contemplated by the inventor. In this first alternate embodiment gear cover 22 is transparent and indicator line 28 is provided on the surface of gear cover 22 which is closest to gears 78 , 86 , 90 , 94 , 98 and 102 . In this first alternate embodiment gear cover 22 is of a form that provides beveled edges 48 which securely mate with dovetail channel 52 providing a secure location for gear cover 22 . Gear cover 22 is retained by friction, ball catch, screw(s), latch(es), magnet(s) or any of the many suitable means that should be apparent to those skilled in the art. The inventor contemplates all such means of securing gear cover 22 in its assembled location within dovetail channel 52 . So located, gear cover 22 retains gears 86 , 90 , 94 , 98 and 102 securely in their proper working locations with their respective gear center holes 76 engaged with their respective axis pivots 72 . Areas of the surfaces of gear cover 22 which are not necessary areas for viewing angle readings determined by indicator line 28 may be masked so as to provide a well delineated reading environment for the several angle readings so provided. It should be understood by those practiced in the art that gear cover 22 may be opaque and readings can be accomplished through openings and/or lenses in its surface; further, it should be understood that many variations of gear retention and reading means for the various scales and indicia are possible and that all such alternatives are contemplated by the inventor. It should be understood that fixed gear assembly 25 may or may not be constructed in union with leg 19 , but in its final form tool 11 comprises a bottom leg 19 that is in fixed union with fixed gear assembly 25 . In operation tool 11 simultaneously provides the miter joint angle measurement, the actual angle made by the legs 15 and 19 , the complementary angle measurement of the actual angle, the supplementary angle measurement of the actual angle, the explementary angle measurement of the actual angle, roof pitch angles, gradients, miter saw settings for constructing equiangular polygons employing miter joints, miter saw settings for constructing equiangular polygons employing butt joints and/or any angle measurement to which the several scales are adapted. It should be understood by those practiced in the art that any number and any size or variety of gears can be employed in infinite configurations and that all such alternative deployments of gears driven by fixed gear assembly 25 and projected axis spindle gear teeth 74 are contemplated by the inventor. It should be further understood by those practiced in the art that, as an alternative, supplement, or addition to the preferred embodiment in which the various gears mesh directly with one another, that a gear-toothed belt drive, friction belt drive, or similar means might be employed as an alternative, supplementary or additional means of rotating all, or some, of the various gears and/or dials and that the inventor contemplates all such variations. Further, the inventor wishes it to be understood that various other friction inducing means other than ‘O’ ring 47 should be apparent to those practiced in the art and that the inventor contemplates all such friction inducing means including the substitution of a suitable magnet for ‘O’ ring 47 and bolt 51 , said magnet located in the bottom of the projected axis spindle 13 and magnetically engaging a magnetized assembly washer 70 . In this alternate embodiment there would be no bolt 51 and assembly washer 70 would have no bolt hole 33 and thus assembly washer 70 would be secured to leg 19 with screws at a point or points located around the outer edge of assembly washer 70 or by any of several other means which should be apparent to those practiced in the art. Alternate embodiments are contemplated by the inventor in which a wide variety of angle readings may be accomplished on the top surfaces, bottom surfaces and edges of either or both of legs 15 and 19 in which leg indicia 45 are employed at various significant intersections of legs 15 and 19 as they bypass each other while being adjusted to the work surfaces which are being measured. Tool 11 , so constructed in this first alternate embodiment, provides a gear train on both legs 15 and 19 for the purpose of displaying dial indicia 43 for any and all angle measurements that might be provided by the precisely pivoting legs which pivot around the center of the circle of which circular shaped end 20 is a part. It should also be understood by those practiced in the art that the first alternate embodiment here described may be so employed so as to deploy a gear train on leg 19 alone, or leg 15 alone, as might be desired for a given assembly of the inventions here described.
It should be understood by those practiced in the art that there are a number of arrangements of interlocking “pins”, “springs”, “cams”, “clips”, “catches”, “levers”, “latches”, “screws”, “projections”, “magnetism”, “holes”, “grooves” and “openings” that will secure projected axis spindle 12 / 13 of leg 14 / 15 in rotational union with axis spindle socket 16 / 84 of leg 18 / 19 together such that they provide tool 10 / 11 with a leg 18 / 19 that revolves securely and accurately around projected axis spindle 12 / 13 of leg 14 / 15 . The inventor contemplates all of these embodiments, including ‘snap-together’ designs and designs employing spring loaded ball catches (with or without an ‘easy release’ button) in addition to those represented in the figures.
The following description of the second alternate embodiment of the invention utilizes the same reference numbers as those described in the preferred embodiment and first alternate embodiment above in such cases where members are the same as those used in either or both of those embodiments as well as in this second alternate embodiment. New reference numerals have been assigned in cases where members are new or in some respects different as utilized in the second alternate embodiment. The second alternate embodiment is applicable to any of the gear trains illustrated in the preferred embodiment and first alternate embodiment described above, as detailed below. FIGS. 32-34 disclose the second alternate embodiment which employs compound gears, the purpose of which are to employ compound gearing to rotate certain gears at a compounded rate as compared to fixed gear assembly 24 of leg 18 of the preferred embodiment, as well as fixed gear assembly 25 of leg 19 and fixed gear assembly 78 of leg 15 of the first alternate embodiment. The compounded rate of rotation of one gear relative to another provides the ability to have certain gears with accurate fractional readings of those results provided by any of the gears described in the preferred embodiment and first alternate embodiment above. It should be understood that the number of gear teeth shown on particular gears in the Figures are not necessarily indicative of the actual number of gear teeth; the depictions of the gear teeth in the Figures are in some instances abbreviated or drawn out of scale for the purpose of clear illustration. For example, FIG. 32 is a plan view of the second alternate embodiment's compound gear train illustrating a gear assembly 110 which revolves at the same, directly proportional, rate as either of the fixed gear assemblies 24 , 25 or 78 , just as each of the gears in the depicted embodiments of tool 10 and tool 11 revolve at the same, directly proportional, rate as fixed gear assemblies 24 , 25 or 78 ; in every case gear assembly 110 is either directly engaged with either of the fixed gear assemblies 24 , 25 or 78 , or is engaged by idler gears such that gear assembly 110 rotates at the same, directly proportional, rate as the fixed gear assemblies 24 , 25 or 78 . In the second alternate embodiment, gear 114 revolves at a rate 180 times greater than that of gear assembly 110 . A full revolution of gear 114 thus provides its full dial face for depiction of fractional readings of any single whole degree increment portrayed on gear assembly 110 , in doing so a more precise reading of a specific angle is accomplished. More specifically, in this example gear assembly 110 is providing the readings for miter cuts on a miter saw, for which the entire 360° dial must be divided into 180 equally spaced dial indicia 43 . Gear 114 thus turns one full revolution for each 1/180 th revolution of gear assembly 110 . The result is a gear 114 which displays fractional readings in tenths, hundredths, or whichever fractional reading is desired. For the purpose of this example, gear 116 is marked as a 180°-0°-180° protractor and revolves at the same rate as gear assembly 110 . The increased number of rotations for gear 114 in comparison to gear assembly 110 and gear 116 is accomplished with compound gears as described below and illustrated in the figures. FIG. 33 is an exploded view of the second alternate embodiment's compound gear train illustrating the components shown in section view 34 and depicted in FIG. 34 . For the purpose of this description leg 14 is the leg upon which the second alternate embodiment's compound gear train is depicted. It should be understood that the second alternate embodiment's compound gear train is suitable for any and all of the legs 14 , 15 , and 19 and that the inventor contemplates all such embodiments. FIG. 34 is a section view of the second alternate embodiment depicted in plan in FIG. 32 . As assembled, gear assembly 110 is located on axis pivot 122 ; idler gear 118 is located on axis pivot 124 ; compound gear 112 is located on top of idler gear 118 on axis pivot 124 ; idler gear 120 is located on axis pivot 126 ; gear 114 is located on top of idler gear 120 on axis pivot 126 ; and gear 116 is located on axis pivot 128 . Gear assembly 110 , while manufactured or assembled as a single piece, comprises two gears, the lower of those two gears, lower gear 106 is closest to leg 14 and engages idler gear 118 , while the upper gear, upper gear 108 , engages the upper gear 113 of compound gear 112 . Compound gear 112 is manufactured or assembled as a single piece and comprises two gears, the lower of those two gears, lower gear 111 is closest to gear 118 and engages gear 114 , while the upper gear, upper gear 113 , engages gear 108 . Idler gear 118 , being thus engaged with lower gear 106 , in turn engages idler gear 120 , which in turn engages gear 116 . This train of gears 106 , 118 , 120 and 116 is driven by a fixed gear assembly, either 24 or 25 or 78 , directly or through idler gear(s), the result being gears 106 and 116 which revolve at the same, directly proportional, rate as the fixed gear assemblies 24 or 25 or 78 . Upper gear 108 of gear assembly 110 contains 120 teeth around its circumference and is engaged with the 6 toothed upper gear 113 of compound gear 112 . The lower gear 111 of compound gear 112 has 45 teeth around its circumference and is engaged with 5 toothed gear 114 . In this second alternate embodiment, compound action of the upper level gears causes the compounded increase in the number of revolutions of gear 114 , providing the fractional readings desired by providing a gear 114 which turns 180 full revolutions for each single revolution of gear assembly 110 . It should be understood by those practiced in the art that infinite deployments of gear ratios may be employed in such a compound gear train and the inventor contemplates them all. It should be further understood that the second alternate embodiment's compound gear train may comprise as few or as many compound gears as desired, in any number of layers and ratios, and that the inventor contemplates all such combinations of gears. Further, it should be understood that the second alternate embodiment's compound gear train herein described is driven by either fixed gear assembly 24 or fixed gear assembly 25 or fixed gear assembly 78 , just as the fixed gear assemblies 24 and 25 and 78 drive the gear trains previously described and depicted in the preferred embodiment and first alternate embodiment denoted respectively as tool 10 and tool 11 above and in the figures. It should be further understood by those practiced in the art that, as an alternative, supplement, or addition to the second alternate embodiment in which the various gears mesh directly with one another, that gear-toothed belt drives, friction belt drives, or similar means might be employed as an alternative, supplementary or additional means of rotating all, or some, of the various gears and/or dials and that the inventor contemplates all such variations. It should be further understood that the compounding of the gear action might be accomplished with epicyclic or planetary gearing or by other gearing means and the inventor contemplates all such variations.
It should be further understood that any number of different scales and indicia can be deployed on any of the gears, leg surfaces or leg edges of the invention, throughout an infinite number of conceivable angle layouts. The inventor contemplates all such variations of the layout of the scales and indicia.
It should be understood by those practiced in the art that all of the above described gears, and those parts in contact or close proximity with those gears, as assembled, may include any of a number of common friction reduction means such as, but not limited to, low-friction materials employed in the construction of the several legs, gears, and gear covers; low-friction washers, bushings, lubricants, or bearings at points of contact between a gear face and another gear face or a gear face and either of the legs 14 , 15 and 19 and/or gear cover 22 . Such a friction reduction means might be a separate part or might be molded, or affixed, directly onto the gear or the contact area of legs 14 , 15 , and 19 and/or gear cover 22 . Similarly .placed ball-bearings, roller bearings or other means might be used to reduce friction and might be a part of, or intermediary for, any of the gears, axis pivots, legs, or gear covers. The inventor contemplates all such friction reduction means.
Although specific embodiments of the invention have been described it should be recognized that additional modification and other alternate embodiments may be apparent to those skilled in the art.
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An angle measurement tool having two legs joined together about a common axis so that one of the legs rotates with respect to the other to form a desired angle the value of which is read utilizing gears that are housed in said legs in combination with indicia means indicating the degree of rotation of the gears.
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BACKGROUND OF THE INVENTION
The present invention relates to spinning frames, and, more particularly to open-end spinning frames which comprise rotary twisters provided with means for yarn pressing in the course of its formation and which can most advantageously be employed to produce heavy or thick yarns. The invention can be also used in frames wherein the process of spinning is effected by means of an electric field of high intensity.
PRIOR ART
There exist prior art open-end spinning frames, which comprise a plurality of spinning arrangements, each of which incorporates a combing drive roll, a feed roller coupled with a drive via a clutch, a rotary twister with provision for yarn pressing in the course of its formation (e.g. a ball or a projection in the twister channel), a motion for retracting the flexible coupling from the twister shaft, a yarn delivery motion providing for the delivery of the yarn out of the twister through the channel provided in the twister shaft, a building motion with a brake member, and a yarn tension pickup lever (cf. FRG Pat. No. 1,560,313).
These prior art frames, however, have no provision for a simultaneous disconnection of the drives of all motions of a spinning arrangement in case of a breakage, nor for their sequential actuation depending on the specific process of yarn production. In the known frames, should there be a breakage, only the drive of the feed roller is stopped in any spinning arrangement, thereby arresting fiber feeding into the twister, for the yarn tension pickup lever is electrically connected only to the clutch transmitting rotation from the frame drive shaft to the feed roller.
It is likewise known to employ an open-end spinning frame, in which each spinning arrangement comprises, apart from the above-listed motions, a housing hinged on the frame and accomodating a feed roller, a combing drive roll, a rotatably pivoted twister and a yarn tension pickup lever (cf. U.S.S.R. Inventor's Certificate No. 217,243). In this frame, each spinning arrangement incorporates motions for reversing the drives of the yarn delivery motion, the building motion and the drive shaft of the feed roller in order to stop fiber feeding into the twister in case of a breakage. Each reversing motion comprises a roller coupled with the drive shaft via a carrier with gears engaging the gear on the drive shaft and the gear on the roller, as well as means, e.g. an electromagnet or a throw-over catch, cooperating with the carrier to stop its rotation together with the drive shaft, thereby reversing the direction of the roller rotation. The latter means is controlled by the yarn tension pickup lever, the reversing motions operating only when the yarn breaks in the delivery channel of the twister shaft and its end is clamped by a special member of the yarn tension pickup lever. As said drives are reversed, the yarn approaches the orifice of the delivery channel and is drawn pneumatically into the twister, with the yarn tautening and the pickup lever responding to the tension by actuating the electromagnets, which throw in the feed roller drive clutch, to change over the drives of the delivery and building motions from reverse to forward motion. As a result, the fibers fed into the twister are pieced-up with the yarn delivered out of the twister and wound on a package.
Should a breakage occur between the delivery channel of the twister and the building motion, the reversing motions fail to provide for automatic yarn feed into the twister, for the end of the yarn is not clamped by the special member of the yarn tension pickup lever.
In such a case, the drives of all the motions (feed roller, twister, delivery motion and building motion) have to be disconnected and the yarn threaded into the twister. To this end, the twister is rotated about the pivot together with the spinning arrangement housing to retract the twister from its drive and clean it from the remaining fibers and yarn. Then, the twister is set to its initial position, the yarn end brought to the orifice of the delivery channel, threaded into the special member of the yarn tension pickup lever, and the drives of all the spinning arrangement motions are actuated to start the process of spinning again.
However, such a method of automatic yarn threading into the twister in case of a breakage is inapplicable to frames in which the spinning arrangements comprise twisters having a provision for yarn pressing in the course of its formation, for the design of such twisters fail to provide for the drawing of the broken yarn end thereinto while the twister is in rotary motion.
OBJECTS AND SUMMARY OF THE INVENTION
The present invention seeks to provide an open-end spinning frame in which each spinning and has a provision for a simultaneous disconnection of the feed roller, the twister and the building motion 38, and well as for a sequential actuation thereof in keeping with the particular yarn production process requirements, thereby materially improving the operating efficiency of the frame and simplifying the task of the operator.
The above and other objects are attained in that in an open-end spinning frame, comprising a plurality of spinning arrangements, each of which incorporates a combing drive roll, a feed roller coupled with its drive via a clutch, a twister with a motion for retracting the flexible coupling from the twister shaft, a yarn delivery motion, a building motion with a brake member, and a yarn tension pickup lever, in accordance with the invention, each spinning arrangement has a motion for simultaneous disconnection of the feed roller, the twister and the building motion as well as for their sequential actuation, with the latter motion being coupled with the yarn tension pickup lever and controlled thereby, and said motion comprises a bar having a means for positively displacing said bar in a vertical plane and two stops which in the two positions of the bar cooperate with the feed roller drive clutch and with the motion for retracting the flexible coupling from the twister shaft, respectively, and a cylinder, said bar passed through the cavity thereof, which is so mounted as to be able to displace together with the bar to one of the positions thereof for effecting said disconnection, with the cylinder having a stop for cooperating with the brake member of the building motion, and a means for temporarily restraining the cylinder from displacing together with the bar to the position in which the building motion is actuated to restart the process of spinning.
Thus, with each spinning arrangement provided with a mechanism for a simultaneous disconnection and sequential actuation of the feed roller, the twister and the building motion, each spinning arrangement can be controlled and any one stopped, without having to shut down the entire frame. This feature is conducive to a considerable rise in the operating efficiency of the frame.
With the motions of the spinning arrangement actuated sequentially, it is possible to accumulate fibers in the twister which are pieced up with the yarn fed from the building motion, thereby forming the yarn. Actuation of the yarn delivery and building motions as spinning is resumed in the twister permits obtaining a yarn without desirable deviations from the prescribed thickness of the pieced-up portions thereof.
The joint displacement of the bar and the cylinder is preferably provided for by means of a longitudinal slot formed in the cylinder and a pin secured in the bar and received in the cylinder slot.
The invention is characterized in that the means for temporarily restraining the cylinder from displacing together with the bar comprises a catch hinged on the frame, the catch being spring-urged into abutment against the cylinder and having a wedge-shaped projection, and a pusher secured on the bar with the pusher cooperating with the wedge-shaped projection and extending beyond the cylinder through a longitudinal cut-out provided in the latter, and the cylinder having projection with which the catch cooperates, restraining the cylinder as the bar is moving until the pusher retracts the catch from the cylinder projection.
The invention is further characterized in that the means for positively displacing the bar to its disconnection position comprises a gib provided with a roller at one end which is connected with the bar at the other end, a load-bearing member coupled with the gib, and a spring-loaded three-arm lever having a depression formed in the central portion thereof, with the depression serving to receive the gib roller, the three-arm lever having one arm hinged on the frame and another pivotally connected with the armature of an electromagnet which is electrically coupled to the yarn tension pickup lever through a switch.
The invention is also characterized in that the means for positively displacing the bar to the actuation position is defined by as a handle hinged on the frame and resting against the pin secured on the bar.
The invention is likewise characterized in that the cylinder is provided with an auxiliary stop adapted to cooperate with the yarn delivery motion in order to actuate or disconnect it in the course of cylinder displacement.
Thus, due to the motion for actuation and disconnecting the motions of each spinning arrangement, the present spinning frame features a high level of operating efficiency, is easy to operate and maintain, requires no precision instruments for the adjustment of each spinning arrangement, alleviates the burden of manual labor for the operators, and can be handled by medium-skilled operators.
The invention will be better understood by reference to the following detailed description of an open-end spinning frame, in accordance with the invention, taken in conjunction with the accompanying drawings, wherein:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a general view of an open-end spinning frame, the view being in side elevation and partly in cross-section;
FIG. 2 illustrates a feed roller drive;
FIG. 3 is a plan view of a twister drive;
FIG. 4 is a view in side elevation of a mechanism for actuating and disconnecting the spinning arrangement motions, the view being partly in cross-section;
FIG. 5 is a partial section of part of a bar with a stop;
FIG. 6 is a view taken on the line VI--VI of FIG. 4;
FIG. 7 is a view, partially in section, of a means for positively displacing the bar to the disonnection position thereof; and
FIG. 8 is a partial section of a means for temporarily restraining the cylinder from displacing together with the bar.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, it will be seen illustrated therein a plurality of spinning arrangements mounted on a frame 1 (FIG. 1) therealong. Each spinning arrangement comprises a feeding arrangement 2, a twister 3, a motion 4 for delivering a yarn 5 out of the twister 3, a building motion 6, and a pickup lever 7 sensing the tension of the yarn 5, with the elements being mounted one beneath another sequentially in the direction of yarn formation. In order that fibrous material in the form of a sliver or a roving out of which the yarn 5 is subsequently formed in the twister 3 may be fed to the feeding arrangement, there is provided a box 8 for the sliver or the roving, a feeding trough 9 mounted on the frame 1, and a drive shaft 10 delivering the sliver or the roving to the trough 9 leading to the feeding arrangement 2.
The feeding arrangement 2 comprises a feed roller 11, a constantly rotating combing roll 12 and a guide table (not shown) by means of which the fibrous sliver is directed from the feed roller 11 to the combing roll 12. The feed roller 11 is rotated via a jaw clutch 14 (FIG. 2) from a constantly rotating shaft 13 mounted in bearings on the frame 1 and extending the entire length of the frame. One semiclutch 15 of the clutch 14 is mounted on a shaft 16 and connected with the feed roller 11, and the other semiclutch, 17 is connected with a gear 18 meshing with a gear 19 mounted on the shaft 13.
The frame employs a known type of twister 3, defined by a rotor (not shown) provided with a channel for feeding fibers thereinto and delivering the formed yarn therefrom. There is a clamping means (a ball or projection) provided in the twister to condense the yarn as it is being formed. The channel through which the formed yarn is delivered passes through a shaft 20 (FIG. 1) of the twister 3.
The twister 3 is driven into rotation by a flexible coupling 21 (FIG. 3), e.g. a tape or a belt, passing through the entire frame for imparting rotation simultaneously to the shafts of the twisters of all the spinning arrangements. The flexible coupling 21 is entrained about a tension shaft 22 and a drive shaft 23 which actuates the flexible coupling 21. For independent stoppage of each twister 3, the latter is provided with a motion 24 for retracting the flexible coupling 21 from the shaft 20 of the twister 3. The motion 24 may be made in a variety of designs, e.g. as a two-arm lever 24a hinged on the frame 1, and one arm of which cooperates with the flexible coupling 21 to retract the same from the shaft 20 of the twister 3.
The motion 4 (FIG. 4) for delivering the yarn out of the twister 3 is constituted by a constantly rotating shaft 25 extending the entire length of the frame and a roller 26 in permanent contact with the shaft 25. The roller 26 is mounted on a vertically rotatable two-arm lever 27 spring-loaded by a spring 28 which presses the roller 26 against the shaft 26 to be frictionally rotated thereby.
The yarn 5 delivered out of the twister 3 and fed into the building motion 6 is controlled by the pickup lever 7 disposed between the delivery motion 4 and the building motion 6. The pickup lever 7 is defined by an L-shaped lever hinged on the frame 1. One end of the lever carries a roller 29 about which is entrained the yarn passing over a roller 30 rotatably mounted on the frame 1. If the yarn-forming process proceeds normally, the L-shaped lever is suspended by the yarn and held thereby.
The other end of the L-shaped lever is disposed adjacent a switch 31 coupled into the electric control circuit by an electromagnet 32.
The building motion is defined by a constantly rotating shaft 33 mounting a disk frictionally coupled with a drum 34 of a traverse motion, the latter being mounted in bearings on the shaft 33 with a package 35 being spring pressed thereagainst by a known means in order that the yarn may be wound thereon.
Adjacent the drum 34, a hinged lever 36 is mounted on the frame, with the lever 36 carrying a brake shoe 36a cooperating with the drum 34 should it be required to stop the building motion.
Each spinning arrangement of the frame incorporates a motion 37 for a simultaneous disconnection of the feed roller 11, the twister 3 and the building motion 6 as well as for their sequential actuation, with the motion 37 being coupled with the pickup lever 7 and controlled thereby.
The motion 37 comprises a bar 38 provided with means 39 and 40 for positively displacing the bar 38 in a vertical plane to two positions, e.g. upward and downward, to effect the disconnection and actuation, respectively, and a cylinder 41 with the spring-loaded bar 38 passing through a cavity 42 of the cylinder 41.
The bar 38 displaces in guides 43 and 44 disposed on the frame 1 and has two stops 45 and 46 mounted along the length of the bar 38 at a distance one from the other. The stop 46 is fixed on the bar 38 and is in constant cooperation with motion 24 for retracting the flexible coupling 21 from the shaft 20 of the twister 3. The stop 45 is defined by a screw threadedly received in a hole 47 (FIG. 5) formed in the end of the bar 38. By turning the screw, the distance between the stops 45 and 46 is varied in order to provide for a sequential actuation of the feed roller 12 and the twister 3.
The stop 45 (FIG. 2) is designed to cooperate with the clutch 14 of the feeding arrangement 3 via an L-shaped lever 48 pivotally mounted on the frame 1 on a revolving axle 49. One arm of the lever 48 cooperates with the semi-clutch 17 of the clutch 14. In the other arm of the lever 48, there is formed a longitudinal slot 50 through which the bar 38 passes, with the lever 48 being so positioned that the arm through which the bar 38 passes is disposed adjacent the stop 45 in order to cooperate therewith while the bar 38 is in motion.
The bar 38 (FIG. 4) is pressed against the cylinder 41 (FIG. 4) by a spring 51 which rests with one end against projections 52 secured on the inner surface of the cylinder 41 and against a projection 53 secured on the bar 38.
The cylinder 41 incorporates guides 54 and 55 in which the bar 38 moves, with the guides 54 and 55 preventing the cylinder 41 from moving radially with respect to the bar. The cylinder 41 is adapted to move together with the bar 38 to one of the positions thereof, viz. downward to the position in which the feed roller 11, the twister 3 and the building motion 6 are disconnected. To make such a joint movement possible, the bar 38 with the cylinder 41 are interconnected by a pin 56 (FIGS. 6 and 7) secured on the bar 38, the cylinder 41 having a longitudinal slot 57 accomodating the pin 56.
The cylinder 41 (FIG. 4) has a stop 58 for cooperating with the lever 36 of the brake shoe 36a of the building motion 6, as well as a means 59 for temporarily restraining the cylinder 41 from accompanying the bar 38 to its other position, viz. upward to the position in which the building motion 6 is actuated after the feeding arrangement 2 and the twister 3 have been placed into operation.
The means 59 (FIG. 8) for temporarily preventing the cylinder 41 from moving jointly with the bar 38 comprises a catch 60 pivotally mounted on an axle 61 in the frame 1, a pusher 62 secured on the bar 38 and extending beyond the cylinder 41 through a longitudinal cut-out 63 in the cylinder 41. The catch 60 is pressed against the cylinder 41 by a flat spring 64, with one end thereof being rigidly secured on the frame 1 and the other end resting against the catch 60, and the catch 60 has a wedge-shaped projection 65 with which the pusher 62 of the bar 38 cooperates.
On the cylinder 41, there is provided a projection 66 cooperating with the catch 60 for restraining the cylinder 41 as the bar 38 is moving upward until the catch 60 is retracted from the projection 66 by the pusher 62.
In addition, there is an auxiliary stop 67 provided in the upper portion of the cylinder 41 (FIG. 4) on a cylinder projection 68, with the stop 67 being cooperable with the lever 27 of the delivery motion 4.
The means 40 for positively displacing the bar 38 upward to the position of actuation of the feeding arrangement 2, the twister 3 and the building motion 6 is defined by a handle hinged on the frame 1 and resting against a pin 69 secured on the bar 38.
The means 39 (FIG. 7) for positively displacing the bar 38 downward to the position of disconnection in case of a slack or breakage may be made in a variety of designs. In one of the possible embodiments, the means 39 comprises a gib 70, a load-bearing member 71 and a three-arm lever 72.
At one end of the gib 70, there is disposed an axle 73 carrying a roller 74, whereas the other end of the gib 70 is provided with a fork enveloping the cylinder 41 as shown in FIG. 6, with slots 75 formed in the prongs of the fork to receive the pin 58 of the bar 38 (FIG. 7).
The central portion of the gib 70 is connected with the load-bearing member 71 which may be a compression spring as shown in FIG. 7, or an electromagnet, a pneumatic or hydraulic cylinder.
The three-arm lever 72 has a depression 76 formed in the central portion of the lever in which the roller 74 of the gib 70 is accomodated, and one arm of the lever 72 is coupled by a link 77 with an armature 78 of the electromagnet 32. Another or second arm is pivotally mounted on an axle 79 on a case 80 of the load-bearing member 71 mounted on the frame 1, and the third arm of the lever is a free one serving as a guide carrying the roller 74 emerging from the depression 76 as the lever 72 turns.
In another embodiment, the means 39 is constitutedly a lever 81 (FIG. 4), with one end thereof being pivotally mounted on the frame 1 while the other end formed, similarly to the fork of the gib 70, as a fork enveloping the cylinder 41, as described hereinabove and shown in FIG. 7.
The lever 81 is provided with projections 82, 83 and 84, with the projection 82 being disposed adjacent a switch 85 electrically coupled into the control circuit of the electromagnet 32 in series with the switch 31. The projection 83 is hinged with the armature 78 of the electromagnet 32; and the projection 84 is coupled with an extension spring 86.
The shafts 10 (FIG. 1), 13, 23 (FIG. 3), 25 (FIG. 1), 33 and 87, with the latter rotating the combing roll 12 via a belt drive, are driven into rotation by a conventional method from a common drive (not shown) in the figures as being widely known in textile engineering.
The frame of this invention operates as follows:
The common drive of the frame is actuated, thereby imparting rotation to the shafts 10, 13, 23, 25, 33 and 87.
The rotating shaft 10 and feed roller 11 supply the sliver or roving along the trough 9 into the feeding arrangement 2 wherein the sliver is separated into individual fibers which are fed into the twister 3 in which the fibers are formed into the yarn 5 delivered out of the twister 3 by the motion 4 and wound on the package 35.
The yarn 5 emerging from the motion 4 goes around the freely rotating roller 30 and matintains the pickup lever 7 in a position such that its end is clear of the electric switch 31 (FIG. 4). At the same time, the projection 82 of the lever 81 cooperates with the electric switch 85, closing the electric control circuit of the electromagnet 32, with the result that the lever 81 is kept by the electromagnet 32 in its upper position and, via the pin 56, holds the bar 38 and the cylinder 41 in the upper position for actuating the feed roller 11, the twister 3 and the motion 4 and 6.
In case the bar 38 and the cylinder 41 are positively displaced by use of the three-arm lever 72 (FIG. 7) and the load-bearing member 71, the lever 72 is so disposed that its axle 79 and the axle 73 of the roller 74 are vertically aligned, and the roller 74 is disposed in the depression 76 of the lever 72, thereby keeping the bar 38 in its upper position via the gib 70 and the pin 56.
If the yarn 5 (FIG. 4) breaks or is positively slackened, the lever 7 turns, with its end actuating the electric switch 31 which opens the control circuit of the electromagnet 32, with the result that the armature 73 of the electromagnet 32 no longer restrains the lever 81 which is urged by the spring 86 to rotate around its axle, with the projection 82 of the lever 81 retiring from the switch 85 series-coupled into the electric control circuit of the electromagnet 32. While rotating, the lever 81 acts on the pin 56 to lower the bar 38 and the cylinder 41 to the disconnection position.
The pusher 62 (FIG. 8) moving together with the bar 38 downward, down the wedge-shaped projection 65, releases the catch 60 which is urged by the spring 64 toward the cylinder 41 to come into contact with the projection 66 of the cylinder 41, with the stop 45 (FIG. 2) of the bar 38 turning the lever 48 which acts on the semiclutch 17, retracting the same from the semiclutch 15, thereby throwing the clutch 14 out of mesh, with the result that rotation is no longer transmitted from the shaft 13 to the feed roller 11, thereby preventing sliver feed to the feeding arrangement 2. The stop 46 (FIG. 4) of the bar 38 acts on the lever of the motion 24 which turns, thus retracting the flexible coupling 21 from the shaft 20 of the twister 3 and thereby preventing rotation from being transmitted thereto.
The cylinder 41, having moved together with the bar 38 downward, acts by way of the stop 67 on the lever 27 which turns, retracting the roller 26 from the shaft 25, whereas the stop 58 of the cylinder 41 turns the lever 36 which cooperates by way of the brake shoe 36a with the drum 34, thereby stopping the same and preventing the yarn from being wound on the package 35.
In order to resume the spinning process, the end of the yarn 5 from the package 35 in introduced through the channel of the shaft 20 into the twister 3, with the yarn 5 being positioned intermediate the shaft 25 and the roller 26 and running over the roller 30. Then, the pickup lever 7 is turned so that its roller 29 is disposed on the yarn 5, and the yarn 5 is tautened betweeen the shafts 25 and 33. As the pickup lever 7 turns, its end breaks contact with the switch 31 so that the latter closes the electric control circuit of the electromagnet 32.
Then, the handle 40 is turned against the action of the springs 51 and 86, moving the bar 38 upward, i.e. to the position of actuation of the spinning arrangement motions, with the handle 40 abutting against the pin 69 and driving upward the bar 38 alone, as the cylinder 41 (FIG. 8) is held in place by the catch 60 cooperating with the projection 66 of the cylinder 41. The stop 45 (FIG. 4) retires from the lever 48 turned by the semiclutch 17 (FIG. 2) which is driven by the spring 88 into engagement with the semiclutch 15, with the result that the feed roller 11 starts rotating, feeding the sliver to the combing roll 12. While the feed roller 11 is feeding the sliver and the twister 3 is being filled with fibers, the stop 46 is caused by the upward displacement of the bar 38 to retire from the lever of the motion 24 for retracting the flexible coupling 21, the latter lever turns and the flexible coupling 21 returns to the initial position, coming in contact with the shaft 20 of the twister 3 and thereby imparting rotation thereto. As the twister 3 rotates, the fibers are pieced up with the yarn left therein. By this time, in the course of the upward displacement of the bar 38, the pusher 62 (FIG. 8) of the bar 38 travels up the wedge-shaped projection 65, retracting the catch 60 from the stop 66 of the cylinder 41. As a result, the cylinder 41 is driven by the compressed springs 51 (FIG. 4) upward so that the stops 67 and 58 of the cylinder 41 break contact with the levers 27 and 36, respectively, the lever 24 turning by the action of the spring 28 and the roller 26 of the lever 24 abutting against the rotating shaft 25, whereas the lever 36 turns, retracting the brake shoe 36a from the drum 34 which, acted upon by the rotating shaft 33, starts rotating, driving into rotation the package 35 pressed thereagainst, so that the yarn 5 starts winding on the package 35. Thus, is the process of spinning, i.e. formation of the yarn 5 in the spinning arrangement, resumed.
At the instant the bar 38 is set to its upper position, the pin 56 of the bar 38 turns the lever 81 and the projection 82 thereof acts on the electric switch 85, thereby closing the electric control circuit of the electromagnet 32. The armature 78 of the electromagnet 32 restrains the lever 81, and thereby the bar 38 and the cylinder 41, in the upper position in which all the motions of the spinning arrangement are operating. Then, the handle 40 is lowered to the initial position, i.e. retracted from the pin 69 of the bar 38.
In the case the three-arm lever 72 is used, as the bar 38 and the cylinder 41 move upward, the roller 74 of the gib 70 likewise moves upward and is received into the depression 76 of the lever 72, securely locking the bar 38 and the cylinder 41 in the upper position.
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An open-end spinning frame which can most advantageously be employed for spinning heavy yarns. The frame incorporates a plurality of spinning arrangements, each comprising a feeding arrangement, a twister, a yarn delivery motion and a building motion as well as a motion for their simultaneous disconnection and sequential actuation. The frame is simple in design and has a high operating efficiency.
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BACKGROUND OF THE INVENTION
[0001] Computed tomography (CT) imaging systems are used to provide three-dimensional or 360° views of a patient. These systems typically have an annular gantry frame that spins about a patient or object to be imaged. An X-ray tube is mounted to the gantry frame. A cooling system is also provided within the gantry frame to dissipate heat generated by the X-ray tube.
SUMMARY OF THE INVENTION
[0002] A heat exchange unit in a heat exchanger assembly is provided for use in a cooling system of a CT imaging system having a gantry frame with an annular interior region. The heat exchange unit is formed of a plurality of tubes bent at discrete locations to provide several straight leg sections so that the heat exchange unit can fit within an arcuate portion of the annular interior region of the gantry frame.
[0003] In one embodiment, a heat exchange unit includes a plurality of tubes having open ends and flat exterior upper and lower surfaces. Flow passages for a first heat exchange fluid extend through the interior of the tubes. The tubes are attached to a pair of tube sheets, which maintain the tubes in an array spaced apart a distance to allow fluid flow of a second heat exchange fluid between the flat exterior surfaces of the tubes.
[0004] Each of the tubes has at least one bend formed at discrete locations to divide each of the tubes into a plurality of straight leg sections. The tube sheets maintain the tubes in an array with each of the straight leg sections of adjacent tubes generally parallel and the bends generally radially aligned with respect to the gantry frame. In one embodiment, the bends in the tubes are located symmetrically about a centerline through an arc tangent to the tubes at the centerline and where the tubes join the tube sheets.
[0005] The tubes are joined to the tube sheets at end portions extending perpendicular to the faces of the tube sheets. The faying surfaces of the tubes and the slots of the tube sheets are flat and parallel, leading to a dependable joint formed by, for example, brazing or welding.
[0006] In another aspect, the heat exchange unit is part of a heat exchanger assembly including mounting brackets for mounting to the gantry frame. The mounting brackets are attached to opposite sides of the heat exchange unit adjacent the tube sheets and include mounting fixtures that extend in the axial direction of the gantry frame. This reduces the stress on the mounting fixtures and the mounting brackets, compared to prior art heat exchanger assemblies that use radially oriented mounting fixtures.
DESCRIPTION OF THE DRAWINGS
[0007] The invention will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings in which:
[0008] FIG. 1 is an isometric view of an embodiment of a heat exchange unit according to the present invention;
[0009] FIG. 2 is an isometric view of the heat exchanger assembly of FIG. 1 installed in an arcuate portion of a gantry frame;
[0010] FIG. 3A is a front view of the heat exchange unit of FIG. 1 ;
[0011] FIG. 3B is an enlarged view of a portion of FIG. 3A ;
[0012] FIG. 3C is a side view of a tube sheet employed in the heat exchange unit of FIG. 3A ;
[0013] FIG. 4 is a front view of the heat exchange unit of FIG. 1 illustrating various geometric relationships;
[0014] FIG. 5 is a front view of an embodiment of a heat exchange unit illustrating three bends;
[0015] FIG. 6 is a front view of an embodiment of a heat exchange unit illustrating four bends;
[0016] FIG. 7A is an illustration of a rectangular heat exchange unit overlaid on an arcuate portion of a gantry frame; and
[0017] FIG. 7B is an illustration of the heat exchange unit of FIG. 1 overlaid on an arcuate portion of a gantry frame for comparison with FIG. 7A .
DETAILED DESCRIPTION OF THE INVENTION
[0018] One embodiment of a heat exchanger assembly that fits within an annular or arc-shaped interior region of a gantry frame of a CT system to provide cooling for an X-ray tube is shown in FIG. 1 . The heat exchanger assembly 10 includes a heat exchange unit 12 formed from a plurality of tubes 14 arranged in parallel and spaced a distance apart. When the heat exchanger assembly is installed in a gantry frame 16 , a first heat exchange fluid flows through the interior of the tubes 14 , for heat transfer with a second heat exchange fluid that flows in the regions 18 between the tubes and past the exterior surfaces of the tubes.
[0019] The tubes 14 are bent at bends 22 to form several straight leg sections 24 to accommodate the annular configuration of the gantry frame 16 . See FIG. 2 . The tubes are typically flat tubes and may contain microchannels or baffles, as known in the art. Mounting brackets 32 (described further below) are attached at each side of the heat exchange unit 12 for attachment to the gantry frame 16 . The mounting brackets also enclose manifolds (not shown) for delivering and discharging the first heat exchange fluid to and from the interior of the tubes of the heat exchange unit. In the embodiment shown, inlet and outlet fittings 34 are connected to the heat exchange unit through the mounting brackets 32 . Alternatively, inlet and outlet fittings may be connected at opposite sides of the heat exchanger assembly through both mounting brackets if desired for a particular application. The inlet and outlet fittings connect via suitable piping to a fluid tank or reservoir and fluid pump (not shown) for the heat exchange fluid.
[0020] In operation, the first heat exchange fluid flows on a circulatory flow path through appropriate piping past an X-ray tube (not shown), where the fluid is heated by heat transfer with the X-ray tube. The heated fluid then flows to the heat exchange unit 12 , where it flows through flow passages within the tubes 14 and is cooled through heat transfer with the second heat exchange fluid, typically air, flowing in the regions 18 and across the exterior surfaces of the tubes 14 . The air flows in an axial direction of the gantry frame (indicated by axis 44 , shown in FIG. 2 ) and generally perpendicular to the elongated direction the tubes. Additional heat exchange elements, such as fins made of corrugated aluminum (not shown), may be disposed within the regions 18 to assist in the heat transfer between the fluids. A fan or other air moving device (not shown) may be provided to force the air flow through the heat exchange unit.
[0021] Referring to FIGS. 1 , 3 A, 3 B, and 3 C, the tubes 14 of the heat exchange unit 12 are supported at their opposite ends by tube sheets 52 . Both tube sheets are identical, which simplifies their manufacture. Each tube sheet may be formed from a plate with opposed flat surfaces 54 , 56 having a plurality of elongated, parallel slots 58 . An end portion 62 of each tube 14 is received in an associated slot 58 , as shown more particularly in FIG. 3B . The end portions 62 of the tubes 14 may be fastened to the tube sheets 52 in any suitable manner, such as by brazing or welding. The end portions 62 of the tubes are perpendicular to the flat surfaces 54 , 56 of the tube sheets 52 where they enter the slots 58 . The faying surfaces 64 , 66 of the end portions and the slots are flat and parallel to each other. Thus, clearances between the faying surfaces are minimized, allowing the joint to wet throughout during the jointing process, for example, vacuum brazing, which aids in ensuring a strong, dependable joint. The tubes may also be supported by upper and lower plates 67 , 69 .
[0022] In one embodiment, the discrete bends 22 in the tubes 14 are located symmetrically about a centerline 70 of the heat exchange unit 12 , as shown in FIG. 4 . The centerline is coincident with a radial direction of the gantry frame when the unit is installed in the gantry frame. In this embodiment, three legs 24 are shown, defined by two discrete bends 22 . For each tube, each of the end legs 24 A has the same length A, and the center leg 24 B has a length B. The tube centerline 70 is perpendicular to a tangent to an arc C that extends from the end portions 62 of the tubes where they enter the tube sheets 52 on the end legs 24 A and is tangent to the center leg 24 B at the center line. For a two-bend unit, the bend angle D is equal to angle E/ 2 .
[0023] The bent tube heat exchange unit 12 can be readily sized to fit gantry frames having a variety of circumferences and arc lengths. If the angle E of the arc becomes large, the number of bends can be increased to increase the resolution of the arc while maintaining symmetry about the centerline of the heat exchange unit. For example, FIG. 5 shows a heat exchange unit 12 ′ with three bends 22 ′. One bend is along the centerline 70 ′. Two bends are offset from the centerline an equal distance in each direction along the arc C′. FIG. 6 shows a heat exchange unit 12 ″ with four bends 22 ″. A first set of two bends are offset from the centerline 70 ″ a first distance in each direction along the arc C″, and a second set of two bends are offset from the centerline a further distance in each direction along the arc C″.
[0024] By having a symmetrical arrangement with paired legs of equal length, the tube can be formed more simply. For example, a press brake can be set up with one angle for all the bends. For tubes with two bends, one back stop setting can be used for both end legs of the tube. Forming discrete bends with a press brake is faster and more efficient than bending a large arc gradually between rollers and comparing it to a template, such as with curved tubes used in some prior art heat exchange devices. Also, forming the discrete bends takes place away from the faying surfaces where the tube passes through the slot in the tube sheet. The tubes can thus be held perpendicular to the surfaces of the tube sheets, as noted above, leading to a dependable joint. In contrast, with an arced or curved tube, it is more difficult to be assured of that perpendicularity at the tube sheet. Bending the tube at discrete locations also results in less plastic deformation to the tube than forming an arc, which improves repeatability. A better joint can be made between the tubes and the tube sheets, because the parallelism of the tubes can be more readily controlled due to the long flat sections of the tubes and their undeformed condition. Tooling for the jointing process is also more simple to manufacture and change, because the pressure is applied with a flat surface in a linear direction, eliminating the need to form curved tooling.
[0025] Depending on the angle E of the annular portion of the gantry frame to be covered, the present heat exchange unit presents a surface area of the tubes to the entering air that is comparable to the surface area of a curved-tube heat exchanger geometry. Also, the present angled or bent configuration of the heat exchange unit presents more surface area than a prior art square or rectangular heat exchanger geometry, resulting in a 25 to 50% increase in heat rejection. FIGS. 7A and 7B illustrate a comparison in which a rectangular heat exchange unit 101 is overlaid over an annular frame 16 . For example, the surface area of the tubes of the rectangular configuration is 719.6 cm 2 , compared to a surface area of 980.7 cm 2 for a bent tube heat exchange unit 12 . In this case, the present heat exchange unit results in a 36.3% increase in surface area. Also, the increased surface area presented by the tubes results in a lower pressure drop across the tubes for the same air flow rates compared to a square or rectangular geometry.
[0026] In a further aspect, the mounting brackets 32 of the heat exchanger assembly 10 include circumferentially extending ear portions 84 that have apertures 86 that align with the axial direction 44 of the gantry frame 16 when the assembly is installed therein. Bolts or other fastener members pass through the axial apertures for attachment to the gantry frame. In this manner, the weight of the heat exchanger assembly is supported primarily by the surface-to-surface contact of the mounting brackets and the inside diameter of a drum of the gantry frame. This configuration is less dependent on the strength of the fasteners and the mounting bracket, in contrast to prior art designs, in which the heat exchanger assembly is mounted with bolts extending in the radial direction of the gantry frame. This prior art design puts a greater amount of tension force on the bolts in a spinning mechanism.
[0027] It will be appreciated that the embodiments and aspects of the present invention may be combined with each other in various ways. For example, although the embodiments illustrated show symmetrically located bends, the bends do not have to be symmetrically located. The invention is not to be limited by what has been particularly shown and described, except as indicated by the appended claims.
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A heat exchange unit for a heat exchanger assembly is provided for use in a cooling system of a CT imaging system having a gantry frame with an annular interior region. The heat exchange unit is formed of a plurality of tubes bent at discrete locations to divide the tubes into straight leg sections to fit within an arcuate portion of the gantry frame's annular region. The bent tubes are maintained between a pair of tube sheets in an array with the straight leg sections parallel and the bends generally radially aligned. The tubes are orthogonally joined to the tube sheets, and the faying surfaces are flat and parallel, leading to a dependable joint. The heat exchanger assembly includes mounting brackets with mounting fixtures axially aligned with the gantry frame, to reduce stress on the fasteners and the mounting brackets.
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TECHNICAL FIELD
[0001] The present invention relates to an optical connector for connecting an optical fiber to another optical fiber or an optical element.
BACKGROUND ART
[0002] For example, in JP 2001-56420 A, there is described an optical connector including a ferrule (27) having a flange (26), and a housing (constituted by a front portion (12) and a rear portion (13)) for holding the ferrule. A through-hole is formed in the housing, and the ferrule is held in an inner periphery of the through-hole. Specifically, the through-hole is formed in each of the front portion (12) and the rear portion (13) of the housing. A forward end side of the ferrule is inserted into the through-hole of the front portion, and a proximal end side of the ferrule (which is hereinafter represented as a side opposite to the forward end side thereof) is inserted into the through-hole of the rear portion. In this state, the front portion and the rear portion are fixed to each other, and thus the ferrule is mounted in the inner periphery of the through-hole of the housing.
[0003] The above-mentioned optical connector has a spring (coil spring (29)) mounted between the flange of the ferrule and the rear portion (13) of the housing, and hence the ferrule is biased toward the front portion (12). When such optical connector on one part is connected to an optical connector on the other part through an optical adapter, a forward end of the ferrule on the one part is brought into contact with a ferrule on the other part. Consequently, the ferrule on the one part retreats against resilience of the coil spring. Owing to a buffer function of the spring, the forward ends of the ferrules can be reliably brought into contact with each other.
Citation List
[0004] Patent Literature
Patent Literature 1: JP 2001-56420 A
SUMMARY OF INVENTION
Technical Problem
[0005] As described above, owing to a configuration in which the ferrule is completely received in the through-hole of the housing constituted by the front portion (12) and the rear portion (13), it is possible to reliably protect the ferrule from external impact. However, an optical connector used behind the wall (BTW), i.e., in an inside of a module box or the like, is rarely subjected to external contact, and hence the external impact is less likely to be applied thereto in comparison with an optical connector used on the wall (OTW). Thus, in the optical connector used on a place where the optical connector is rarely subjected to the external impact, the configuration having the above-mentioned housing constituted by a plurality of components becomes sometimes excessive.
[0006] An object of the present invention is therefore to simplify a structure of the optical connector and to achieve reduction in cost.
Solution to Problem
[0007] In order to achieve the above-mentioned object, the present invention provides an optical connector including: a ferrule including a flange portion; and a housing including a through-hole formed to hold the ferrule therein, in which the through-hole is opened in a side surface of the housing, and the ferrule is allowed to be mounted to an inner periphery of the through-hole from an opening portion formed in the side surface.
[0008] As described above, the through-hole is opened in the side surface of the housing, and the ferrule is allowed to be mounted to the inner periphery of the through-hole from an opening portion formed in the side surface. Thus, it is unnecessary to constitute the housing by a plurality of components, and reduction in the numbers of components and assembly steps and reduction in cost can be achieved. The above-mentioned optical connector can be preferably used on a place where the optical connector is rarely subjected to external contact (behind the wall, for example).
[0009] The optical connector may further include a reference surface formed integrally with the housing, for regulating retreat of the ferrule by being brought into contact with the flange portion of the ferrule from a proximal end side thereof. When the optical connector is mounted to an optical adapter, the ferrule on one part of the optical connector is pushed to the proximal end side by being brought into contact with a ferrule on the other part, and thus the flange portion is brought into contact with the reference surface. In this way, the retreat of the ferrule is regulated. As described above, the ferrule is positioned in the housing during use of the optical connector (during mounting to the optical adapter) by the reference surface provided integrally with the housing, and hence it is possible to omit a spring, and to achieve further reduction in cost. Such optical connector on the one part has no buffer function of the spring, and hence can be preferably used in a case where the optical connector on the other part connected thereto has a buffer function of the spring or the like. In this case, when a position of the reference surface is set within a movable range of the ferrule on the other part, it is possible to reliably bring the forward ends of the ferrules into contact with each other by the buffer function of the ferrule on the other part.
[0010] Incidentally, it is desirable that a fiber core of an optical fiber inserted through the ferrule be arranged at a central axis position of the forward end of the ferrule. However, actually, due to factors such as eccentricity of an insertion hole with respect to an outer peripheral surface of the ferrule, eccentricity of the optical fiber with respect to an inner peripheral surface of the insertion hole, and eccentricity of the fiber core with respect to an outer peripheral surface of the optical fiber, the fiber core is arranged to be eccentric to the central axis position of the ferrule. For example, when, of a pair of ferrules of optical connectors connected together through the optical adapter, a fiber core of one ferrule is eccentric in an upward direction and a fiber core of the other ferrule is eccentric in a downward direction, deviation of the fiber cores is increased when the ferrules are brought into contact with each other. In contrast, when eccentric directions of the fiber cores of both the ferrules are aligned with a predetermined direction (upward direction, for example), the deviation of the fiber cores can be decreased. (As described above, an operation for aligning the eccentric directions of the fiber cores with the predetermined direction is referred as to “centering”.)
[0011] When the ferrule is detachably attached to the housing, it is possible to easily perform centering. That is, in a state in which the ferrule is mounted to the housing, the eccentric direction of the fiber core of the optical fiber inserted through the ferrule is ascertained. Then, the ferrule is temporarily detached from the housing, rotated by a predetermined angle, and re-mounted to the housing. In this state, the eccentric direction of the fiber core is ascertained. The above-mentioned operation is repeated, and the ferrule is mounted to the housing at a position at which the eccentric direction is aligned with the predetermined direction. Consequently, the centering is completed.
[0012] When provided is a cover portion which is formed integrally with the housing, covers an outer periphery of the ferrule projecting to the proximal end side thereof relative to the housing, and extends to the proximal end side relative to a proximal end of the ferrule, it is possible to protect the optical fiber inserted into the ferrule.
[0013] When the ferrule is held in close contact with the housing on a cylindrical outer peripheral surface of the ferrule in a peripheral region extending over more than half of a circumference of the cylindrical outer peripheral surface, the ferrule can be restrained in an entire radius direction. Therefore, it is possible to reliably hold the ferrule by the housing.
ADVANTAGEOUS EFFECTS OF INVENTION
[0014] As described above, according to the present invention, it is possible to simplify a structure of the optical connector and to achieve reduction in cost.
BRIEF DESCRIPTION OF DRAWINGS
[0015] FIG. 1A A perspective view of an optical connector.
[0016] FIG. 1B A perspective view of the optical connector.
[0017] FIG. 2A A side view of the optical connector.
[0018] FIG. 2B A plan view of the optical connector.
[0019] FIG. 2C A front view of a forward end side of the optical connector.
[0020] FIG. 2D A front view of a proximal end side of the optical connector.
[0021] FIG. 3A A cross-sectional view taken along the line A-A of FIG. 2B .
[0022] FIG. 3B A cross-sectional view taken along the line B-B of FIG. 2A .
[0023] FIG. 3C A cross-sectional view taken along the line C-C of FIG. 2A .
[0024] FIG. 3D A cross-sectional view taken along the line D-D of FIG. 2A .
[0025] FIG. 4 An enlarged view of FIG. 3A .
DESCRIPTION OF EMBODIMENTS
[0026] In the following, an embodiment of the present invention is described with reference to the drawings.
[0027] As illustrated in FIGS. 1A and 1B , an optical connector 1 according to the embodiment of the present invention includes a ferrule 10 and a housing 20 for holding the ferrule 10 . The optical connector 1 is mounted to an optical adapter (not shown), and is a so-called LC-type optical connector in which the ferrule 10 and the housing 20 are prevented from slipping off through engaging, with a locking portion of the optical adapter, a latch 22 provided to the housing 20 of the optical connector 1 . Note that, in the following, for convenience of the description, a central axis direction (Y direction in FIGS. 1A and 1B ) of the ferrule 10 mounted to the housing 20 is referred to as an “axial direction”, a side on which a capillary 11 of the ferrule 10 projects from the housing 20 in the axial direction is referred to as a forward end side, and a side opposite thereto is referred to as a proximal end side. Further, a Z direction illustrated in FIGS. 1A and 1B is referred to as an up-down direction, a side on which the latch 22 of the housing 20 is provided is referred to as an upper side, and a side opposite thereto is referred to as a lower side. Moreover, a direction (X direction in FIGS. 1A and 1B ) orthogonal to both of the axial direction and the up-down direction is referred to as a width direction.
[0028] The ferrule 10 is attached to a forward end of an optical fiber (optical fiber wire or optical fiber wire with coating (not shown)). As illustrated in FIG. 2A , the ferrule 10 includes the capillary 11 , a capillary holding portion 12 , and a protective tube 13 . The capillary 11 is made of a material such as ceramics (zirconia, for example) or glass, and has a micropore 11 a which extends in the axial direction and through which the optical fiber is inserted (see FIG. 3A ). The capillary holding portion 12 is made of a metal material such as brass, and has an inner hole 12 a which extends in the axial direction and through which the optical fiber is inserted. On the forward end side of the inner hole 12 a , there is provided a fixation hole 12 a 1 having a diameter slightly larger than a diameter of the inner hole 12 a . The capillary 11 is press-fitted and fixed into the fixation hole 12 a 1 . A radial shoulder surface 12 a 2 is formed between the inner hole 12 a and the fixation hole 12 a 1 , and an axial gap is formed between the shoulder surface 12 a 2 and a proximal end 11 c of the capillary 11 (see FIG. 4 ).
[0029] A flange portion 12 b projecting to a radially outer side thereof is formed at the forward end of the capillary holding portion 12 . As illustrated in FIG. 4 , in the flange portion 12 b , there are formed a forward end surface 12 b 1 extending in a radial direction, a tapered surface 12 b 2 extending from the forward end surface 12 b 1 to the proximal end side to gradually increase in diameter to the proximal end side, and a larger-diameter outer peripheral surface 12 c extending from the tapered surface 12 b 2 to the proximal end side. On the proximal end side of the flange portion 12 b in an outer peripheral surface of the capillary holding portion 12 , a smaller-diameter outer peripheral surface 12 d is formed. The larger-diameter outer peripheral surface 12 c has a regular hexagonal cross-section in the radial direction (see FIG. 3C ), and the smaller-diameter outer peripheral surface 12 d has a cylindrical surface (see FIG. 3D ). A shoulder surface 12 e is formed between the larger-diameter outer peripheral surface 12 c and the smaller-diameter outer peripheral surface 12 d (see FIG. 4 ).
[0030] In the proximal end of the capillary holding portion 12 , there is provided a cylinder portion 12 f which includes a claw portion at its end and has a diameter still smaller than a diameter of the smaller-diameter outer peripheral surface 12 d (see FIG. 3A ). The cylinder portion 12 f projects to the proximal end side relative to a main body 21 of the housing 20 . The optical fiber (not shown) is inserted through an inner periphery of the cylinder portion 12 f , and the protective tube 13 is mounted so as to cover both of the outer peripheral surface of the cylinder portion 12 f and the outer peripheral surface of the optical fiber. The protective tube 13 is made of a material (fluororesin or rubber, for example) being elastic enough to be able to be mounted on the outer periphery of the cylinder portion 12 f . Further, the protective tube 13 may be made of a material having a heat shrinkage property and be formed into a so-called heat-shrinkable tube. By being caused to shrink by heating, the protective tube 13 may be brought into close contact with the cylinder portion 12 f and the optical fiber. The claw portion of the cylinder portion 12 f bites into an inner peripheral surface of the protective tube 13 , and thus the protective tube 13 is elastically deformed to the radially outer side thereof. As a result, the protective tube 13 and the claw portion are engaged with each other in the axial direction, and hence the protective tube 13 is regulated from slipping off.
[0031] The housing 20 is integrally die-molded (injection-molded, for example) of a resin material, etc. The housing 20 includes the main body 21 of a substantially rectangular parallelepiped, the latch 22 provided on one side surface (upper surface) of the main body 21 , and a cover portion 23 extending from the main body 21 to the proximal end side.
[0032] The main body 21 has a through-hole 30 formed to pass through the main body 21 in the axial direction. The ferrule 10 is held in an inner periphery of the through-hole 30 . The through-hole 30 is opened in a side surface (surface except for end surfaces on both sides in the axial direction) of the housing 20 . In the illustrated example, the through-hole 30 is opened in one side surface in the width direction of the main body 21 over an entire axial length thereof. Thus, the main body 21 is formed into a substantially C-shape in its front view (see FIGS. 2C and 2D ). Note that, except for a case where the through-hole 30 is opened in the side surface as in the illustrated example, the through-hole 30 may be opened in the other side surface in the width direction of the housing 20 or a side surface on the lower side of the housing 20 .
[0033] The through-hole 30 includes a larger-diameter hole 31 opened in the forward end surface of the main body 21 , and a holding hole 32 provided on the proximal end side of the larger-diameter hole 31 (see FIG. 3A ). The capillary 11 is placed in the inner periphery of the larger-diameter hole 31 , and the capillary holding portion 12 is held in the inner periphery of the holding hole 32 .
[0034] As illustrated in FIG. 4 , in the inner peripheral surface of the holding hole 32 , there are formed a partially-tapered inner surface 32 a gradually decreasing in diameter to the forward end side to be opened in one side surface in the width direction of the housing 20 , a partially-angled inner surface 32 b extending from the partially-tapered inner surface 32 a to the proximal end side to be opened in the one side surface in the width direction thereof (see FIG. 3C ), and reference surfaces 32 c extending upright from the partially-angled inner surface 32 b radially inward. The partially-tapered inner surface 32 a , the partially-angled inner surface 32 b , and the reference surfaces 32 c are die-molded integrally with the housing 20 . The partially-tapered inner surface 32 a and the partially-angled inner surface 32 b are opposed to the flange portion 12 b of the capillary holding portion 12 through a gap, and the reference surfaces 32 c are brought into contact with the proximal-end side surface 12 e (shoulder surface 12 e ) of the flange portion 12 b from the proximal end side. The reference surfaces 32 c are provided to end surfaces on the forward end side of protrusions 21 a projecting from two upper and lower positions in an inner surface of the holding hole 32 of the main body 21 .
[0035] As illustrated in FIG. 3D , at a deep side in the width direction (an opposite side to an opening side) of the holding hole 32 , which is formed between protrusions 21 a provided at the upper and lower positions, there is provided a partially-rounded inner surface 32 d for holding the smaller-diameter outer peripheral surface 12 d of the capillary holding portion 12 of the ferrule 10 . The partially-rounded inner surface 32 d is held in close contact with the smaller-diameter outer peripheral surface 12 d in a peripheral region M extending over more than half of a circumference of the smaller-diameter outer peripheral surface 12 d . Thus, the ferrule 10 is restrained in an entire radius direction. In the illustrated example, the partially-rounded inner surface 32 d is held in close contact with the smaller-diameter outer peripheral surface 12 d in an entire region on a deep side in the width direction with respect to an upper end and a lower end of the smaller-diameter outer peripheral surface 12 d and in a partial region on the opening side in the width direction with respect to the upper end and the lower end thereof. An inner diameter of the partially-rounded inner surface 32 d of the housing 20 before mounted with the ferrule 10 is slightly smaller than an inner diameter D of the smaller-diameter outer peripheral surface 12 d of the ferrule 10 , and is set to be slightly larger than a space S in the up-down direction between the protrusions 21 a . Therefore, the ferrule 10 is mounted to the partially-rounded inner surface 32 d of the holding hole 32 of the housing 20 while elastically deforming the housing 20 by pushing the smaller-diameter outer peripheral surface 12 d in between the upper and lower protrusions 21 a . Note that, a configuration of the partially-rounded inner surface 32 d is not limited to the above-mentioned one. For example, the inner diameter of the partially-rounded inner surface 32 d may be equal to the space S in the up-down direction between the upper and lower protrusions 21 a . In this case, through press-fitting the ferrule 10 to the partially-rounded inner surface 32 d while deforming the housing 20 , the partially-rounded inner surface 32 d can be held in close contact with the smaller-diameter outer peripheral surface 12 d of the ferrule 10 in the peripheral region extending over more than half of the circumference of the smaller-diameter outer peripheral surface 12 d.
[0036] The latch 22 extends obliquely upward from a forward-end side portion of the upper surface of the main body 21 to the proximal end side, and includes on its middle portion a locking surface 22 a facing the proximal end side. In a state in which the optical connector 1 is mounted to the optical adapter, the locking surface 22 a is engaged with the locking portion of the optical adapter in the axial direction, and thus the optical connector 1 is regulated from slipping off from the optical adapter. The latch 22 is pushed downward while being elastically deformed, and engagement between the locking surface 22 a and the locking portion of the optical adapter is released. Consequently, the optical connector 1 can be detached from the optical adapter.
[0037] In the optical connector 1 , in order to reliably bring the forward end of the ferrule 10 of the optical connector 1 on one part into contact with a ferrule of an optical connector on the other part connected thereto through the optical adapter, it is necessary to set a projecting amount of the capillary 11 with respect to the housing 20 within a range defined by a predetermined standard. Specifically, as illustrated in FIG. 2A , it is necessary to set an axial length L 1 between a forward end 11 b of the capillary 11 and the reference surfaces 32 c of the housing 20 , and an axial length L 2 between the reference surfaces 32 c and the locking surface 22 a . As in this embodiment, when the locking surface 22 a and the reference surfaces 32 c are die-molded integrally with the housing 20 , those surfaces can be finished with high dimensional accuracy. Thus, it is possible to set the projecting amount of the capillary 11 with respect to the housing 20 with good accuracy.
[0038] The cover portion 23 covers the outer periphery of the cylinder portion 12 f of the ferrule 10 projecting to the proximal end side relative to the main body 21 , and extends to the proximal end side beyond the proximal end of the cylinder portion 12 f . In the illustrated example, a pair of long plate-like members provided above and below the cylinder portion 12 f constitute the cover portion 23 . As in the illustrated example, the cylinder portion 12 f and a connecting portion connected to the optical fiber are covered with the protective tube 13 , and the cover portion 23 protects the connecting portion from above and below. Thus, it is possible to prevent a situation in which the optical fiber (not shown) is bent at an entrance portion (proximal end) of the cylinder portion 12 f when operating the latch 22 .
[0039] The optical connector 1 having the above-mentioned configuration is assembled as follows. First, an adhesive is applied to the inner periphery of the ferrule 10 mounted with the protective tube 13 , and the adhesive is cured after the optical fiber (not shown) is inserted through the inner periphery of the ferrule 10 applied with the adhesive. Consequently, the ferrule 10 and the optical fiber are integrated together. In this state, after eliminating a portion of the optical fiber sticking out of the forward end 11 b , the forward end 11 b of the capillary 11 is polished and finished with high accuracy. The ferrule 10 thus formed is inserted in the inner periphery of the through-hole 30 from the opening portion formed in the side surface of the main body 21 of the housing 20 . Specifically, while guided by cutout portions 21 a 1 provided at the ends on the opening side of the protrusions 21 a , the smaller-diameter outer peripheral surface 12 d of the capillary holding portion 12 of the ferrule 10 is pushed in between the pair of upper and lower protrusions 21 a provided on the inner peripheral surface of the through-hole 30 , and is press-fitted therebetween while elastically deforming the housing 20 and expanding the space between the protrusions 21 a . When the smaller-diameter outer peripheral surface 12 d reaches the partially-rounded inner surface 32 d located at the deep portion in the width direction, the housing 20 is elastically restored, and the partially-rounded inner surface 32 d is held in close contact with the smaller-diameter outer peripheral surface 12 d . Thus, the ferrule 10 is held by the housing 20 (see FIGS. 3B and 3D ). In this way, in order that the housing 20 is deformed within its elastic range when the ferrule 10 is mounted to the housing 20 , a diameter of the smaller-diameter outer peripheral surface 12 d of the ferrule 10 and the space between the upper and lower protrusions 21 a are appropriately set. As a result, the ferrule 10 is detachably attached to the housing 20 , and to easily perform a centering operation described below. Note that, the forward end 11 b of the capillary 11 may be polished not only before the ferrule 10 is mounted to the housing 20 as described above but also after the ferrule 10 is mounted to the housing 20 . However, in comparison with a case where the ferrule 10 is polished while being assembled to the housing 20 , a backlash during polishing and assembly tolerance between members are more likely to be suppressed and polishing with higher accuracy can be attained in a case where the ferrule 10 is polished alone as described above. Therefore, it is possible to finish the forward end 11 b with higher accuracy.
[0040] Then, the centering operation is performed. Specifically, in a state in which the ferrule 10 is mounted to the housing 20 , a fiber core is connected to an optical connector (not shown) being eccentric in a predetermined direction (upward direction, for example), and splice loss in connection is measured. Then, the ferrule 10 is detached from the housing 20 , and rotated by a predetermined angle (60°, for example). The ferrule 10 is re-mounted to the housing 20 , and the splice loss is measured. The above-mentioned operation is repeated. An eccentric direction of the fiber core of the optical connector 1 is considered to be most close to the predetermined direction (upward direction, for example) when the splice loss becomes lowest, and the ferrule 10 is mounted in this direction. With the above-mentioned operation, assembly of the optical connector 1 is completed. Note that, a centering method is not limited to the above-mentioned one. For example, centering may be performed after the splice loss is measured in the ferrule 10 alone and the eccentric direction of the fiber core is ascertained. Thereafter, the ferrule 10 may be mounted to the housing 20 .
[0041] As described above, in the optical connector of the present invention, the side surface of the housing 20 is opened, and hence the ferrule 10 can be mounted to the housing 20 with one-touch operation. The optical connector can be preferably used on a place where the optical connector is rarely subjected to external impact (in an inside of a module box, for example). On such place, it is less necessary to protect the optical fiber with a resin jacket or the like, and the optical connector can be used in a state in which the optical fiber is exposed. As a matter of course, there may be used a so-called optical cable in which the optical fiber is protected with the resin jacket or the like and a reinforcing fiber is interposed between the resin jacket and the optical fiber.
[0042] The present invention is not limited to the above-mentioned embodiment. For example, in the above-mentioned embodiment, as illustrated in FIG. 4 , though the gap is formed between the partially-tapered inner surface 32 a of the holding hole 32 of the housing 20 and the tapered surface 12 b 2 of the ferrule 10 , those surfaces may be brought into contact with each other (not shown). In this case, in a state in which the reference surfaces 32 c are elastically deformed, the ferrule 10 is brought into contact with the housing 20 from the proximal end side of the flange portion 12 b , and the flange portion 12 b is sandwiched between the partially-tapered inner surface 32 a and the reference surfaces 32 c of the housing 20 from the both sides in the axial direction. As a result, the ferrule 10 can be reliably held by the housing 20 .
REFERENCE SIGNS LIST
[0000]
1 optical connector
10 ferrule
11 capillary
12 capillary holding portion
12 b flange portion
13 protective tube
20 housing
21 main body
21 a protrusion
22 latch
22 a locking surface
23 cover portion
30 through-hole
31 larger-diameter hole
32 holding hole
32 a partially-tapered inner surface
32 b partially-angled inner surface
32 c reference surface
32 d partially-rounded inner surface
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Provided is an optical connector in which a through-hole of a housing is opened in a side surface of the housing and a ferrule can be mounted to the housing from an opening portion formed in the side surface of the housing. Thus, it is unnecessary to constitute the housing by a plurality of components. Consequently, reduction in the numbers of components and assembly steps and reduction in cost can be achieved.
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FIELD OF THE INVENTION
The present invention relates to a method and apparatus for the destruction of the inner lining of body organs, and, more particularly, to a method and apparatus for the selective destruction of the endometrium.
BACKGROUND OF THE INVENTION
In certain circumstances it may be advantageous to destroy one or more layers of the inner lining of various body organs. Such destruction may be advantageous in the treatment or prevention of certain diseases or other physical conditions. In particular, dysfunctional uterine bleeding (DUB) which can be a problem for many women, and particularly for postmenopausal women. Various methods and apparatus have been used to destroy layers of living tissue without damaging the underlying layers. Some of the apparatus include devices for heating the layer to be destroyed using, for example, radio frequency energy and microwave energy. Alternatively, other thermal techniques for destroying the inner lining of various body organs include chemical treatments, cryotherapy, laser therapy and electrosurgery.
U.S. Pat. No. 5,277,201 describes a method and apparatus for endometrial ablation utilizing an electrically conductive balloon adapted to supply Monopolar RF energy to the endometrial layer when the balloon is expanded within the body organ. U.S. Pat. No. 5,277,201 further illustrates a balloon device for use in endometrial ablation wherein the balloon surface includes a plurality of selectively excitable RF electrodes along with a plurality of selectable temperature sensors adapted to measure the temperature of the endometrium during the ablation process. U.S. Pat. No. 4,979,948 describes thermal ablation of the mucosal layer of a gallbladder by resistive heating with an RF balloon electrode. Electric current is delivered via a conductive expansion liquid which fills the balloon. Balloon catheters supplied with a heated fluid have also been used for thermal ablation of hollow body organs as described in U.S. Pat. No. 5,045,056. Application of microwave and high frequency RF energy to destroy tissue, using electrodes enclosed in expanded balloons have been described in, for example, U.S. Pat. Nos. 4,662,383 and 4,676,258.
SUMMARY OF THE INVENTION
According to the present invention, an apparatus for heating tissue in the interior of a body organ, for example the uterus, comprises an expandable element adapted to fit within the body organ wherein the expandable element is covered with a web of optically conductive material arranged to conduct light to the interior surface of the body organ. In this embodiment, the expandable element may include a reflective surface which reflects light from the optically conductive material to the interior surface of the body organ.
In one embodiment of the present invention, the web of optically conductive material may be, for example, a web of optical fibers connected to one or more light sources, for example high intensity lamps or lasers, which generate the light energy transmitted by the optically conductive material. In a further embodiment of the present invention, temperature detection devices, for example thermocouples, are attached to the expandable element to measure the temperature of the lining of the body organ as it is being heated by the light energy transmitted by the optically conductive material.
The present invention further includes a method of selectively heating the lining of a body organ utilizing the apparatus of the present invention including the steps of inflating the expandable element to fit within the body organ, heating the interior surface of the body organ by passing light energy from the light source through the optically conductive material to the lining. In addition, a method according to the present invention may include the step of measuring the temperature of the lining and selectively turning the light sources on and off to control the temperature of the lining.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features of the invention are set forth with particularity in the appended claims. The invention itself, however, both as to organization and methods of operation, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in conjunction with the accompanying drawings in which:
FIG. 1 illustrates an optical ablation system according to the present invention including an ablation instrument and an electro-optic generator.
FIG. 2 is a cross sectional view of the ablation instrument illustrated in FIG. 1 along view line 2--2.
FIG. 3. illustrates an optical ablation system according to the present invention including an ablation instrument and an alternative embodiment of an electro-optic generator.
FIG. 4 is a cutaway view of a cross section of an expandable diffusing web according to the present invention.
FIG. 5 is a cutaway side view of the distal end of the ablation instrument according to the present invention prior to deployment of the expandable diffusing web.
FIG. 6 is a cutaway side view if the distal end of the ablation instrument according to the present invention after deployment of the expandable diffusing web.
FIG. 7 is a side view of a balloon for use in the present invention.
FIG. 8 is a side view of the distal end of the ablation instrument according to present invention illustrating a first optical fiber mesh with a first thermocouple.
FIG. 9 is a side view of the distal end of an ablation instrument according to the present invention illustrating first and second heating element segments including first and second thermocouples.
FIG. 10 is a side view of the distal end of an ablation instrument according to the present invention illustrating first, second and third heating element segments including first, second and third thermocouples.
FIG. 11 is a flow diagram illustrating one embodiment of the control flow for the electro-optic circuitry for an ablation instrument according to the present invention.
FIG. 12 is a flow diagram illustrating one embodiment of the control flow for the electro-optic circuitry for an ablation instrument according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates an optical ablation system 15 according to the present invention including an ablation instrument 10 and an electro-optic generator 11. In FIG. 1, Optical Energy in the form of light is supplied to ablation instrument 10 by electro-optical generator 11. As used herein, the term "optical" is intended to include that portion of the electromagnetic spectrum including radiation in the ultraviolet, visible and infrared wavelengths. Electro-optical generator 11 includes an optical energy source 12, one or more energy coupling devices 14, one or more optical filters 16, one or more variable attenuators 18 which may also comprise a variable neutral density filter, one or more fiber optic bundles 20, one or more thermocouple inputs 24 and control circuitry 22. Optical energy source 12 may be, for example, a laser, a halogen lamp, a conventional incandescent lamp or other optical energy source. Optical energy source 12 may be a single source which provides light which is white or spectrally pure at a specific wavelength. Alternatively, Optical energy source 12 may include a plurality of light sources having any combination of wavelengths and power levels. Optical energy source 12 is coupled to fiber optic bundle 20 by energy coupling lens 14, optical filter 16 and variable attenuator 18.
Energy coupling lens 14 focuses optical energy from optical energy source 12 through optical filter 16 and variable attenuator 18 onto the proximal end of fiber optic bundle 20. The intensity and/or wavelength of optical energy source 12 may be controlled by, for example, signals from control circuit 22 transmitted through control line 72. Optical filter 16 may be a single frequency filter adapted to filter out all but one of the wavelengths generated by optical energy source 12. Alternatively, Optical filter 16 may be a plurality of selectable filters from which a filter effective at one or more wavelengths may be chosen to selectively filter optical energy generated by optical energy source 12. Optical filter 16 may also be a spectral filter adapted to pass energy within a band of wavelengths. Optical filter 16 may also be a filter wheel which contains a number of band pass filters. The wavelength of light filtered by optical filter 16 may be controlled by, for example, signals from control circuit 22 transmitted through control line(s) 70. After passing through optical filter 16, energy from optical energy source 12 passes through variable attenuator 18. Variable attenuator 18 may also be referred to as a variable neutral density filter. Variable attenuator 18 is adapted to control the energy level of the light which is focused on to the proximal end of fiber optic bundle 20. The setting of variable attenuator 18 may be controlled by, for example, signals from control circuit 22 transmitted through control line(s) 74. The energy passed by variable attenuator 18 may be controlled by signals from control circuit 22 to ensure that the appropriate energy level is input to the proximal end of fiber optic bundle 20.
Energy coupling lens 14 may include a plurality of energy coupling lenses, for example the three energy coupling lenses 14a, 14b and 14c illustrated in FIG. 1. Optical filter 16 may include a plurality of optical filters, for example, the three optical filters 16a, 16b and 16c illustrated in FIG. 1. Variable attenuator 18 may include a plurality of variable attenuators, for example, the three variable attenuators 18a, 18b and 18c illustrated in FIG. 1. In addition, fiber optic bundle 20 may include a plurality of fiber optic bundles, for example, the three fiber optic bundles illustrated in FIG. 1. The number of energy coupling lenses, optical filters, variable attenuators and fiber optic bundles will depend upon the design of the ablation system 15, however, the number of coupling lenses, optical filters, variable attenuators and fiber optic bundles will generally correspond to the number of regions the ablation instrument is designed to separately heat within the body cavity being treated.
Electro-optic generator 22 includes temperature signal wires 24 which are adapted to relay signals representative of the temperature at selected points at the distal end of ablation instrument 10 to control circuit 22. The number of temperature signal wires 24 will depend upon the design of ablation system 15, however, the number of thermocouple inputs will generally correspond to a multiple of the number of regions the ablation instrument is designed to separately heat. In the embodiment of the ablation instrument illustrated in FIG. 1, the electro-optic generator includes three temperature signal wires 24a, 24b and 24c. In one embodiment of the present invention, temperature signal wires 24 comprise a pair of wires which are connected through ablation instrument 10 to a thermocouple at a distal end of the ablation instrument.
Fiber optic bundles 20 and temperature signal wires 24 terminate at generator connector 19 which is adapted to mate with instrument connector 26. In FIG. 1, instrument connector 26 is shown in cutaway view to show fiber optic bundles 21a, 21b and 21c and to show thermocouple inputs 25a, 25b and 25c which are positioned within instrument connector 26 and flexible sleeve 27. Fiber optic bundles 20 exit electro-optic generator 11 at generator connector 19 where each fiber optic bundle 20a, 20b and 20c is butt-coupled to a corresponding fiber optic bundle 21a, 21b and 21c such that optical energy is transmitted from fiber optic bundles 20a, 20b and 20c to fiber optic bundles 21a, 21b and 21c, respectively. Temperature signal wires 24 also exit electro-optic generator 11 at generator connector 19 where temperature signal wires 24a, 24b and 24c are connected to temperature signal wires 25a, 25b and 25c, respectively. Fiber optic bundles 21 and temperature signal wires 25 pass through flexible sleeve 27 to instrument handle 28 and through instrument handle 28 to rigid sleeve 34.
Instrument handle 28 includes connector 35, fluid source connector 29, sleeve retractor 32, sleeve retractor stop 33 and fluid line 36. Flexible sleeve 27, terminates at connector 35 while fiber optic bundles 21 and temperature signal wires 25 pass through connector support 27 and the central portion of instrument handle 28 to the central annulus of rigid sleeve 34. Fluid source connector 29, which is adapted to receive a fluid source such as, for example, syringe 30, is connected to fluid line 36. In the embodiment of FIG. 1, syringe 30 includes plunger 31 which is adapted to force fluid, for example air, through fluid line 36. Fluid line 36 extends from fluid source connector 29 to the annulus of rigid sleeve 34.
In instrument handle 28 as illustrated in FIG. 1, sleeve retractor 32 is connected to sleeve collar 37 which is connected to rigid sleeve 34 such that rigid sleeve 34 may be retracted in the proximal direction by moving sleeve retractor 32 in the proximal direction. The travel of sleeve retractor 32 is limited by sleeve retractor stop 33, thus limiting the proximal travel of rigid sleeve 34. As rigid sleeve 34 is retracted, expandable sleeve tip 40 at the distal end of rigid sleeve 34 opens, releasing the balloon or other device positioned in the central annulus of rigid sleeve 34 at the distal end of sleeve 34.
FIG. 2 is a cross sectional view of the ablation instrument illustrated in FIG. 1 along view line 2--2. In FIG. 2, fluid line 36 is surrounded by fiber optic bundles 21a, 21b and 21c and by temperature signal wires 25a, 25b and 25c. As illustrated in FIG. 2, fiber optic bundles 21a, 21b and 21c each include one or more fiber optic fibers 38 which are adapted to transmit optical energy. Temperature signal wires 25 are adapted to transmit signals representative of temperature. Fluid line 36 is adapted to transmit fluid such as, for example, air.
FIG. 3 illustrates an optical ablation system according to the present invention including an ablation instrument and an alternative embodiment of an electro-optic generator. In the embodiment of electro-optic generator 11 illustrated in FIG. 3, optical energy source 12 of FIG. 1 is divided into a plurality of controllable optical energy sources 12a, 12b and 12c. In one embodiment of the present invention, the intensity of optical energy sources 12 is controllable and the energy from optical energy sources 12a, 12b and 12c is controlled by energy control signals from control circuit 22 which are transmitted through, for example, control lines 72. Each of energy sources 12a, 12b and 12c pass optical energy through energy coupling lenses 14a, 14b and 14c respectively. Energy coupling lenses 14a, 14b and 14c focus optical energy on fiber optic bundles 20a, 20b and 20c through optical filters 16a, 16b and 16c respectively. In one embodiment of the present invention, optical filters 16 may include a plurality of selectable optical filters which may be selected by filter selection signals from control circuit 22 which are transmitted through, for example, control lines 70. The number of energy coupling lenses, optical filters and fiber optic bundles will depend upon the design of ablation system 15, however, the number of coupling lenses, optical filters and fiber optic bundles will generally correspond to the number of regions the ablation instrument is designed to separately heat within the body cavity being treated. In all other respects, the ablation system 15 illustrated in FIG. 3 is substantially identical to the ablation system 15 illustrated in FIG. 1.
FIG. 4 is a cutaway view of a cross section of an expandable diffusing web 46 according to the present invention. In FIG. 3 expandable defusing web 46 includes reflective coating 42, balloon 44, optical fiber mesh 47 and an adhesive layer 50 for attaching the fiber optic mesh to the balloon. Reflective coating 42 may be, for example, a coating of silver or other reflective material which covers the outer surface of Balloon 44. Balloon 44 may be constructed of, for example, mylar or other expandable balloon material. Optical fiber mesh 47 may include optical fibers 48, reflective fiber terminator 52 and fill threads 49. Fill threads 49 may be solid as illustrated in FIG. 4. Alternatively, fill threads 49 may be made of an optically conductive material. Optical fiber mesh 47 may be, for example, a light emitting woven light emitting panel which is manufactured by Ploy-Optic or by Lumitex. Reflective fiber terminator 52 is located at the end of optical fiber 48 to reflect any optical energy which reaches the end of optical fiber 48 without being diffused.
FIG. 5 is a cutaway side view of the distal end of ablation instrument 10 according to the present invention prior to deployment of expandable diffusing web 46. In FIG. 5, the distal end of rigid sleeve 34, including expandable diffusing web 46 is disposed within uterus 56. Expandable diffusing web 46 is folded to fit within rigid sleeve 34. The interior of uterus 56 is covered by an endometrial layer 58. As rigid sleeve 34 is withdrawn, by, for example moving sleeve retractor 32, expandable diffusing web 46 forces expandable sleeve tip 40 open, exposing expandable diffusing web 46. Fluid line 36 is connected to the proximal end of expandable diffusing web 46 such that a fluid, such as air, supplied at fluid source connector 29 fills the interior of expandable diffusing web 46, forcing expandable diffusing web 46 to expand.
FIG. 6 is a cutaway side view if the distal end of ablation instrument 10 according to the present invention after deployment of expandable diffusing web 46. In FIG. 6, rigid sleeve 34 has been retracted, exposing expandable diffusing web 46. Expandable diffusing web 46, which includes balloon 44 and optical fiber mesh 47 is expanded to fit against endometrial lining 58 of uterus 56 by filling balloon interior 60 with a fluid such as air. Fluid line 46 connects balloon interior 60 to fluid source connector 29.
FIG. 7 is a side view of a balloon 44 for use in the present invention. It will be recognized that balloon 44 may be shaped to fit within any body cavity, however, in the embodiment of the invention described herein, expandable diffusing web 46 is designed to be used within the uterus to destroy the endometrial lining. Thus, balloon 44 illustrated in FIG. 7 is shaped to fit within the uterus and to hold the optical fiber mesh firmly against at least a substantial portion of the endometrial lining. Nor is it necessary that the invention be limited to the use of a balloon as an expandable element since any means of expanding expandable diffusing web 46 to position optical fiber mesh near or adjacent the interior lining (e.g. the endometrium) of the body cavity to be treated is within the scope of the present invention. In FIG. 7, balloon 44 has been expand ed by filling interior 60 with an appropriate fluid, such as air, and the expanded balloon 44 takes on the shape of the interior of a uterus.
FIG. 8 is a side view of the distal end of ablation instrument 10 according to the present invention illustrating a portion of expandable diffusing web 46 which includes a first optical fiber mesh 47a. The embodiment of the invention illustrated in FIG. 8 further includes a first thermocouple 62a. In FIG. 8, optical fiber mesh 47a is disposed on the distal end of balloon 44. In FIG. 8, optical fiber mesh 47a includes optical fibers 48a which are interwoven with fill threads 49a. At their proximal end, optical fibers 48a of optical fiber mesh 47a are connected to the distal end of one of fiber optic bundles 21 which extend through rigid sleeve 34, alternatively, optical fibers 48a of optical fiber mesh 47a may be a continuation of one of the optic fiber bundles 21. For example, the proximal ends of fiber optics 48a may be gathered together to form an optical fiber bundle 51a which is connected to, for example, the distal end of fiber optic bundle 21a using, for example a butt-connector such as the one used to connect fiber optic bundle 20a with fiber optic bundle 21a, alternatively, fiber bundle 51a may be a continuation of the distal end of fiber optic bundle 21a. Fiber optic bundle 21a is joined to or disperses to form optical fibers 48a such that optical energy is passed from fiber optic bundle 21a to optical fibers 48a, thus optical energy generated at optical energy source 12 may be transmitted through fiber optic bundle 20a to fiber optic bundle 21a and through fiber optic bundle 21a to optical fibers 48a of optical fiber mesh 47a. Thermocouple 62a is positioned to detect the temperature of tissue adjacent optical fiber mesh 47a. Temperature signal wires 25a, being connected to thermocouple 62a, relay a signal representative of the temperature at thermocouple 62a to temperature signal wires 24a which, in turn relay the signal to control circuit 22. Optical fiber mesh 47a, being positioned on balloon 44, is held in place against the tissue to be treated by the expansion of balloon 44 as a result of the fluid supplied through fluid line 36.
FIG. 9 is a side view of the distal end of ablation instrument 10 according to the present invention illustrating a portion of expandable diffusing web 46 which includes a first optical fiber mesh 47a and a second optical fiber mesh 47b. The embodiment of the invention illustrated in FIG. 9 further includes a first thermocouple 62a and a second thermocouple 62b. In FIG. 9, a second optical fiber mesh 47b has been wrapped around the distal end of the balloon illustrated in FIG. 8 to increase the surface area of balloon 44 covered by optical fiber mesh 47. Thus, the previous description of the instrument with respect to FIG. 8 is applicable with respect to like elements of FIG. 9. In addition to the elements described with respect to FIG. 8, FIG. 9 illustrates optical fiber mesh 47b which includes optical fibers 48b which are interwoven with fill threads 49b. At their proximal end, optical fibers 48b of optical fiber mesh 47b are connected to the distal end of one of fiber optic bundles 21 which extend through rigid sleeve 34. For example, the proximal ends of fiber optics 48b may be gathered together to form an optical fiber bundle 51b which is connected to, for example, the distal end of fiber optic bundle 21b using, for example, a butt-connector such as the one used to connect fiber optic bundle 20b with fiber optic bundle 21b, alternatively, fiber bundle 51b may be a continuation of the distal end of fiber optic bundle 21b. Fiber optic bundle 21b is joined to optical fibers 48b such that optical energy is passed from fiber optic bundle 21b to optical fibers 48b, thus optical energy generated at optical energy source 12 may be transmitted through fiber optic bundle 20b to fiber optic bundle 21b and through fiber optic bundle 21b to optical fibers 48b of optical fiber mesh 47b. Thermocouple 62b is positioned on balloon 44 to detect the temperature of tissue adjacent optical fiber mesh 47b. Temperature signal wires 25b, being connected to thermocouple 62b, relay a signal representative of the temperature at thermocouple 62b to temperature signal wires 24b which, in turn, relay the signal to control circuit 22. Optical fiber mesh 47b, being positioned on balloon 44, is held in place against the tissue to be treated by the expansion of balloon 44 as a result of the fluid supplied through fluid line 36.
FIG. 10 is a side view of the distal end of ablation instrument 10 according to the present invention illustrating a portion of expandable diffusing web 46 which includes a first and optical fiber mesh 47a, a second optical fiber mesh 47b and a third optical fiber mesh 47c. The embodiment of the invention illustrated in FIG. 10 further includes a first thermocouple 62a, a second thermocouple 62b and a third thermocouple 62c. In FIG. 10, a third optical fiber mesh 47c has been wrapped around the distal end of the balloon illustrated in FIG. 8 and FIG. 9 to increase the surface area of balloon 44 covered by optical fiber mesh 47. Thus, the previous description of the instrument with respect to FIG. 8 and FIG. 9 is applicable with respect to like elements of FIG. 10. In addition to the elements described with respect to FIG. 8 and FIG. 9, FIG. 10 illustrates an optical fiber mesh 47c which includes optical fibers 48c which are interwoven with fill threads 49c. At their proximal end, optical fibers 48c of optical fiber mesh 47c are connected to the distal end of one of fiber optic bundles 21 which extend through rigid sleeve 34. For example, the proximal ends of fiber optics 48c may be gathered together to form an optical fiber bundle 51c which is connected to, for example, the distal end of fiber optic bundle 21c using, for example, a butt-connector such as the one used to connect fiber optic bundle 20c with fiber optic bundle 21c, alternatively fiber bundle 51c may be a continuation of the distal end of fiber optic bundle 21c. Fiber optic bundle 21c is joined to optical fibers 48c such that optical energy is passed from fiber optic bundle 21c to optical fibers 48c, thus optical energy generated at optical energy source 12 may be transmitted through fiber optic bundle 20c to fiber optic bundle 21c and through fiber optic bundle 21c to optical fibers 48c of optical fiber mesh 47c. Thermocouple 62c is positioned on balloon 44 to detect the temperature of tissue adjacent optical fiber mesh 47c. Temperature signal wires 25c, being connected to thermocouple 62c, relay a signal representative of the temperature at thermocouple 62c to temperature signal wires 24c which, in turn, relay the signal to control circuit 22. Optical fiber mesh 47c, being positioned on balloon 44, is held in place against the tissue to be treated by the expansion of balloon 44 as a result of the fluid supplied through fluid line 36.
The embodiment of the invention illustrated in FIG. 1 is adapted to controllably heat three separate regions within the uterus of a human patient to selectively destroy the endometrial layer within those regions. The energy and depth of penetration of the optical energy may be controlled by controlling the energy level and wavelength of the energy transmitted to the proximal end of each fiber optic bundle 20a, 20b and 20c. Longer wavelengths penetrate deeper into tissue. Shorter wavelengths, for example, blues and greens, may be used to achieve surface heating. Thus, depending on the effect that is desired, different wavelength of optical energy may be selected. Optical energy is transmitted through optical bundles 20 to optical bundles 21 and optical bundles 51. Optical energy which passes through optical bundles 51 is diffused by optical fiber mesh 47 of expandable diffusing web 46. Reflective coating 42 acts to reflect optical energy away from balloon 44 and into tissue surrounding expandable diffusing web 46. The depth of penetration of the optical energy into surrounding tissue will be a function of a number of factors, including the wavelength of the optical energy radiated by expandable diffusion web 46 and the distance from the expandable diffusion web 46 to the tissue to be treated. The rate at which the tissue is heated will also depend upon a number of factors, including the output energy generated by optical energy source 12, the losses in electro-optic generator 11 and ablation instrument 10, the distance from the expandable diffusion web 46 to the tissue to be treated and the wavelength of the optical energy. However, by monitoring the tissue as it is treated using, for example, thermocouples 62, the surgeon may control the temperature of the tissue being treated with relative accuracy.
In use a surgeon will introduce the distal end of ablation instrument 10 into the body cavity of a patient such that expandable sleeve tip 40 is positioned at a predetermined depth within the body cavity. For the purposes of this discussion, the body cavity to be treated will be the uterus of a female human being. It will be recognized that, with slight modification, the present invention may be used to treat other body cavities. Once sleeve tip 40 is inserted into the uterus 56 as illustrated in FIG. 5, sleeve retractor 32 may be used to slide rigid sleeve 34 back away from expandable diffusing web 46. As rigid sleeve 34 is retracted, expandable diffusing web 46 forces expandable sleeve tip 40 open. Once sleeve retractor 32 reaches its proximal most travel point it is stopped by sleeve retractor stop 33 which prevents rigid sleeve 34 from retracting further. Once rigid sleeve 34 is retracted, expandable diffusing web 34 may be expanded to contact the interior of the uterus by, for example inflating balloon 44 by injecting an appropriate fluid, such as, for example air into balloon interior 60. Fluid is introduced into balloon 44 through fluid line 36 which is connected to fluid source connector 29 which, in the embodiment illustrated in FIG. 1, is connected to a syringe and plunger which may be used to inflate or deflate balloon 44. Expandable diffusing web 46, being shaped to fit the body cavity, e.g. the uterus, being treated, is designed to force optical fiber mesh 47 against a substantial portion of the interior surface of the body cavity. Thus, when expandable diffusing web 46 is fully expanded, optical fiber mesh 47 is positioned directly adjacent or in direct contact with endometrium 58 of uterus 56.
Once expandable diffusing web 46 is positioned within uterus 56, optical energy may be supplied to optical fiber mesh 47 by turning on optical energy source 12. Once optical energy source 12 is turned on, the light radiated by optical energy source 12 is focused on the proximal end of optical fiber bundle 20 by energy coupling lens 14. As optical energy passes through optical filter 16, it is filtered to remove unwanted wavelengths. As optical energy passes through variable attenuator 18 the energy level is attenuated. Therefore, the optical energy focused upon fiber optic bundle 20 is filtered and attenuated such that it is optical energy of a selected wavelength and energy level. Optical energy focused upon the proximal end of fiber optic bundle 20 is transmitted through fiber optic bundle 20 to fiber optic bundle 21 and from fiber optic bundle 21 to expandable diffusing web 46 where it is radiated into the endometrial layer from optical fiber mesh 47. Where different optical energy levels or wavelengths are to be transmitted to different regions of the endometrium, a plurality of energy coupling lenses 14a-14c, optical filters 16a-16c and variable attenuators 18a-18c may be used to focus filtered optical energy onto a plurality of fiber optic bundles 20a-20c as illustrated in FIG. 1. Alternatively, where different optical energy levels or wavelengths are to be transmitted to different regions of the endometrium, a plurality of optical energy sources 12a-12c, energy coupling lenses 14a-14c and optical filters 16a-16c may be used to focus filtered optical energy onto a plurality of fiber optic bundles 20a-20c as illustrated in FIG. 2. The optical energy focused on optical bundles 20a-20c may then be transmitted through optical fiber bundles 21a-21c to each optical fiber mesh 47a-47c.
Once the optical energy reaches expandable diffusing web 46, it is radiated by optical fibers 48 which are woven with fill threads 49 to form optical fiber mesh 47. Radiation from optical fibers 48 which is not directed into the tissue adjacent optical fiber mesh 47 is reflected by reflective coating 42 as illustrated in FIG. 4. Thus, both the energy radiated toward the tissue and the reflected energy is absorbed by the tissue adjacent to fiber optic mesh 47. Further, since the energy is transmitted optically, it is not necessary for the tissue to be directly adjacent fiber optic mesh 47 as the radiated energy will be absorbed by any tissue illuminated by the energy from the mesh. This arrangement provides for uniform escape or emission of energy focused on the fiber optic bundles 20 in fiber optic generator 11. Further, in an arrangement according to the present invention, energy is evenly radiated from the outside of the expandable diffusing web, and is, therefore absorbed by the endometrial lining of the uterus causing temperature of the tissue to rise.
The control sequence for control circuit 22 of the electro-optic generator illustrated in FIG. 1 is illustrated in FIG. 11. Once expandable diffusing web 46 has been positioned and inflated as described previously, optical energy may be supplied to expandable web 46 to heat endometrial lining 58. The first step in supplying optical energy to endometrial lining 58 is to select an appropriate wavelength. In particular, red and near infrared wavelengths would be selected for heating deep (e.g. 0-10 millimeters) into uterine tissue. Ultraviolet, blue or green wavelengths would be used for heating uterine tissue to a depth of, for example, (0-3 millimeters). Once the appropriate optical energy wavelength has been selected by, for example, adjustment of optical filter 16 or by appropriate selection of optical energy source 12, optical energy may be supplied to expandable web 46. The energy level or intensity of the optical energy supplied to expandable web 46 may be controlled by controlling the attenuation of variable attenuators 18 or by controlling the intensity of optical energy source 12. Temperature feedback from thermocouple 62 may be used to adjust the energy level supplied to fiber optic bundles 20. Thus, the temperature of the body lining being treated is controlled by controlling the energy level supplied to expandable web 18 while the depth of penetration of the energy supplied to expandable web 46 is controlled by controlling the wavelength of the optical energy supplied to fiber optic bundles 20.
The flow diagram of FIG. 11 illustrates the control sequence for the electro-optic generator illustrated in FIG. 1. The temperature of endometrial lining 58 is sensed by, for example, thermocouple 62 which provides a signal to control circuit 22 through temperature signal wires 24 and 25. As illustrated in FIG. 11, control circuit 22, in step 67, senses the temperature at thermocouple 62 and produces a signal 100 which is representative of the temperature measured at thermocouple 62. In step 68, signal 100 is compared to a predetermined set point temperature such as, for example, any temperature between 42° C. and 100° C. for a time sufficient to destroy the inner lining of the organ in question. If the temperature represented by signal 100 is lower than the set point temperature, control circuit 22 generates a signal 103. In step 71, signal 103 causes control circuit 22 to decrease the attenuation of the optical energy focused on optical fiber bundle 20, thus increasing the optical energy supplied to expandable web 46. Once the attenuation has been reduced, control circuit 22 generates a signal 105 which causes control circuit 22 to return to step 67 where the temperature is measured again and a new signal 100 is generated. Once the temperature represented by signal 100 reaches the set point temperature control circuit 22, in step 69, generates a signal 106 which is representative of the time the endometrium has been at the desired temperature. The time represented by signal 106 is compared, in step 72 to a predetermined set time and if the time represented by signal 106 is less than the predetermined set time, control circuit 22 generates signal 107 which returns control circuit 22 to step 67. If during the control cycle, the signal 100 rises above the set point temperature, then signal 102 is generated, causing control circuit 22 to increase attenuation at variable attenuators 18, thus decreasing the optical energy delivered to expandable diffusing web 46. Once the actual time at the desired temperature, represented by signal 106, reaches the predetermined set time in step 72, signal 108 is generated indicating, in step 73, that the procedure is complete and generating signal 109 which turns off optical energy source 12 in step 74.
The flow diagram of FIG. 12 illustrates the control sequence for the electro-optic generator illustrated in FIG. 2. The temperature of endometrial lining 58 is sensed by, for example, thermocouple 62 which provides a signal to control circuit 22 through temperature signal wires 24 and 25. As illustrated in FIG. 12, control circuit 22, in step 80, senses the temperature at thermocouple 62 and produces a signal 200 which is representative of the temperature measured at thermocouple 62. In step 81, signal 200 is compared to a predetermined set point temperature. If the temperature represented by signal 200 is lower than the set point temperature, control circuit 22 generates a signal 203. In step 84, signal 203 causes control circuit 22 to increase the optical energy from optical energy source 12 which increases the intensity of the optical energy focused on optical fiber bundle 20, thus increasing the optical energy supplied to expandable web 46. Once optical energy has been increased, control circuit 22 generates a signal 205 which causes control circuit 22 to return to step 80 where the temperature is measured again and a new signal 200 is generated. Once the temperature represented by signal 200 reaches the set point, temperature control circuit 22, in step 82, generates a signal 206 which is representative of the time the endometrium has been at the desired temperature. The time represented by signal 206 is compared, in step 85 to a predetermined set time and, if the time represented by signal 206 is less than the predetermined set time, control circuit 22 generates signal 207 which returns control circuit 22 to step 80. If during the control cycle, the signal 200 rises above the set point temperature, then signal 202 is generated, causing control circuit 22 to decrease the optical energy from optical energy source 12, which decreases the intensity of the optical energy focused on optical fiber 20, decreasing the energy delivered to expandable diffusing web 46. Once the actual time at the desired temperature, represented by signal 206, reaches the predetermined set time in step 85, signal 208 is generated indicating, in step 86, that the procedure is complete and generating signal 209 which turns off optical energy source 12 in step 87.
In operation, ablation instrument 10 would be connected to electro-optic generator 11 and the distal end of instrument 10 would be inserted into the appropriate body organ, for example, into the uterus 56. Rigid sleeve 34 would then be retracted using sleeve retractor 32, thereby exposing expandable diffusing web 46 which includes balloon 44. Balloon 44 is inflated using, for example, balloon inflator syringe 30 which includes plunger 30. Once balloon 44 is inflated forcing expandable diffusing web 46 to conform to the interior of uterus 56, electro-optic generator 11 is activated, thus delivering optical energy to optical fibers 48 of optical fiber mesh 47 on expandable diffusing web 46. Control circuit 22 is then used to monitor the heating of endometrial layer 58 of uterus 56 through thermocouple(s) 62. Control circuit 22 acts to bring endometrial layer 58 up to a desired temperature, hold endometrial layer 58 at that temperature for a predetermined length of time and then turn off optical energy to the endometrial layer. Expandable diffusing web 46 may then be collapsed by deflating balloon 44 using, for example syringe 30. Once expandable diffusing web 46 is deflated, it may be retracted from uterus 56.
Use of an ablation instrument according to the present invention may be advantageous, when compared to electrosurgical or other apparatus for use in endometrial ablation, for example: Light energy may be less likely to interfere with the operation of the thermocouples; a light diffusing fiber-optic web may be more adaptable to expansion than RF electrodes; contact with the uterine wall is not required as it may be in an RF device; it is possible to control the depth of heating by controlling the wavelength of the optical energy applied to the endometrial lining.
According to one embodiment of the present invention, light energy from optical energy source 12, which may be, for example, common projection lamps, may be used to uniformly heat the endometrium 58° to 70° C. and thereby ablate the endometrium. The array of fiber-optic mesh or webs 47 are connected individually to an array of high intensity lamps 12 via fiber-optic cables 20 and 21. Fiber optic mesh 47 may Heating of the endometrium 58 is achieved through absorption of the optical radiation transmitted through fiber optic cables 20 and 21. The temperature of each fiber optic web, for example fiber optic webs 47a-47c, is monitored by a thermocouple, for example 62a-62c, which, through a feedback loop including temperature signal wires 24 and 25 which are connected to control circuitry 22, controls the intensity of its associated lamp 12. In this embodiment, fiber-optic mesh 47 and thermocouples 62 cover the outside of an inflatable silvered mylar pouch or balloon 44. Balloon 44 is inserted into the uterus and then inflated. Inflation brings fiber-optic webs 47 and thermocouples 62 into contact with the endometrium or endometrial layer 58. Lamps 12 are then turned on and the temperature of the endometrium is monitored intensity of the optical energy supplied to fiber optic webs 47 is controlled by monitoring feedback from thermocouples 62 until therapy is complete. The silvered surface of mylar balloon 44 directs all the optical radiation into the endometrium for heating.
While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims.
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A method of performing endometrial ablation comprising heating entire surface of the endometrium to a temperature of between 45° C. and 70° C. to destroy the cells of the endometrial lining while maintaining the average temperature of the myometrium at a temperature below approximately 42° C. An apparatus for performing an endometrial ablation comprising an expandable membrane such as a balloon adapted to fit within the uterus and contact the endometrial lining when expanded. A web of light diffusing fiber-optic cables arranged on the outer surface the balloon such that the web contacts the endometrial lining of the uterus when the balloon is expanded. The fiber-optic web is connected to an array of high intensity lamps via a series of fiber-optic cables. The temperature of the endometrium is monitored by a of a series of temperature sensors arranged upon the surface of the balloon.
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TECHNICAL FIELD
This invention is in the field of photography, and more particularly relates to negative-working silver halide emulsions characterized by reduced fog and improved aging stability.
BACKGROUND OF THE INVENTION
A wide variety of organic and inorganic compounds are used for the complex series of steps by which a negative-working silver halide emulsion of high sensitivity is produced. One such step involves the chemical sensitization of the silver halide grains to increase their light sensitivity. Between the time of adding the sensitizer and coating the liquid emulsion, the latter is usually given a heat treatment, called digestion. During digestion a reaction is believed to occur which produces sensitivity sites on the surface of the silver halide grains. Unfortunately, as the digestion reaction is continued in order to obtain a higher level of sensitivity, some silver halide grains become spontaneously developable without exposure. This causes the emulsion to fog. Films made with grains which have undergone digestion to achieve high sensitivity not only exhibit this fog when tested shortly after being coated, but display higher levels of fog as the film is aged. This may reach a level such that the film is unusable and in any case limits the useful life of the film. Undesirable losses in sensitivity may also accompany the increase in fog as the film ages.
Efforts to obtain higher sensitivity for negative-working silver halide emulsions must in some fashion deal with the problem. One practical method of doing this is to tolerate some acceptable fog level in commercial photographic emulsions. Another is to add antifoggant or stabilizer compounds to reduce fresh fog and/or to prevent the formation of aging fog while accepting some sacrifice of sensitivity as a tradeoff for the improvement.
SUMMARY OF THE INVENTION
The present invention attacks the fog problem encountered in negative-working silver halide emulsions by providing a group of organic halogen compounds which are selectively effective in eliminating fresh fog from highly sensitized emulsions and preventing formation of fog on aging.
In accordance with this invention, a negative-working silver halide emulsion of lower fog and superior aging stability is produced by the incorporation therein of one or more organic halogen compounds selected from the following: 2,2,2-trichloroethanol, m-nitrobenzyl chloride, 3-chloroaniline, 2-chloro-4-nitrobenzyl chloride, o-chloranil, p-nitrobenzyl chloride, chlorohydroquinone, 4-chloro-2-nitrobenzyl chloride, 4-chloro-3-nitrobenzyl chloride, o-nitrobenzyl chloride, α,α,α-trichlorotoluene, 4,6-dichloro-5-nitropyrimidine, 5-chloro-2(trichloromethyl) benzimidazole, 2-chloro-3 nitropyridine, and 2-amino-3,5-dichloropyridine.
These compounds lower the fresh and aging fog without adversely affecting speed, gradation, and top density of the coated films. For example small amount of 2-chloro-4-nitrobenzyl chloride, 2,2,2-trichloroethanol, and m-nitrobenzyl chloride reduce the fog of medical X-ray emulsion with little or no speed loss and also improve aging stability. This new technology offers an opportunity to develop products with superior diagnostic clarity, use alternate sensitization techniques which would otherwise give high fog, or trade off all or part of these advantages for lower silver coating weight.
DETAILED DESCRIPTION OF THE INVENTION
The foregoing organic halogen compounds are effective when added to the emulsion in amounts of from 1 to 1000 mg/mole of silver halide at the completion of the chemical sensitization, or even when added immediately prior to coating as e.g. by in-line injection. In some cases it is desirable to hold the emulsion containing the organic halogen compound at an elevated temperature for a period sufficient to allow a reaction to occur which lowers the fog to the desired level. Some of these compounds are believed to be such potent oxidants that they need only a very short holding time in the liquid emulsion, thereby lowering fog initially and on aging.
In general, the organic halogen compounds useful for the present invention may be characterized as oxidizing agents which appear to selectively react with the fog sites on the silver halide grains. Some of those compounds, e.g., 2-chloro-4-nitrobenzyl chloride and o-chloranil, are sufficiently reactive that it is possible to obtain the benefits of the present invention by simply mixing the compound with the emulsion just prior to coating, as by the in-line injection process disclosed in Abele et al, U.S. Pat. No. 4,124,397.
Other compounds such as 3-chloroaniline and o-nitrobenzyl chloride are less effective when in-line injection is attempted. The most beneficial results are obtained when (1) they are added to an emulsion which contains all the additions normally added to completed emulsions prior to coating, (2) followed by a digestion holding period at 35° C. for 15 minutes to 3 hours to allow the oxidation-reduction process to proceed. Higher temperatures accelerate the action of these organic halogen compounds. However, this can become counterproductive because elevated temperatures tend to cause increased fog in highly sensitized emulsions.
The present invention is operative with silver halide grains produced by single jet, splash, and double jet precipitation techniques, to yield heterodisperse and monodisperse grain size distributions. Into the grains made by such known techniques metal ions may be introduced to modify the photographic response, and nonmetallic compounds may be added to increase sensitivity or restrain fog. In some cases it may be desirable to wash grains which have been chemically modified, and to then further increase the size of the grains by precipitating a layer of silver halide over the original grains. The term "core-shell" grain has come to apply to such layered grains.
The silver halide constituent of the negative-working silver halide emulsions described herein may consist of pure or mixed silver chloride, bromide, or iodide, and the grains may be regular or irregular in shape, e.g., cubic, octahedral, rhombohedral, etc.
As a binder agent and peptizing media for these emulsions it is normal to employ gelatin. However, gelatin may be partially or wholly replaced by other natural or synthetic protective colloids known in the art.
Other useful additives include ortho- and panchromatic sensitizing dyes; speed-increasing compounds such as polyalkylene glycols; surface active agents which are useful as coating aids; antifoggants; and stabilizers, including indazoles, imidazoles, azaindenes, heavy metal compounds such as mercury salts, and polyhydroxy benzene compounds.
Other useful ingredients for these negative-working elements include hardeners, antistatic agents, matting agents, plasticizers, brighteners, and natural and synthetic wetting agents. All these ingredients may be combined to yield formulations capable of being coated on suitable supports such as cellulose nitrate film, cellulose ester film, poly(vinyl acetal) film, polystryrene film, poly(ethylene terephthalate) film, and related films, as well as glass, paper, metal and the like.
The invention is illustrated by the following Examples.
EXAMPLE 1
A high speed negative iodobromide emulsion was prepared using gold-sulfur sensitization as well known in the art. 4-hydroxy-6-methyl-1,3,3a,7 tetraazaindene and 1-phenyl-5-mercaptotetrazole were added after the completion of the digestion reaction to stabilize the sensitometric properties of the emulsion. The emulsion was fed by positive displacement gear pumps to a two-slot coating bar where it was applied to a poly(ethylene terephthalate) support and simultaneously wet-overcoated with a protective gelatin overcoat. The two-layer coating was chilled and then dried to produce a photographic film which served as a control.
The setup used for delivering emulsion to the bar contained a provision for in-line injection as described in Abele et al, U.S. Pat. No. 4,124,397. This was used to inject three of the compounds of the present invention. One experimental film contained 133 mg of 2,2,2-trichloroethanol (TCE) per mole of silver halide. Another contained 67 mg of m-nitro benzyl chloride (MNC) per mole of silver halide. Another contained 33 mg of 2-chloro-4-nitrobenzyl chloride (CNC) per mole of silver halide. The coated film samples were held for four days after coating prior to being machine developed. One set of film samples was then exposed in a CRONEX sensitometer and machine developed at 33° C. for 19 sec. in CRONEX XMD continuous tone developer. Another set of film samples was developed at 39° C. for 19 sec. to measure overdevelopment fog (OD fog). Both sets were fixed and washed. Results of these tests are summarized in the following table.
TABLE 1______________________________________Compound 4 day 1 mo. 3 mo.Added test test test______________________________________None Rel. Speed 100 100 100(control) Fog .06 .06 .07 OD Fog .09 .07 .15TCE REl. Speed 103 96 95 Fog .03 .03 .05 OD Fog .07 .04 .10MNC REl. Speed 98 92 105 Fog .03 .03 .06 OD Fog .07 .04 .18CNC Rel. Speed 98 95 100 Fog .05 .04 .05 OD Fog .07 .05 .12______________________________________
The data from Table 1 illustrates that the experimental films containing organic halogen compounds of the present invention not only have lowered fog but have maintained this advantage as the films age. At 3 mo. age all films display relative speeds within a 5% range corresponding to the test error. In two out of three of the experiments on aging the increase in fog caused by overdevelopment (OD fog) is also improved.
The top density and gradient of the experimental films remained equivalent to the control, further illustrating that the fog improvement does not degrade the sensitometric properties of the emulsion.
EXAMPLE 2
Emulsion was prepared as in Example 1 except that it was divided into splits from which individual coatings were made with and without additions of the organic halogen compounds of the present invention. In the cases of addition the experimental emulsions were held for 15 min. at 35° C. after such addition, to permit the fog reduction reaction to take place. Film samples were exposed and developed as in Example 1. Results are given in the following table.
TABLE 2______________________________________ Amount:Compound Mg/mol RelativeAdded AgX Speed Fog______________________________________None (control) -- 100 .093-chloroaniline 333 91 .073-chloroaniline 666 103 .06m-nitrobenzyl chloride 133 97 .05m-nitrobenzyl chloride 267 103 .04______________________________________
These results illustrate that the amount of the organic halogen compound which is effective may vary over a wide range. From 33 to 133 mg gave significant fog reduction with in-line injected compounds. Generally higher amounts were required in the case of those compounds which are best utilized when premixed with the liquid emulsion.
EXAMPLE 3
A comparison was made of the relative effects of 2-chloro-4-nitrobenzyl chloride (CNC), both in-line injected and held in the emulsion for 3 hours at 35° C. prior to coating. Table 3 contains the results.
TABLE 3______________________________________ Amount: Mg/mol RelativeCoating AgX Speed Fog______________________________________Control -- 100 .053 hr. hold 17 98 .043 hr. hold 33 88 .023 hr. hold 67 79 .02In-line injection 23 103 .04In-Line injection 33 105 .03______________________________________
It is evident that in-line injection of CNC avoids the speed loss which occurs when this compound is held in the liquid emulsion.
EXAMPLE 4
A high speed emulsion was prepared as in Example 1 except that 1-phenyl-5-mercaptotetrazole was omitted as a final addition. A portion of this emulsion was coated and overcoated as in Example 2 and served as a control. Two portions of this emulsion received additions of o-nitrobenzyl chloride which were held and mixed for at least 15 minutes at 35° C. prior to coating. Test results of films containing these emulsions are contained in Table 4.
TABLE 4______________________________________Amount Added:mg/mole AgX Relative Speed Fog______________________________________None (control) 100 .09 50 106 .06100 87 .03______________________________________
This illustrates that the organic halogen compound functions even in the absence of a potent antifoggant such as 1-phenyl-5-mercaptotetrazole.
EXAMPLE 5
Tests were run similar to Example 2 except that the emulsion also contained an ortho sensitizing dye to give green sensitivity to films containing this emulsion. A portion of emulsion received no further additions and served as a control, while other portions contained compounds of the present invention mixed in the liquid emulsion for at least 15 minutes at 35° C. prior to coating. Results are shown in Table 5.
TABLE 5______________________________________Compound Amount Added RelativeAdded mg/mole AgX Speed Fog______________________________________None -- 100 .112,2,2-trichloro-ethanol 200 103 .083-Chloroaniline 400 96 .08______________________________________
This illustrates the application of the present invention to dye-sensitized emulsions as well as nonspectrally-sensitized negative-working emulsions.
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Small amounts of specific organic halogen compounds added to medical X-ray emulsions (ex. 2-chloro-4-nitrobenzyl chloride, 2,2,2-trichloroethanol and m-nitrobenzyl chloride) give significantly reduced fog levels accompanied by little or no speed loss.
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This application is a continuation of application Ser. No. 507,070, filed June 23, 1983.
BACKGROUND OF THE INVENTION
This invention relates to a composite fabric for use as a clothing in the sheet forming zone of a papermaking machine.
Clothings of the aforementioned type are referred to as papermachine screens and are frequently comprised of two or three fabric layers which are complete in themselves and are interconnected by additional binder wires. In these types of clothings the lowermost fabric layer is made from relatively coarse threads or wires, since it is subject to considerable wear. The topmost fabric layer, on the other hand, since it supports the sheet of paper pulp, is made from fine wires so that it leaves no marks in the paper. While clothings structured in this manner were expected to result in negligible marking and to provide long service life and high stability, practical experience has not proven this out.
German patent applications (OS) Nos. 2,455,184, 2,455,185 and 2,917,694 disclose clothings comprised of a plurality of interconnected fabric layers. Each layer has interwoven longitudinal and transverse wires and the layers are exclusively interconnected by transverse binder wires. Unfortunately, clothings of this type have not reached their expected long service life, because the transverse wires are seriously degraded after a relatively short time of operation.
Canadian Pat. No. 711,428 and European patent application No. 0 044 053 disclose joining two fabric layers by interweaving the transverse wires of the lower fabric layer with the longitudinal wires of the upper fabric layer at regular intervals without the use of special transverse binder wires. However, with these composite fabrics, the risk of marking is very high.
It is, therefore, an object of the present invention to provide a composite fabric for use as a clothing in the sheet forming zone of a papermaking machine which causes but slight marking while having a long useful life.
SUMMARY OF THE INVENTION
In accordance with the principles of the present invention, the above and other objects are realized in a composite fabric of the above type wherein the interweaving of the transverse wires of a first fabric layer with the longitudinal wires of a successive or adjacent second fabric layer is such that the courses of the transverse wires of the first fabric layer and the transverse wires of the second fabric layer are interchanged.
In a further embodiment of the invention, the transverse wires of the second fabric layer are interwoven with the longitudinal wires of the first fabric layer at the same point at which the transverse wires of the first fabric layer are interwoven with the longitudinal wires of the second fabric layer.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features and aspects of the present invention will become more apparent upon reading the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 shows a first composite fabric in accordance with the principles of the present invention;
FIGS. 2-4 show further embodiments of composite fabrics in accordance with the principles of the present invention.
FIG. 5 shows a cross-section through the fabric or FIG. 1 perpendicular to the tranverse wires of the fabric; and
FIG. 6 shows a cross-section through the fabric of FIG. 4 perpendicular to the tranverse wires of the fabric.
DETAILED DESCRIPTION
FIG. 1 shows a composite fabric in which the upper fabric 1 is a single-layer plain weave of longitudinal wires 3 and transverse wires 6. The lower fabric 2, in turn, is a double layer with longitudinal wires 4 and upper transverse wires 7 and lower transverse wires 8. The lower tranverse wires 8 have long floats on the running side so that--in case of a flat woven papermachine screen--a so-called weft runner is realized. The lower fabric 2 can be a 10-harness weave.
In order to avoid paper marks, the transverse wires 6 of the fabric 1 and the upper transverse wires 7 of the fabric 2 are of equal thickness amd are made of the same material. The longitudinal wires 3 of the fabric 1 are preferably thinner and are made of a more elastic material than are the longitudinal wires 4 of the fabric 2. This is possible, since the longitudinal wires 3 of the fabric 1 serve primarily to form the paperside of the screen, while the fabric 2, like a transmission belt, serves to take up the entire driving load in the paper forming section of the paper machine. Typically, the longitudinal and transverse wires may comprise polyester filaments. Also, the longitudinal wires and particularly the transverse wires of the lowermost fabric may also comprise polyamide filaments on account of the higher wear resistance of these filaments.
In accordance with the principles of the present invention and in order to obtain as firm a connection between the fabrics 1 and 2, the interconnection of the two fabrics is effected such that the transverse wire 6 of the fabric 1, deviates from its otherwise plain weave, and passes beneath a plurality of longitudinal wires 3, shown as three wires, instead of merely under a single wire 3. Also in accordance with the invention and as shown, at this point, the upper transverse wire 7 of the fabric 2 is interwoven with the longitudinal wire 3 which was skipped by wire 6 and with which the wire 6 would normally have been interwoven had the latter followed its usual path. Hence, within a repeat pattern, the courses of the transverse wires 6 and 7 are interchanged with respect to the single longitudinal wire 3. Preferably, this interchange is repeated at regular intervals, e.g., once within each repeat pattern or within each second or third repeat pattern.
FIG. 2 shows a composite fabric similar to that of FIG. 1 in which the courses of the transverse wires 6 and 7 are interchanged along an interval greater than a single longitudinal wire. In this case, the interchange is along an interval of three longitudinal wires 3.
FIG. 3 shows a modification to the embodiment of the invention shown in FIG. 2. In FIG. 3, the transverse wire 6 of the fabric 1, along the interval in which the transverse wire 7 is woven into the longitudinal wires 3 of the fabric 1, is itself interwoven into the fabric 2 in that it passes beneath two longitudinal wires 4.
FIG. 4 shows a further embodiment of the present invention. In this embodiment, the fabric 1 is again woven in plain weave, while the fabric layer 2 is shown as an eight-harness double-layer fabric. At one position of the longitudinal wires 3 and 4, the courses of the transverse wires 6 and 7 are exactly exchanged, i.e., the upper transverse wire 7 of the fabric 2 is passed over a longitudinal wire 3 of the fabric 1, rather than beneath the corresponding longitudinal wire 4 of the fabric 2, and the transverse wire 6 of the fabric 1 passes beneath the longitudinal wire 4 now missed by the transverse wire 7, rather than over the corresponding longitudinal wire 3.
It is preferable in practicing the present invention to interweave each transverse wire of a fabric into the adjacent fabric following the interchange principle of the invention. However, in individual cases, it may be sufficient to weave only each second, third or fourth transverse wire into the adjacent fabric. Also, where a fabric comprises multiple layers, generally only the transverse wires of the external layers should be interwoven into their adjacent layers.
It is also preferable that the composite fabric of the invention be flat woven, but the principles of the invention apply to circularly woven fabric as well. In this connection, in flat woven composites the transverse wires are the weft wires and the longitudinal wires are the warp wires. In a circularly woven composite, on the other hand, the transverse wires are the warp and the longitudinal wires are the weft wires.
It is within the scope of the present invention to interconnect two or more fabric webs which are complete in themselves by weaving the longitudinal wires of one fabric layer along some distance into an adjacent fabric layer, or by the exchange along some distance of longitudinal wires of two adjacent fabric layers. However, the use of longitudinal wires for interconnection is less advantageous in flat woven composites, since the longitudinal wires are maintained under tension during thermosetting and during the use of the papermachine. This makes it difficult to preseve a uniform surface structure on the paper supporting side of the composite. The transverse wires, on the other hand, are a sort of filler material which is relatively unaffected by longitudinal tension. During thermosetting these wires are disposed transversely of the exerted longitudinal tension and form a homogeneous topographic structure despite any deviation from their original course. In circularly woven composites, however, it is the transverse wires (the warp wires) which are subject to tension during weaving. Therefore, in practicing the invention, the least difficulties are encountered when the composite fabric is flat woven and the interconnection is accomplished with the transverse wires.
In the embodiments of the invention illustrated in FIGS. 1-4, the upper fabric layer is a single-layer fabric and the lower fabric layer is a double-layer fabric. However, the composite may also comprise a double-layer upper fabric and a single-layer lower fabric, or two double-layer or multiple layer fabrics. Also, a composite fabric composed of two single-layer fabrics may be used. In the latter case, however, the different diameters of the transverse wires may give an undesirable influence on the paper supporting side of the structure.
The following is an example of a composite fabric made in accordance with the principles of the invention.
EXAMPLE
The layer of a two layers composite fabric is woven flat in plain weave with 30 longitudinal wires per centimeter and 34 transverse wires per centimeter. The longitudinal wires 3 have a diameter of 0.15 mm and are made of polyester monofilament of medium to low longitudinal stability and medium elastic modulus (Trevira 930). The transverse wires 6 also have a diameter of 0.15 mm and are made of polyester monofilament of very low elastic modulus and low thermal shrinkage (Trevira 900).
The layer 2 is an eight-harness, double-layer fabric of No. 0859 weave with long floats of the transverse wires on the running side and shortened floats on the upper side. The layer 2 is woven open with 15 longitudinal wires per centimeter and 17 transverse wires per centimeter. The longitudinal wires have a diameter of 0.30 mm and are made of polyester monofilament of a high elastic modulus. The upper transverse wires 7 of the layer 2 are made of the same material and have the same diameter as the transverse wires 6 of the fabric 1, so that the surface structure of the composite fabric on the paper side is equally uniform at the points of interconnection. The lower transverse wires 8 of the fabric 2 are made of abrasion-resistant material and alternately consist of polyester monofilament and polyamide monofilament having a diameter of 0.32 mm each.
The upper and lower fabrics 1 and 2 are interconnected as shown in FIG. 4 in that each transverse wire 6 of the fabric 1 and each upper transverse wire 7 of the fabric 2 is interchanged at each eighth longitudinal wire 3 and each fourth longitudinal wire 4, respectively.
The longer service life of the composite fabric of the invention is believed to be due to the fact that the great number of bond points between the individual fabric layers causes the layer to be firmly interconnected and to not undergo any relative movement, e.g., when passing around rolls. Therefore, there is little risk that the transverse wires interconnecting the layers are subject to special wear or to high tensile stress, owing to movement of the layers relative to one another.
It is further noted that the individual fabric layers in the composite fabric of the invention are interconnected by structural transverse wires, i.e., transverse wires participating in the formation of the fabric weave in the usual way, rather than by special binder wires. In particular, as discussed above at certain invervals, the structural transverse wires deviate from the normal pattern and are interwoven into an adjacent fabric layer by interchange with the transverse wires of the layer beneath.
In all cases, it is understood that the above-described arrangements are merely illustrative of the many possible specific embodiments which represent applications of the present invention. Numerous and varied other arrangements can be readily devised without departing from the spirit and scope of the invention.
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A composite fabric for use as a clothing in paper-making machines comprising a plurality of interconnected fabric layers, each fabric layer having interwoven longitudinal wires and transverse wires and the fabric layers being interconnected in that at least part of the transverse wires of one or both of two adjacent fabric layers are interwoven with the longitudinal wires of the other fabric layer, the interweaving of the transverse wires of the one fabric layer with the longitudinal wires of the other fabric layer being such that the course of the transverse wires of the one layer and the other layer are interchanged.
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BACKGROUND OF THE INVENTION
1. Field of Invention
The invention relates to new benzoindole styryl compounds and, in particular, to new benzoindole styryl compounds and their uses in high-density optical recording media.
2. Related Art
With the coming of information and multimedia era, computer, communication and consumer electronics have higher demands for larger storage density and capacity. Due to the large amount of information exchange, it is desirable to develop a high-density, small and cheap storage medium. Conventional magnetic storage media are already insufficient for current uses; high-density optical information storage media are the main subject under study. There had been some proposed principles and methods for increasing the storage density in optical information storage media. Some of them are important and have already been successfully implemented. One method is to shorten the wavelength of the laser beam. For example, red lasers are replaced by blue lasers. One can also achieve the same goal by increasing the NA (Numerical Aperture) of the lens. Another method is to improve the digital signal coding means or to utilize optical disk recording with the so-called ultra-high resolution near-field optical structure. These methods can all effectively increase the storage density.
On the other hand, another research field of optical information storage media is to replace the organic dyes used in optical recording layers by those with better optical properties. In recent years, one-time recording compact discs (CD-R) have become people's favorite storage media due to their cheap prices, fast burning speeds, convenience in carriage, and high compatibility among different personal computers. To achieve high-density storage, dyes for such media as one-time recording digital versatile discs (DVD-R) with 4.7 GB capacity have become an important subject under research. Since the laser for high-density storage media such as DVD-R's has a light wavelength of 650 nm, which is different from that of the laser for CD-R's (780 nm), the dyes cannot be shared between the two kinds of media. This is why developing new organic dyes for high-density storage media is an urgent need.
SUMMARY OF THE INVENTION
It is an objective of the invention to provide new benzoindole styryl compounds and their uses in high-density recordable optical discs. Such benzoindole styryl compounds have a maximum absorption for light wavelengths in the range of 500 nanometers to 700 nanometers (λ=500 nm˜700 nm). The benzoindole styryl compounds also have high sensitivity, chemical stability toward light and heat and good solubility for organic solutions.
To achieve the above objective, the invention provides new benzoindole styryl compounds which have the following graphical chemical structure (I).
As shown in the structure (I), R 1 , R 2 , R 3 , R 4 , R 5 and Y − represent groups connected to different positions on the chemical structure. In particular, when R 1 is CH 2 C 6 H 4 CO 2 R 6 , (CH 2 ) n SO 3 R 7 , or (CH 2 ) n CO 2 R 7 , Y − can be selected from (TCNQ − ) n (teteacyano-p-quinodimethane) and (TCNE − ) n , (tetracyanoetylene) (n=0, 1), ClO 4 − , SbF 6 − , PF 6 − , BF 4 − and halide ions (X − ). R 2 and R 3 are same or different groups selected from hydrogen atoms, alkyl groups with one to eight carbons (C 1-8 ), alkyl-oxygen groups with one to eight carbons (C 1-8 ) and alkyl-ester groups one to eight carbons (—CO 2 R 8 ). R 2 and R 3 can be connected to form a pyrrolidine ring, R 2 and R 3 can be connected to benzene ring to form a julolidine ring. R 4 and R 5 are same or different groups selected from hydrogen atoms, alkyl groups with one to eight carbons (C 1-8 ), trifluoromethyl groups, alkyl-oxygen group, carboxyl groups, nitric groups, amide groups (CONR 9 R 10 ), sulfonic groups, SO 3 R 11 , alkyl-ester groups with one to eight carbons (C 1-8 ), and halide ions (X − ).
When the choice of Y − needs to match R 1 and R 1 is an alkyl group with one to eight carbons (C 1-8 ), Y − must be one of (TCNQ − ) n , (teteacyano-p-quinodimethane) and (TCNE − ) n , (tetracyanoetylene)(n=0, 1). Moreover, when R 1 is one of CH 2 C 6 H 4 CO 2 R 6 , (CH 2 ) n SO 3 R 7 , and (CH 2 ) n CO 2 R 7 , Y − can be one of (TCNQ − ) n , (teteacyano-p-quinodimethane), (TCNE − ) n , (tetracyanoethylene) (n=0, 1), ClO 4 − , SbF 6 − , PF 6 − , BF 4 and halide ions.
When R 1 of the new benzoindole styryl compound is one of (CH 2 ) n CO 2 R 6 , (CH 2 ) n SO 3 R 7 , and (CH 2 ) n CO 2 R 7 , R 6 and R 7 can be an alkyl or alkyl fluoride (C 2 F 4 , CF 3 ) with one to eight carbons.
When R 4 and R 5 in the new benzoindole styryl compound is an alkyl-ester group (—CO 2 R 8 ) with one to eight carbons (C 1-8 ), R 8 can be an alkyl or alkyl fluoride (C 2 F 4 , CF 3 ) with one to eight carbons. If R 4 and R 5 are amide groups (—CONR 9 R 10 ), R 9 and R 10 may be same or different groups. R 9 and R 10 can be hydrogen atoms or alkyl groups with one to six carbons. When R 4 and R 5 are —SO 3 R 11 groups, R 11 may be hydrogen atoms or alkyl groups with one to six carbons. The above choices of groups can be selectively applied to the chemical formula (I).
Furthermore, the manufacturing method of the new benzoindole styryl compounds requires the reaction between the compound (II) and the compound (III) in an organic solution. The manufacturing method of the new benzoindole styryl compounds is explicitly as follows:
Mix the compound (II) and the compound (III) in an organic solution. They undergo a reaction to obtain a benzoindole styryl compound (IV) with halide ions (X − ).
Finally, as shown in the following reaction formula, the benzoindole styryl compound (IV) with halide ions and one of the lithium, sodium and potassium salt (LiY, NaY, KY) are mixed in an organic solution to exchange ions, obtaining a new chemical compound with the chemical formula (I).
The disclosed benzoindole styryl compounds can be directly applied to usual DVD's and the recording layers of other high-density data storage media.
It is another objective of the invention to provide a high-density data storage medium using the new benzoindole styryl compound dyes in its recording layer. Since this kind of benzoindole styryl compounds is easy to synthesize and purify, they are cheaper than other usual dyes. In addition, the high-density data storage media using the disclosed benzoindole styryl compounds have good photosensitivity and superior chemical stability in the recording layer.
It is yet another objective of the invention to use the new benzoindole styryl compounds as the recording layer of a recordable optical disc to form a high-density optical recording medium. The recordable optical disc comprises: a first substrate, which is a transparent substrate with grooves, a recording layer, which is formed on the first substrate surface using the new benzoindole styryl compounds, a reflective layer formed on the recording layer, a second substrate, which is a transparent substrate with grooves connected to the reflective layer with an attachment layer. One feature of the invention is that the new benzoindole styryl compounds are used as dyes in the recording layer.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will become more fully understood from the detailed description given hereinbelow illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 is a schematic view of the chemical formula (I) of the disclosed benzoindole styryl compounds;
FIG. 2 is a schematic view of an embodiment of the invention using the new benzoindole styryl compound dyes in high-density recordable optical discs; and
FIG. 3 shows the spectrum of the reflective index versus the wavelength for the disclosed high-density recordable optical discs.
DETAILED DESCRIPTION OF THE INVENTION
This specification discloses new benzoindole styryl compounds and their uses in high-density recordable optical discs. The benzoindole styryl compounds have the structure in the chemical formula (I) with different group combinations.
To explain the invention, we illustrate in the following paragraphs the synthesis procedure and the chemical formula of the new benzoindole styryl compounds. FIG. 1 shows the general chemical structure of the benzoindole styryl compounds.
In a first embodiment, 5 g of initial material (II) with an R 1 being —CH 2 C 6 H 4 CO 2 CH 3 and 2.1 g of material (III) with the same R 2 and R 3 (—C 2 H 5 ) are dissolved in 120 ml alcohol. The system is heated for three to four hours of reaction. After the reaction is completed, the system is filtered and dried to obtain a green solid crystal (A) with a chemical formula (IV), where R 4 and R 5 are hydrogen atoms (H), X − is an iodine ion, and the reaction yield is 90%. After material analysis, we find that the compound (A) has an absorption wavelength of 583 nm (UV max =583 nm). The compound (A) further undergoes an ion exchange reaction with one of the lithium, sodium and potassium ionic compounds in an organic solution, forming various kinds of new compounds with the chemical formula (I). The following lists the manufacturing procedure and properties of the new compounds (A) formed from the ion exchange reaction:
(1) Take 3.2 g of the solid crystal of compound (A) and 0.73 g of NaClO 4 and dissolve them in 50 ml alcohol. Heat them up to perform ion exchanges. After the reaction, the products are filtered and dried to obtain dark green solid crystal of compound (B) with the chemical formula (I), R 4 and R 5 =H, and Y=ClO 4 − . The reaction yield is computed to be 95%. The material analysis indicates that the compound (B) has an absorption wavelength of 582.5 nm (UV max =582.5 nm) and the absorption coefficient ε=7.36×10 4 .
(2) Take 3.2 g of the solid crystal of compound (A) and 1 g of NaPF 6 and dissolve them in 50 ml alcohol. Heat them up to perform ion exchanges. After the reaction, the products are filtered and dried to obtain gold green solid crystal of compound (C) with the chemical formula (I), R 4 and R 5 =H, and Y=PF 6 − . The reaction yield is computed to be 96%. The material analysis indicates that the compound (C) has an absorption wavelength of 583 nm (UV max =583 nm).
(3) Take 3.2 g of the solid crystal of compound (A) and 1.6 g of NaSbF 6 and dissolve them in 50 ml alcohol. Heat them up to perform ion exchanges. After the reaction, the products are filtered and dried to obtain green thin needle crystals (D) with the chemical formula (I), R 4 and R 5 =H, and Y=SbF 6 − . The reaction yield is computed to be 95%. The material analysis indicates that the compound (D) has an absorption wavelength of 583.5 nm (UV max =583.5 nm) and the absorption coefficient ε=8.62×10 4 .
(4) Take 3.2 g of the solid crystal of compound (A) and 1.27 g of LiTCNQ and dissolve them in 50 ml alcohol. Heat them up to perform ion exchanges. After the reaction, the products are filtered and dried to obtain dark brown crystals (E) with the chemical formula (I), R 4 and R 5 =H, and Y=TCNQ − . The reaction yield is computed to be 94%. The material analysis indicates that the compound (E) has a breaking temperature of 233° C., an absorption wavelength of 583 nm (UV max =583 nm) and an absorption coefficient ε=7.38×10 4 .
A second embodiment of the invention also has new compounds with the chemical formula (I). The side group R 1 is selected to be —(CH 2 ) 4 CO 2 CH 3 . Take 4.39 g compound with the chemical formula (II) as the initial material, where R 1 is —(CH 2 ) 4 CO 2 CH 3 , and 2.1 g compound with the chemical formula (III), where R 2 and R 3 are the same —C 2 H 5 groups, and dissolve them into 100 ml alcohol. Heat up the alcohol to its backflow temperature for reaction for three to four hours. After the reaction is completed, the products are filtered and dried to obtain green solid crystals of the compound (F), with a chemical formula (IV), R 4 and R 5 =H, X=I − , and a reaction yield of 90%. The material analysis indicates that the compound (F) has an absorption wavelength of 572 nm (UV max =572 nm). The compound (F) and different lithium, sodium, and potassium ionic compounds are mixed in an organic solution for ion exchanges, forming various kinds of new compounds with the chemical formula (I). The following lists the manufacturing procedure and properties of the new compounds (F) formed from the ion exchange reaction:
(5) Take 3 g of the solid crystal of compound (F) and 0.74 g of NaClO 4 and dissolve them in 50 ml alcohol. Heat them up to perform ion exchanges. After the reaction, the products are filtered and dried to obtain dark green solid crystals of compound (G) with the chemical formula (I), R 4 and R 5 =H, and Y=ClO 4 − . The reaction yield is computed to be 95%. The material analysis indicates that the compound (G) has an absorption wavelength of 573 nm (UV max =573 nm).
(6) Take 3 g of the solid crystal of compound (F) and 1 g of NaPF 6 and dissolve them in 50 ml alcohol. Heat them up to perform ion exchanges. After the reaction, the products are filtered and dried to obtain golden green solid crystals of compound (H) with the chemical formula (I), R 4 and R 5 =H, and Y=PF 6 − . The reaction yield is computed to be 95%. The material analysis indicates that the compound (H) has an absorption wavelength of 573 nm (UV max =573 nm).
(7) Take 3 g of the solid crystal of compound (F) and 1.6 g of NaSbF 6 and dissolve them in 50 ml alcohol. Heat them up to perform ion exchanges. After the reaction, the products are filtered and dried to obtain blue needle crystals of compound (I) with the chemical formula (I), R 4 and R 5 =H, and Y=SbF 6 − . The reaction yield is computed to be 95%. The material analysis indicates that the compound (I) has a breaking temperature of 266° C., an absorption wavelength of 573 nm (UV max =573 nm), and an absorption coefficient ε=8.6×10 4 .
(8) Take 3 g of the solid crystal of compound (F) and 1.27 g of LiTCNQ and dissolve them in 50 ml alcohol. Heat them up to perform ion exchanges. After the reaction, the products are filtered and dried to obtain dark brown solid crystals of compound (J) with the chemical formula (I), R 4 and R 5 =H, and Y=TCNQ − . The reaction yield is computed to be 94%. The material analysis indicates that the compound (J) has a breaking temperature of 230° C., an absorption wavelength of 573 nm (UV max =573 nm), and an absorption coefficient ε=9.5×10 4 .
The compounds (A) and (F) formed in the first and second embodiments are benzoindole styryl compounds with iodine ions. They are mixed with lithium, sodium and potassium salts in an organic solution for ion exchanges. After the reaction is completed, the products are filtered and dried to obtain the disclosed benzoindole styryl compounds (B), (C), (D), (E), (G), (H), (I), (J), (K) and (L). The chemical formulas and the maximal absorption wavelengths of the various new compounds are listed in Table 1.
TABLE 1
The chemical formulas and the maximal absorption wavelengths of
various new compounds.
No
Compound structure
λmax (nm)
ε
A
583
—
B
582.5
7.36 × 10 4
C
583
—
D
584
1.09 × 10 5
E
583
7.38 × 10 4
F
572
—
G
573
—
H
573
—
I
573
8.76 × 10 4
J
573
9.5 × 10 4
K
572.5
8.37 × 10 4
L
573
—
M
583.5
9.53 × 10 4
N
583.5
1.12 × 10 5
After the new benzoindole styryl compounds obtained from the disclosed embodiments are appropriately diluted and processed, we then obtain dyes for high-density optical discs. One can also mix more than one kinds of benzoindole styryl compounds or other dyes in order to obtain required properties for high-density optical discs.
We further apply the new benzoindole styryl compounds to form the recording layer of high-density recordable optical discs. With reference to FIG. 2 , the high-density recordable optical disc is comprised of: a first substrate 10 , which is a transparent substrate, a recording layer 20 , which is benzoindole styryl compounds formed on the surface of the first substrate 10 , and a reflective layer 30 , which is formed on the recording layer 20 and coated with a resin protection layer 40 , a second substrate 60 , which is a transparent substrate, and an attachment layer, which connects the resin protection layer 40 and the second substrate 60 .
The benzoindole styryl compounds mentioned here has the structure shown in the chemical formula (I) and can be combined with different ion groups. The material selection and manufacturing method of the benzoindole styryl compound dyes can be understood from the following text.
The steps of the manufacturing method are as follows: First, dissolve 1.8 g of the new benzoindole styryl compounds in 2,2,3,3-tetrafluoropropanol and make a 100 g solution. This solution is applied on the first substrate 10 by coating. Afterwards, a drying procedure is employed to form a recording layer 20 of the new benzoindole styryl compounds on the substrate surface. The recording layer 20 is formed with a reflective layer 30 by sputtering a metal material, followed by the application of a resin protection layer 40 . Finally, a second substrate is provided to combine with the resin protection layer 40 using an attachment layer. This completes the manufacturing of a high-density recordable optical disc.
The first substrate and the second substrate are transparent substrates with lands and grooves. The track pitch is between 0.3 μm and 0.8 μm. The groove depth is between 70 nm and 200 nm. The material of the substrate can be polyesters, polycarbonates (PC), PMMA, MCOC, etc.
The formation method of the recording layer can be spin coating, vacuum evaporation, jet coating, rolling coating, or soaking. It is preferably to use spin coating, forming a recording layer of 70 nm to 250 nm thick.
The organic solution for coating can be selected from alcohols with one to six carbons (C 1-6 ), ketones with one to six carbons, ethers with one to six carbons, halide compounds, cyclanes and amides. The alcohols can be methanol, ethanol, isopropanol, diacetonalchol (DAA), 2,2,3,3-tetrafluoropropanol, trichloroethanol, 2-chloroethanol, octafluoropentanol, or hexafluorobutanol. The ketones can be acetone, methyl isobutyl ketone (MIBK), methyl ethyl ketone (MEK), and 3-hydroxy-3-methyl-2-butanone. The suitable halide compounds include chloroform, dichloromethane, and 1-chlorobutane. The amides include dimethylformamide (DMF) and dimethylacetamide (DMA). The cyclane is methylcyclohexane (MCH).
The material of the reflective layer sputtered on the recording layer is selected from gold, silver, aluminum, silicon, copper, silver-titanium alloys, silver-chromium alloys, and silver-copper alloys. The combination of the first substrate and the second substrate can be achieved using spin coating, half-tone printing, hot gluing, and double-sided tapes.
The thickness of the recording layer on the substrate in this embodiment is between 70 nm and 250 nm. A reflective layer of 50 nm to 200 nm thick is directly coated on the recording layer. Finally, the substrate formed with the reflective layer and the recording layer is combined with another blank substrate with a thickness of 0.6 mm. (As described before, the connection can be achieved using spin coating, half-tone printing, hot gluing, and double-sided tapes.) A high-density recordable optical disc of 120 mm thick can be thus formed. FIG. 3 shows the optical spectrum of the reflective index of the high-density recordable optical disc versus the wavelength in accordance with the invention. As shown in the drawing, the reflective index is greater than 45% for wavelength between 635 nm and 650 nm.
We further use in the embodiment a PULSTEC DDU-1000 evaluation test machine to write and read the test results.
The recording conditions are: the constant linear velocity (CLV) is 3.5 m/s, the wavelength is 658 nm, the numerical aperture (NA) is 0.6, and the writing power is 7˜14 mW. The reading conditions are: the CLV is 2.5 m/s, the wavelength is 658 nm, the NA is 0.6, and the reading power is 0.5˜1.5 mW. Table 2 has the CNR values under different writing powers in the embodiment.
TABLE 2
Writing Power
(mW)
7
8
9
10
11
12
13
14
3T CNR (dB)
50.9
56.6
58.3
58.4
58.7
59.1
58.8
58.3
From Table 2, we see that when the writing power is above 8 mW, the CNR value is greater than 55 dB. CNR even reaches 58 dB and the jitter is 12.7% when the writing power is above 9 mW. This means that the high-density optical disk according to the invention has the advantages of high sensitivity and chemical stability of light and heat.
EFFECTS OF THE INVENTION
The disclosed new benzoindole styryl compounds are easy to synthesize and purify. Therefore, they are much cheaper than normal dye compounds used in DVD optical discs. The R1 side group in the structure of new benzoindole styryl compounds can enhance its photosensitivity and stability to light and heat. These benzoindole styryl compounds have extremely good solubility in organic solutions, which is ideal for the spin coating procedure for the optical discs. Thus, it is of great advantage to use the new benzoindole styryl compounds in the recording layer of high-density recordable optical discs. The disclosed recordable optical discs in comparison with conventional one made of normal dye compounds will be cheaper in price, while having better stability under the shorter laser beam used for high-density recordable media.
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternative embodiments, will be apparent to persons skilled in the art. It is, therefore, contemplated that the appended claims will cover all modifications that fall within the true scope of the invention.
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The invention discloses new benzoindole styryl compounds and its use for a high-density optical recording medium. The invention uses the dyes of the new benzoindole styryl compounds to form the recording layer of high-density recording media. The new benzoindole styryl compounds are easy to prepare and purify, so they are cheaper when comparing to the compounds generally used in high-density optical recording media. The benzoindole styryl compounds has a maximum absorption for the light wavelength in the range of 500 nanometers to 700 nanometers. The benzoindole styryl compounds also have high sensitivity and chemical stability for light and heat. Using the new benzoindole styryl compounds to form a high-density optical recording medium can match up with the short-wavelength laser beam for high-density optical recording media and have the advantage of a stable quality.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a deep dyeing process of a polyamide (PA or nylon including Nylon 4, Nylon 6, Nylon 46, Nylon 66, Nylon 7, Nylon 8, Nylon 9, Nylon 610, Nylon 1010, Nylon 11, Nylon 12, Nylon 13, Nylon 612, Nylon 9T, Nylon 13, MC Nylon, Nylon MXD6 and all polyamide derivatives) and a polyolefin (including ethylene copolymer, propylene copolymer, and related derivatives), and the deep dyeing process uses a compatibilizer precursor and an amino, hydroxyl or epoxy group containing chemical to modify the polyamide and polyolefin, and the modified polyamide and polyolefin has a low-temperature dyeability, and finally uses a reactive dye and/or an acid dye to perform the dyeing process, such that the dyed polyamide and polyolefin fibers have excellent dye fastness, light fastness, rubbing fastness and washing fastness.
2. Description of Related Art
In general, polyamide (PA) or nylon is a linear condensation polymer composed of repeated primary bonds of amide groups (—CONH—), and featuring high crystallization, chemical resistance, oil resistance, solvent resistance, and abrasion resistance, a small coefficient of friction, a high level of thermal degradation, a broad manufacturing scope, and a self-lubrication. In addition, the mechanical properties of nylon has the advantages of high tensile strength, high impact resistance and excellent elasticity, tenacity and extensibility, and thus nylon can be used extensively as a composite material for the textile industry, an industrial fiber or an agent for enhancing fibers.
The structure of nylon is characterized in that an end of its molecular chain includes a functional group such as a carboxyl group (—COOH) and an amino group (—NH 2 ) having a good dyeability, and a large number of carbon-hydrogen bonds (—CH 2 ) and amide groups (—NHCO—) at the middle of the molecular chain, and thus various different types of dyes such as ionic dyes, acid mordant dyes, metal complex acid dyes, direct dyes, dispersive dyes, azo dyes, vat dyes, and acid dyes can be used for dyeing nylon fibers, and the dyeability of fibers depends on the dispersion of the dye and the affinity between the fibers and dye as well as their connection. In the aforementioned dyes, only the acid dye contains hydrophilic groups of sodium sulfonate radicals (—SO 3 Na) that can be combined with the amino groups (—NH+) of the nylon fibers by the ionic bonds or electrostatic forces to provide better dyeability and brighter color, and the rest of the aforementioned dyes are combined with the nylon fibers by hydrogen bonds or Van der Waals forces to provide a lighter color. As to the uniform dyeability, the acid dye is the first choice for dyeing nylon fibers, and thus the acid dye is a popular application used most in related industries.
With reference to FIG. 2 for a conventional polyamide fiber dyeing process, the polyamide fibers are modified in a modification process and dyed with the acid dye, wherein the conventional modification process of the polyamide adds a chain regulator of different types and additive quantities to increase the content of amino groups (—NH 2 ) at the ends of a molecular chain of the nylon, while introducing a functional group with a special structure or adds a dye leveling agent or another co-agent in the dyeing process and performing a supersonic treatment, and finally a color fixation is performed after the dyeing process takes place in an oxidation-reduction system or water is used as a ring opening agent to perform an open ring polymerization of the amide group (—NHCO—) to reduce the polymerization induction period and improve the reaction speed, such that when a new equilibrium is reached, the number of polymer molecules is increased, and the content of amino groups (—NH 2 ) will be increased accordingly, and the temperature before/after the hydrolysis and polymerization of the amide group (—NHCO—) will be increased appropriately, such that the content of amino groups (—NH 2 ) at the ends of the molecular chain can be increased to achieve the modification effect.
Since the content of amino groups (—NH 2 ) at the ends of the molecular chains of the nylon is very low (about 5˜10% of wool only), therefore the aforementioned modification process still cannot achieve the effect of improving the content of amino groups (—NH 2 ) significantly. In other words, the dyeing effect of the nylon is relatively poor. Obviously, the conventional nylon fiber dyeing process has the following drawbacks:
1. The conventional process can achieve a mid-depth dyeing effect only. Since the acid dye and the polyamide are combined by the ionic bond or the electrostatic force, the bonding is relatively weak, and only a mid-depth dyeing effect can be obtained.
2. The conventional process generally results in poor dye fastness, light fastness, and washing fastness. The color of a dyed nylon processed by the conventional polyamide fiber dyeing process may be faded or stained easily by rinsing or exposures to sunlight or gas. The conventional dyed nylon has poor dye fastness, light fastness, and washing fastness.
3. The conventional process gives a non-level dyeing quality and incurs a high cost. In the conventional deep dyeing process of polyamide fibers, color difference, color deviations and stained spots may occur easily due to the dyeing condition and the selection of co-agents. In the meantime, the conventional deep dyeing process of the nylon fibers involves complicated dyeing process and color fixation and incurs a high cost.
4. The conventional process requires a high dyeing temperature. The temperature for the conventional polyamide fiber dyeing process must be over 100˜120° C., and thus the process causes high costs and power consumptions.
Obviously, the conventional polyamide fiber dyeing process requires further improvements.
In addition, polyolefin (such as polyethylene and polypropylene) has the features of a light weight, a plentiful resource, a simple manufacturing process, a small specific gravity, and a low water absorption and the functions of chemical resistance, electrostatic resistance, and pollution resistance, and thus polyolefin is used extensively in many areas due to its functions and low production cost.
The non-polar structure of polyolefin is generally considered as a major hidden problem that polyolefin cannot be dyed, since the polyolefin fibers have a very low hydrophilic property, and thus the affinity between a dye and a chemical co-agent is poor, and conventional dyeing and printing methods are unable to achieve an expected dyeing effect. At present, an organic or inorganic dye is generally used for dyeing the polyolefin fibers and such method of coloring the polyolefin fibers incurs a low cost and achieves a better fastness. However, this method is suitable for a mass production of products in a single series of colors only, and unable to meet the requirements of the consumer market, and its drawbacks include an incapability of printing patterns and a high inventory, etc. As a result, polyolefin is primarily used for manufacturing a large quantity of carpets or a small quantity of clothes that require less color only. Therefore, it is an important subject for manufacturers to apply a general dyeing technique to the polyolefin fibers, and for scholars to do researches to improve the dyeing effect of polyolefin fibers, and some scientists have used a chlorination of sodium hypochlorite and a photo-chemical bromination to modify the polypropylene fibers in order to perform the dyeing with a cationic dye, and the modified polypropylene fibers and dye produce covalent forces to achieve the effects of enhancing the bleaching fastness, washing fastness, seawater fastness and moisture regain, while reducing the strength and requiring a post-treatment to improve the light fastness. Some manufacturers have also attempted using a series of polyurethane compounds and a radiating beam to polymerize the polypropylene compounds to produce a copolymer suitable for the dyeing process with a cation dye, an acid dye or a dispersive dye, and some manufacturers have added a polar additive to polypropylene to produce fibers that are dyed with an acid dye, and some manufacturers even have attempted using hydrogenated oligocyclopentadiene or wool to weave polypropylene fibers. With the aforementioned methods, manufacturers attempted to increase the dyeability of polypropylene, but also lowered the photo-sensitivity and mechanical property of the polypropylene at the same time. Mostly important, the high cost of the modification makes polypropylene unfavorable to commercial applications. The dispersive dye and the hydrophobic fiber having a good compatibility among molecules in supercritical carbon dioxide are suitable for a dyeing process without requiring any co-agents. With the aforementioned perfect PET dyeing technology, the dispersion of the dispersive dye in the fibers and the solubility of the dispersive dye of a supercritical condition are studied. The dispersion and solubility of dyes can be determined by the properties of the dyes. In addition, the dispersive dye in supercritical CO 2 can be used for dyeing polyolefin fibers, and the dye can be a dispersive azo dye having a benzene ring structure, and thus its color is darker than a general dispersive dye. In addition to the high cost and the incapability for commercialization, the use of azo dyes is not recommended due to the issue of environmental protection and even prohibited in some developed countries (such as European Union). In summation of the description above, the conventional polyolefin fiber dyeing process still has the following shortcomings:
1. The conventional dyeing process only provides a mid-depth dyeing effect. Since the conventional modified polyolefin is dyed with a dispersive dye and the attraction force between physical bonds (such as hydrogen bonds or Van der Waal forces) has a weaker bonding, only a mid-depth dyeing effect can be obtained.
2. The conventional dyeing process has poor dye fastness, light fastness, and washing fastness. The polyolefin fibers dyed by the conventional dyeing process may be faded or stained easily under sunlight or exposure to special gases due to the poor dye fastness, light fastness, washing fastness and rubbing fastness.
3. The conventional dyeing process has a non-level dyeing quality and incurs a high cost. A color difference, a color deviation and a stained spot may occur easily due to the dyeing conditions and the selection of co-agents. In the meantime, the conventional deep dyeing process of the nylon fibers involves complicated dyeing process and color fixation and incurs a high cost.
4. The conventional dyeing process requires a high dyeing temperature. The temperature for the conventional polyamide fiber dyeing process must be over 90˜120° C., and thus it causes high cost and power consumption.
5. The conventional dyeing process is incompliant with the requirements of environmental protection. Azo dyes and metal-containing dyes are not recommended due to the issue of environmental protection, and they are even prohibited in some developed countries (such as European Union).
Therefore, the conventional polyolefin fiber dyeing process still has the foregoing shortcomings and requires immediate attention and feasible solutions.
SUMMARY OF THE INVENTION
Therefore, it is a primary objective of the present invention to provide a deep dyeing process of polyamide and polyolefin, and the deep dyeing process uses a compatibilizer precursor and an amino, hydroxyl or epoxy group containing chemical to modify a polyamide (PA or nylon) including Nylon 4, Nylon 6, Nylon 46, Nylon 66, Nylon 7, Nylon 8, Nylon 9, Nylon 610, Nylon 1010, Nylon 11, Nylon 12, Nylon 13, Nylon 612, Nylon 9T, Nylon 13, MC Nylon, Nylon MXD6 and all polyamide derivatives) and a polyolefin (including ethylene copolymer, propylene copolymer, and related derivatives) and then uses a reactive dye and/or an acid dye for a dyeing process, so as to overcome the shortcomings of the conventional nylon fiber dyeing process that is capable of providing a mid-depth dyeing effect only and resulting in poor dye fastness, light fastness, rubbing fastness, and washing fastness, and a non-level dyeing quality, a high dyeing temperature, and a high cost.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, as well as its many advantages, may be further understood by the following detailed description and drawings in which:
FIG. 1 is a flow chart of the present invention;
FIG. 2 is a flow chart of a conventional dyeing process of polyamide fibers;
FIG. 3 show test results of light absorptions of polyamides dyed at 100° C. and with a reactive dye by a conventional polyamide fiber dyeing process and by a dyeing process in accordance with the present invention respectively and measured by an ultraviolet spectroscope; and
FIG. 4 shows test results of color strengths (K/S) of polyamides dyed at 100° C. and with a reactive dye by a conventional polyamide fiber dyeing process and by a dyeing process in accordance with the present invention respectively and measured by a spectral color meter.
DETAILED DESCRIPTION OF THE INVENTION
To make it easier for our examiner to understand the technical characteristics and operating procedure of the present invention, we use preferred embodiments together with the attached drawings for the detailed description of the invention as follows.
In a deep dyeing process of polyamide and polyolefin in accordance with the present invention, a compatibilizer precursor (such as a carboxyl polymer, an anhydride polymer, a hydroxyl polymer, an epoxy polymer and a cyanate-based compound) and an amino group (wherein the amino group containing chemical is one selected from the collection of ethylene diamine, diethylenetriamine, triethylenetetramine, tetra-ethylene pentamine, pentaethylenehexamine, hexaethyleneheptamine, polyethylene polyamine and their related derivatives), and a hydroxyl group or epoxy group containing chemical are used for modifying the polyamide (PA or nylon) and polyolefin (PO), and then a reactive dye and/or an acid dye are used for the dyeing process to provide the dyed polyamide and polyolefin with excellent dye fastness, light fastness, rubbing fastness, and washing fastness, so as to overcome the shortcomings of the conventional polyamide fiber dyeing process.
With reference to FIG. 1 for a flow chart of the aforementioned deep dyeing process of the present invention, the deep dyeing process comprises the following steps:
Step 1 performs a first modification of polyamide and polyolefin. A compatibilizer precursor (CP, which is alkylcarboxy-substitute polyolefin used in the present invention) is added into the polyamide and polyolefin, and a mixing tool (such as a double screw extruder or mixer) is used for performing the first modification of polyamide and polyolefin at a predetermined temperature (which is 150˜250° C., and preferably 240° C.) by a predetermined round-per-minute extrusion and mixing process (at 1 Hz to 200 Hz) to prepare a modified polyamide (MPA) and a modified polyolefin (MPO).
Step 2 performs a second modification of polyamide and polyolefin. An amino group containing chemical (which is triethylenetetramine (TETA) used in the present invention) is added into the modified polyamide and the modified polyolefin, and then the mixing tool is used for performing a second modification of the polyamide and polyolefin at the predetermined temperature by the predetermined round-per-minute extrusion and mixing process. The modified polyamide and modified polyolefin are modified again, and their chemical formulae are given below:
Step 3 uses a reactive dye for the dyeing process. After a melt spinning is performed for the second modified polyamide (MPA) and polyolefin (MPO) at a predetermined temperature (which is 235° C. adopted in the present invention), a reactive dye (which is a Lanasol dye produced by Ciba Company and used in the present invention) is used for the dyeing process to complete the deep dyeing of the polyamide and polyolefin.
In the aforementioned deep dyeing process, the compatibilizer precursor (CP) and the amino, hydroxyl or epoxy group containing chemical (which is triethylenetetramine (TETA) used in the present invention) can be added into the polyamide and polyolefin at the same time, and the mixing tool is used for the modification at the predetermined temperature by a predetermined round-per-minute extrusion and mixing process (at 1 Hz to 200 Hz).
A melt spinning is performed for the modified polyamide (MPA) and modified polyolefin (MPO), and a reactive dye is used for the dyeing process to complete the deep dyeing of the polyamide and polyolefin.
The following test results show that the polyamide and polyolefin dyed by the deep dyeing process of the present invention have an excellent dyeing depth.
Table 1 shows the test results of a pollution fastness, a color fading fastness, and a washing fastness of modified polyamides (MPA) dyed by the conventional Nylon (PA) dyeing process and the dyeing process of the present invention taken at 60° C., 80° C. and with a reactive dye respectively:
TABLE 1
Six Types (W, A, T, N, C, Ac) of Pollution Fastnesses of Test Fabrics
Polyamide (PA)
Modified Polyamide (MPA)
Sample
Red
Blue
Black
Yellow
Red
Blue
Black
Yellow
Pollution
W
4
4
4
4
5
5
5
5
Fastness
A
5
5
5
5
5
5
5
5
T
5
5
5
5
5
5
5
5
N
4
4
4
4
5
5
5
5
C
4
4
4
4
5
5
5
5
Ac
5
5
5
5
5
5
5
5
Color Fading
Levels
Levels
Levels
Levels
Level 5
Level 5
Level 5
Level 5
Fastness
4~5
4~5
4~5
4~5
In Table 1, the test results show that the pollution fastnesses and color fading fastness of the conventional polyamide (PA) fall in Levels 4˜5. On the other hand, the pollution fastnesses and color fading fastness of the modified polyamide (MPA) dyed by the dyeing process of the present invention fall at Level 5 (which is the highest level), and thus it shows that the deep dyeing process of the present invention can enhance the washing fastness of the polyamide fibers substantially.
Table 2 shows the test results of a light (xenon arc light) fastness of modified polyamides (MPA) dyed by the conventional polyamide (PA) dyeing process and the dyeing process of the present invention taken at 80° C. and with a reactive dye respectively:
TABLE 2
Tetra-ethylene
Pentamine
(TEPA) Content
Modified
(%) of Modified
Polyamide
Polyamide
Polyamide (MPA)
(PA)
(MPA)
Level
Blue
5-6
8
Red
6
8
Black
5-6
8
Yellow
6
8
In Table 2, the test results show that the light (xenon arc light) fastness of the conventional polyamide (PA) fall in Levels 4˜5. On the other hand, the light (xenon arc light) fastness of the modified polyamide (MPA) dyed by the dyeing process of the present invention fall at Level 8 (which is the highest level), and thus it shows that the deep dyeing process of the present invention can enhance the light fastness of the polyamide fibers substantially.
Table 3 shows the test results of a rubbing fastness of modified polyamides (MPA) dyed by the conventional polyamide (PA) dyeing process and the dyeing process of the present invention taken at 60° C. and 80° C. and with a reactive dye respectively:
TABLE 3
Polyamide (PA)
Modified Polyamide (MPA)
Sample
Red
Blue
Black
Yellow
Red
Blue
Black
Yellow
Dry
Pollution
5
5
5
5
5
5
5
5
Rubbing
Fastness
Level
Color
5
5
5
5
5
5
5
5
Fading
Fastness
Wet
Pollution
4
4-5
4-5
4
5
5
5
5
Rubbing
Fastness
Level
Color
Level 4
Levels
Levels
Level 4
Level 5
Level 5
Level 5
Level 5
Fading
4~5
4~5
Fastness
In Table 3, the test results show that the wet rubbing fastness of the conventional polyamide (PA) fall at level 4 or in Levels 4˜5. On the other hand, the rubbing fastness of the modified polyamide (MPA) dyed by the dyeing process of the present invention fall at Level 5 (which is the highest level), and thus it shows that the deep dyeing process of the present invention can enhance the rubbing fastness of the polyamide fibers substantially.
With reference to FIG. 3 for test results of light absorptions of polyamides dyed at 100° C. and with a reactive dye by a conventional polyamide fiber dyeing process and by a dyeing process in accordance with the present invention respectively and measured by an ultraviolet spectroscope, the test results show that the light absorption of the polyamide (PA) dyed by the conventional dyeing process is only 0.47, and the light absorptions of the modified polyamides dyed by the dyeing process of the present invention with a tetra-ethylene pentamine (TEPA) content of 0.5%, 1%, 1.5% and 2% fall within a range of 0.9˜1.5, and thus it shows that the deep dyeing process of the present invention improves the dyeing quality substantially.
With reference to FIG. 4 for the test results of color strengths (K/S) of polyamides dyed at 100° C. and with a reactive dye by a conventional polyamide fiber dyeing process and by a dyeing process in accordance with the present invention respectively and measured by a spectral color meter, the test results show that the K/S value of the polyamide (PA) dyed by the conventional dyeing process is only 19, and the K/S values of the modified polyamide (MPA) dyed by the dyeing process of the present invention with a tetra-ethylene pentamine (TEPA) content of 0.5%, 1%, 1.5% and 2% fall within a range of 28.7˜35.2, and thus it shows that the deep dyeing process of the present invention improves the dyeing depth of the nylon fibers substantially.
In summation of the description above, the main characteristics and differences of the present invention from the conventional nylon fiber dyeing process are listed below:
1. The present invention is novel and improves over the prior art. Since the conventional polyamide fiber dyeing process uses an acid dye for dying nylon fibers, and a bonding of an ionic bond and an electrostatic force is formed between the acid dye and the polyamide fiber, therefore the affinity is weaker. On the other hand, the present invention uses a reactive dye and/or an acid dye for the dyeing process, and thus provides a better and brighter color effect and a better recurrence, and a very strong bonding of covalent bonds is formed between the reactive dye and/or acid dye and the polyamide and polyolefin, so that the dyed polyamide and polyolefin have excellent dye fastness, light fastness, and washing fastness to overcome the weaker bonding affinity caused by the conventional nylon fiber dyeing process that can provide a mid-depth dyeing effect only, and poor dye fastness, light fastness, and washing fastness. Thus, the present invention is novel and improves over the prior art.
2. The present invention is practically useful. The conventional polyamide fiber dyeing process requires adding a dye leveling agent or another co-agent in the dyeing process to maintain the dyeing quality. On the other hand, the present invention uses two times of modification to increase the content of amino groups (—NH 2 ) at an end of a molecular chain of the polyamide for bonding the reactive dye and/or the acid dye to achieve a level dyeing effect. In the meantime, the invention can lower the cost significantly to overcome the shortcomings including the non-level dyeing quality and the high cost of the conventional polyamide fiber dyeing process. Thus, the present invention is practically useful.
3. The present invention has a low-temperature dyeability for achieving the purpose of energy saving and carbon reduction. The conventional nylon fiber dyeing process requires a high-temperature dyeing at a temperature over 100˜120° C., and incurs a high power consumption and much effort. On the other hand, the present invention can perform the dyeing process at 60° C., and thus the invention complies with the requirements for cost-effectiveness, low cost, and energy saving and carbon reduction policy promoted by the government. The invention can overcome the shortcoming of the conventional nylon dyeing process that requires a high temperature for the dyeing, and thus achieves the energy saving and carbon reduction effects.
Many changes and modifications in the above described embodiment of the invention can, of course, be carried out without departing from the scope thereof. Accordingly, to promote the progress in science and the useful arts, the invention is disclosed and is intended to be limited only by the scope of the appended claims.
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In a deep dyeing process of a polyamide (PA) including Nylon 4, Nylon 6, Nylon 46, Nylon 66, Nylon 7, Nylon 8, Nylon 9, Nylon 610, Nylon 1010, Nylon 11, Nylon 12, Nylon 13, Nylon 612, Nylon 9T, Nylon 13, MC Nylon, Nylon MXD6, and all polyamide derivatives, and a polyolefin (PO) including ethylene copolymer, propylene copolymer and their derivatives, a compatibilizer precursor is used for modifying the polyamide and polyolefin of an amino, hydroxyl or epoxy group containing chemical, and then a reactive dye and/or an acid dye is used for dyeing the polyamide and polyolefin, so that the dyed polyamide and polyolefin have excellent dye fastness, light fastness, rubbing fastness, washing fastness and low-temperature dyeability to overcome the shortcomings of conventional nylon fibers including a poor dyeing effect, a non-level dyeing quality, a high dyeing temperature (100° C. to 120° C.) and a high cost.
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This is a division, of application Ser. No. 796,271, filed May 12, 1977, U.S. Pat. No. 4,160,063 which is a division of application Ser. No. 614,093 filed Sept. 17, 1975, U.S. Pat. No. 4,039,717 which in turn is a division of application Ser. No. 416,712 filed Nov. 16, 1973, U.S. Pat. No. Re. 28,257.
BACKGROUND OF THE INVENTION
It frequently is desirable to make the surfaces of various tanks, vessels, or other equipment resistant to the adherence of various oily materials, particularly crude oil. One example is tanks and vessles that are used to contain or transport crude oil or refined products, particularly where contamination of the subsequent contents is a problem. Thus, the removal of substantially all of the oil upon draining of a tanker or other vessel or container poses several attractive advantages. First, there is the advantage of avoiding wasted oil. Approximately 0.3% of the cargo of oil tankers is presently lost because it cannot be removed economically. A second advantage is that material is not left behind in the vessel which will contaminate subsequent cargoes. Such contamination can lead to great expenses in purifying subsequent cargoes. A third and principle advantage is the avoidance of pollution of the ocean. As is frequently the practice today, residual oil washed out of the tanker with salt water is discharged into the open sea with ecologically disastrous results. Accordingly, if the surfaces of such tankers or vessels could be treated to minimize the adherence of oil to the walls thereof and to facilitate cleaning or washing thereof, such would be greatly beneficial.
A further example of equipment which is desirably resistant to the adherence of oil is oil spill cleanup equipment such as skimmers and booms. Such equipment is used periodically on oil-coated waters and, accordingly, must be cleaned as frequently. Further, the adherence of heavy oil, such as Bunker C, on various critical surfaces of these equipments can cause the equipment to malfunction. Thus, not only would treatment of the surfaces of this equipment reduce maintenance thereof but it would also ensure its efficient operation.
Yet another example of equipment which would desirably have surfaces resistant to the adherence of oil is that associated with oil wells. In some oil wells the crude is so viscous that production is limited by the speed of sucker rod descent during each stroke. Further, the oil tends to foul much of the production equipment that it contacts, resulting in added effort for recovery. Accordingly, if the various contacting surfaces could be rendered resistant to adherence by oil, production efficiency would be increased markedly.
The present invention in response to these needs of the art overcomes the above described difficulties and provides successful solutions to the problems of the art, as will be apparent from the following description thereof.
SUMMARY OF THE INVENTION
The primary purpose of this invention resides in providing a method for treating the surfaces of equipment which comes into contact with various oily materials so that such surfaces will resist the adherence of various oily materials and thereby may more easily be cleaned of such materials.
The above purpose has been achieved through the utilization of oleophobic films for coating such surfaces which are polyacrylamide and carboxymethylcellulose complexed or cross-linked with salts of polyvalent metals such as aluminum, chromium and iron.
The method of this invention broadly extends to the removal of residual oil from contacting surfaces by coating the surfaces with a film of a polyacrylamide cross-linked in the presence of water with a salt of a polyvalent metal. The method further extends to the removal of residual oil from contacting surfaces by coating the surfaces with a film of carboxymethylcellulose cross-linked in the presence of water with a salt of a polyvalent metal.
Within the framework of the above described methods, the present invention not only solves the above mentioned problems of the prior art, but also achieves further significant advantages as will be apparent from the description of preferred embodiments following.
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention is drawn to a method for reducing the adherence of oily materials to surfaces by the application of a coating thereto that is itself resistant to the adherence of oil, i.e. oleophobic. The coating is a water-soluble polymer that has been cross-linked or complexed with a suitable material. Once cross-linked or complexed, the polymeric material is viscid, tenacious, and essentially insoluble in water. In this form as a coating, it adheres readily to properly prepared surfaces of metal, wood, or plastic and is not readily removed either by dissolution, washing, or attrition due to contact by various materials.
The present ivnention particularly applies to the transportation of petroleum products in vessels and barges. It is, however, broadly pertinent to removing oil or preventing the adherence of oil to various contacting surfaces such as in conduits or storage tanks. Even further, it finds broad usage, as above noted, in preventing the adherence or facilitating the removal of oil from oil spill cleanup equipment such as skimmers and booms, and is well suited to use on oil well equipment, particularly when the crude is so viscous that production is limited by the speed of sucker rod descent during each stroke. Thus, wherever there is a problem with oil which adheres to a contacting surface, the present invention can be utilized to alleviate this problem by coating the contacting surface with the compounds envisioned by the present invention and thereby reducing the adherence of oil to such contacting surfaces and facilitating the cleaning thereof.
While the present invention is particularly pertinent to petroleum products, it is equally applicable to similar products which adhere to contacting surfaces and which adherence can be avoided or reduced by the use of the present invention. Thus, the invention pertains to a wide variety of products which exhibit such adherence characteristics, for example oils and fats of animal and/or vegetable origin.
Polymeric coatings useful in the present invention exhibit a strong adherence to metals and have substantial internal strength. It is important that such polymeric coatings have strong adherence and strength inasmuch as it is desirable that the coating be used over and over again in whatever particular application it is employed. To produce a polymeric coating of this strength, a cross-linking or complexing step is employed after the polymer has been dissolved in water so that the coating material is largely made up of water enclosed or entrapped within a network of membranes. While the membranes are permeable to water, the transfer is only accomplished at a slow rate, e.g. about 0.01 lb/ft 2 surface/hr. at 75° F. and 55% RH. These water permeable membranes within which water is entrapped are always somewhat wet, and as such are very oleophobic and shed oil or similar sticky materials readily. While various polymeric materials are known to have this property, most such materials are inadequate for one or more reasons, e.g. the polymeric materials may either lack the quality of strong adherence or internal strength. In accordance with the invention, however, two very successful polymeric materials have been discovered for forming such oleophobic films--complexed polyacrylamide and complexed carboxymethylcellulose. These materials when dissolved in fresh or sea water are cross-linked with salts of polyvalent metals such as aluminum, chromium and iron. Typical salts include basic aluminum acetate, ferric chloride, ferrous chloride, chromic potassium sulfate, aluminum sulfate, aluminum nitrate, chromic acetate, aluminum potassium sulfate, aluminum ammonium sulfate. The speed of cross-linking varies markedly from less than a minute up to several hours depending on the type of metal available.
Polyacrylamide under the trade name Reten A0-1 from Hercules has been found to work very suitably with the present invention. Carboxymethylcellulose under the trade name CMC from Hercules, Incorporated also performs well with the present invention.
Polymer concentrations of about 0.25 to about 2.0% by weight in both fresh water and sea water are found to be highly suitable. Cross-linking agent solutions of from about 1 to about 5% by weight, basis water, have been used in a manner such that the resultant mixture, polymer plus cross-linking agent, is satisfactory for use. Depending upon the nature and size of the apparatus to be covered, the concentrations of these solutions can be further optimized as desired.
The coating of the present invention may be applied in several different ways. In one case, where a large surface if to be covered, the polymer solution can be applied first, followed by an application of the complexing solution. In another case, the polymer solution and the complexing solution can be mixed simultaneously as they are being applied. In still another case, particularly where relatively small surfaces have to be covered, the polymer and complexing solutions can be mixed prior to application. Application of the coating materials to surfaces can be made by various conventional means such as spraying or painting. appropriately located nozzles may be employed which will coat the metal or other surface as the oil or other material is brought into contact therewith. The same nozzles can also be used to remove the oil or other material during the emptying or draining process. In addition, the polymer film may be put on the contacting surface by dipping, brushing or other means suitable for achieving full contact between the contacting surface and the film. Where the vessel or barge has ribs inside its tank or other structural obstructions, the polymer may be applied as a foam so that it gets underneath the ribs or other obstructions by applying the foam to the top of the oil as the oil fills the container. The foam floats on the oil and touches the underside of ribs or other obstructions as it passes upwardly in the tank. Such polymer may be foamed in any conventional manner and may be foamed during or after addition of the complexing material.
If the polymer coating is allowed to dry, it will remain affixed to the coated surface. the film will regain its ability to resist oil if it is flushed with water prior to use. Where it is desired to retain the coating as a wet material, humectants such as glycerine or ethylene glycol may be added thereto to retard the drying out of the complexed polymer film when in contact with air for extended periods of time. Other low molecular weight polyalcohols function well as humectants. The introduction of oil to the polymer solution as a dispersion prior to complexing also serves to reduce drying of the coating when in contact with air.
The complexed material can be modified to suit specific circumstances. Thus, the complexed polymer can be extended and the density and rheology altered by the addition of solid, liquid or gaseous inert ingredients such as finely divided clay, oil or air. The solid inert material should be added to the polymer solution prior to complexing. The liquid inert material should be emulsified in the polymer solution prior to complexing. The gas should be injected into the polymer solution before complexing.
Use of inert solids to extend the polymeric coating can (1) decrease the amount of polymer necessary for coating and thus reduce cost, (2) decrease the fluidity of the polymeric coating and thus reduce the tendency to flow prior to and after complexing, and (3) reduce the tendency of the polymer solution to splash when applied before complexing. Use of inert liquids (oils) to extend the polymeric coating can (1) decrease the amount of polymer necessary for coating and thus reduce cost, (2) decrease the fluidity of the polymeric coating and thus reduce tendency to flow prior to and after complexing, (3) reduce the tendency of the polymer solution to splash when applied before complexing, (4) reduce the density of the polymeric coating and (5) reduce the tendency of the aqueous coating to dry out when subjected to a dry atmosphere.
The polymeric coating extended with finely divided gas bubbles has the qualities listed for the coating extended with the liquid inerts with the exception that gas does not retard film drying.
Small amounts of surfactant may be added to the polymer solution to improve the coverage of various surfaces; alkyl phenoxyl polyethoxyethanols are favored surfactants; a Rohm and Hass product manufactured under the trade name "Triton X-100" is preferred. The addition of the surfactant to the film facilitates removal of the oil after emptying of the contents of the vessel or other container. A wide range of surfactants is broadly suitable, for example, up to about 500 parts per million based on the complexed polymer. A preferred range is from about 2 to about 500 parts per million. It is also preferred that the surfactant be combined with the polymer for joint application rather than being applied separately. In general, the only qualification absolutely required of the surfactant is that it be compatible with the complexed polymer. The polymeric material of the present invention may also contain other additives for such purposes as preventing bacterial decay and/or metal corrosion, provided such is necessary. An example of such additives include formaldehyde as a bactericide and sodium chromate as a corrosion inhibitor.
The following examples are presented to further exemplify the invention but are not intended to be limiting thereof.
EXAMPLE I
Three test solutions were made and labeled as follows:
Solution A=1%w Reten A-01 (polyacrylamide from Hercules, Incorporated) dissolved in a 10%w sodium chloride solution.
Solution B=1%w hydrated aluminum nitrate, Al(NO 3 ) 3 .9H 2 O in water.
Solution C=1%w chromic potassium sulfate, Cr 2 (SO 4 ) 3 .K 2 SO 4 .24H 2 O in water.
Four steel test panels (4"×8"×1/8") were cleaned and coated as follows:
Panel 1 was coated by painting on a layer of Solution A followed by painting on a layer of Solution B.
Panel 2 was coated by painting on a layer of Solution A followed by painting on a layer of Solution C.
Panel 3 was coated by painting on a layer of material consisting of a mixture of 20 parts of Solution C and 100 parts of Solution A.
Panel 4 was not covered by any coating and was used as a control.
After allowing the coated panels to cure for 20 minutes, they were immersed in No. 6 fuel oil. After 18 hours in the oil, the panels were removed and rinsed in a stream of tap water. The oil was readily removed from panels 1, 2 and 3, whereas panel 4 was covered by a thick layer of oil essentially unaffected by the water wash.
EXAMPLE II
Four test solutions were made and labeled as follows:
Solution A=0.5% carboxymethylcellulose (CMC type 7H3S, Hercules Incorporated) in tap water.
Solution B=0.25%w CMC in tap water.
Solution C=0.5%w CMC in synthetic sea water.
Solution D=0.25%w CMC in synthetic sea water.
Four steel panels (4"×8"×1/8") were cleaned and each was coated by painting on a layer of one of the test solutions. Each test panel was then painted with a layer of a 1%w aqueous solution of aluminum nitrate.
The four coated panels were immersed in No. 6 fuel oil. After 20 hours in the oil, the panels were removed and allowed to drain for about 30 minutes. At this time, they were immersed in clean tap water. The remaining No. 6 fuel oil adhering to the panels came off readily and floated on the surface of the wash water leaving the test panels oil-free.
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A method for facilitating the removal or preventing the adherence of residual oil in oil tankers and other vessels or containers, on the surfaces of oil spill cleanup equipment such as skimmers and booms, and on sucker rods or other surfaces in oil wells, by coating surfaces contacting the oil with a film of a polymer that prevents or reduces oil adherence. Materials effective in reducing oil adherence are oleophobic films formed by complexing a polyacrylamide or carboxymethylcellulose with salts of polyvalent metals such as aluminum, chromium and iron.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention concerns a device and a method to transfer product stacks.
[0003] 2. Description of the Prior Art
[0004] The manufacturing of plastic containers (such as bowls, covers and shells) normally ensues in a machine cycle in a two-dimensional pattern or a product matrix. The products produced in a machine cycle can then be inserted into stacking shafts. The manufacturing of the next product series subsequently ensues in a product matrix. These products are also again inserted into the stacking shaft etc. until these are filled. Such a stacking shaft is normally a very simple bar stock carrier. The stack formation can ensue either horizontally, at an angle or vertically. The stack is discharged via a lifter mechanism or a blade and passed to a worker for further relaying. In the next work step, the product stack is either packaged directly in a carton or supplied beforehand to a shrink-wrapping machine to wrap the individual product stacks in film, and is subsequently packaged in a box.
[0005] The action of the packing and repacking the product stack presently normally ensues by hand. In particular if the product stack is shifted into horizontal stack magazines, such as by means of a blade, it can occur that the product stack falls apart, such that in addition to handling the stack a worker must first correct this. Because the product stack is discharged and additionally processed or packaged by hand, the maximum stack height is limited since otherwise the danger exists of such a product stack breaking apart. The same problem also occurs in vertical stack cages. Here the stack is transferred row by row or block by block onto a conveyer belt via a separate lifter mechanism after reaching a specific stack quantity. Here as well, there is a risk that the stacks will fall apart. The conveyer belt additionally serves as a buffer storage. After discharging the stacks, these are supplied to a packing machine that shrink-wraps the individual product stacks with a film. The wrapped product stacks are then likewise manually packaged.
[0006] It is disadvantageous that the relaying and the packaging of such product stacks cannot ensue in a fully automated manner. The fact that a number of different products for which the shaping, punching and discharging tools are to be refitted are produced on such shaping machines also contributes to this disadvantage.
[0007] Although it is already known to transfer product stacks vertically from a stack magazine into a rigid receptacle in the form of an external stack cage or grabber (WO 2005/061353 A2, WO 2006/027053 A1), a flexible, fully automatic additional processing of product stacks in the aforementioned sense is still not also possible with this.
SUMMARY OF THE INVENTION
[0008] The invention is therefore based on the object to enable a fully automatic relaying of product stacks, in particular of molded plastic products.
[0009] According to the invention, this object is achieved by a device of the aforementioned type, with a discharge station such as a deep-draw machine, a receiving station such as a packing machine, and with a transfer device, the latter with a connection element to connect the device with a transport device, with multiple receiver regions for product stacks that are limited by guide elements provided with spring-loaded closure elements, and with plates to be moved in the receiver regions on the closure elements in a spring-loaded manner along the direction of the guide elements.
[0010] The closure elements are pressed by spring-loading against a stop in a closed position, by which a movement of the product stack out of the transfer device is prevented.
[0011] In a preferred embodiment of the transfer device according to the invention the guide elements are arranged near the axes of symmetry of the receiving regions, in particular they are arranged on the axes of symmetry. It is thus possible to have the transfer device engage in the manner of a comb in a stack magazine at a discharge station, in which stack magazine the guide rods are typically arranged at corner or edge regions.
[0012] In a further embodiment the plates are spring-loaded by means of sheathed cables directed deflection rollers and connected with a tension spring arranged in a floor area, and the plates furthermore have engagement elements to engage external sliders and the engagement elements project beyond the outer contour of the transfer device, in particular releasing elements are associated with the closure elements of the transfer device. In this embodiment a discharge of the products to a container or receiver station for the products can be supported by the action of the spring-loaded plate and release of the closure elements. In a further version, the transfer device according to the invention can possess side walls that surround it.
[0013] The above object also is achieved in accordance with the invention by a transfer device with the described features that receives product stacks from a transfer device, the transfer device is characterized by releasing elements associated with the closure elements of the transfer device.
[0014] The above object also is achieved according to the invention by a method wherein elastically pretensioned closure elements holding the product stack in the transfer device are released by releasing elements provided at the receiver station in order to release the product stack, and the product stacks are slid out of the transfer device by plates under elastic force.
[0015] The plates under elastic force are primarily provided to secure the product stacks upon insertion into the transfer device at the deep-draw machine and only assist in the ejection of the products. The ejection ensues by external sliders.
[0016] In an embodiment the ejection is assisted by action of at least one slider provided at the receiving station, and in particular the at least one slider engages with outer engagement elements connected with plates sliding out the product stack.
[0017] The transfer of the product stack from the transfer device for additional processing (for example for packaging in a packing station) ensues at a receiving station to receive the product stack, which is characterized by releasing elements associated with the closure elements of the transfer device. At least one slider associated with the shiftable plates is preferably provided, the at least one slider engaging the engagement elements of the transfer device.
[0018] The device with a discharge device, a receiving station and a transfer device designed according to the invention as in the preceding is preferably formed as a manipulation apparatus (such as a robot) to move the transfer device between the discharge station and the receiving station.
[0019] In accordance with the invention (in particular the embodiment of the transfer device according to the invention) it is possible to automatically take up product stacks not only in vertical alignment but also in any alignment (i.e. also horizontal or angled alignment) from the production machine or, respectively, its discharge device, for example in the form of stack magazines and to supply them to an—automatic—further processing. According to the invention, the process can operate in non-combed or combed manner, wherein in the last cited case an additional slider at the discharge station can be omitted if a coupling between the transfer device and a transport mechanism (such as a robot) is maintained.
[0020] A combing magazine offers the advantage that it can be realized very simply and also can be continuously filled. However, the entire product stack must be picked up after the last machine cycle or between two successive machine cycles. For this purpose, given decoupling of the transfer device from a robot, a type of barrier or spacer can be introduced into a stack after reaching the required product count, so the discharge and the removal of the finished product stack can be divorced from the machine cycle. In the case of a non-combing stack magazine there is the difficulty in the transfer of the stack magazine therefrom into the transfer device, if the stack is to be completely transferred during a single machine cycle, that this must occur faster the higher the stack, so the requirements for the transferrer are increased.
[0021] In accordance with the invention it is possible to fulfill different requirements of production and to satisfy these, in particular with regard to throughput and capacity, flexibility and reliability.
[0022] Furthermore, within the scope of the invention it is possible to achieve a one-to-one association between production machine and additional processing, in particular to associate only one packing machine given a production machine with high capacities or even multiple production machines, and thereby to provide a linear axis for the movement manipulation apparatus bearing a transfer device according to the invention between the individual production machines and towards the machine for additional processing.
[0023] In particular with such a multi-machine loading the transfer device is decoupled in the production machine and/or additional processing machine/packing machine from a manipulation apparatus transporting it and there directly serves as a stack magazine. Alternatively, it can be placed next to or above a stationary stack magazine. This is in particular in the case in which different products for which different transfer devices are required are produced from multiple machines. Such a manipulation apparatus can take on additional transport tasks for the further production machines. The transfer devices can also be fashioned differently in terms of their stack height.
[0024] If emptying of the transfer device should occur quickly at the machine for additional processing, this transfer device can remain docked to the transport device (such as the manipulation apparatus), and this transport device can subsequently bring the transfer device back to a corresponding production machine. Alternatively, the manipulation apparatus can separate the transfer device at the machine for additional processing and, during the emptying of the transfer device, pick up an already-emptied transfer device already located there and bring it back to the associated production machine, and may possibly take an additional stack from a different production machine back to the machine for further processing.
[0025] In a preferred embodiment, a manipulation apparatus or a robot of the device can be fashioned with two coupling points for transfer devices.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a perspective representation of a transfer device as viewed from the side of the closure elements of the transfer device.
[0027] FIG. 2 is a perspective rear view (flange-side) representation of the transfer device.
[0028] FIG. 3 is an enlarged detail presentation of the transfer device.
[0029] FIG. 4 is a plan view of the transfer device from its open side or, respectively, the side of the closure elements.
[0030] FIG. 5 is a section corresponding to A-A of FIG. 4 .
[0031] FIG. 6 is a longitudinal section through a transfer device.
[0032] FIG. 7 a is the presentation of the transfer of product stacks from a production machine (for instance a deep-draw machine) in a non-combed manner with a transfer device.
[0033] FIG. 7 b is the presentation of the transfer of product stacks from a production machine (for instance a deep-draw machine) in combed manner with a transfer device.
[0034] FIGS. 8 a and 8 b are schematic detail views of a stationary stack magazine with pivotable barriers to separate a product stack to be picked up by the transfer device from additional products stacked in the stack magazine.
[0035] FIGS. 9 a and 9 b are a section through the stack magazine of FIGS. 8 a and 8 b.
[0036] FIG. 10 is a presentation of a horizontal transfer of product stacks from the transfer device to a packing machine.
[0037] FIG. 11 is a layout representation of a device according to the invention for the implementation of the method given high capacities of the deep-draw machines.
[0038] FIG. 12 is a layout representation of a device according to the invention for the implementation of the method at medium and low capacities of the deep-draw machines.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] The invention initially contains a transfer device 1 to transfer of product stacks from products produced in a deep-draw machine (for instance bowl stacks or the like), i.e. to receive the stack from the deep-draw machine, to transport the stack to a processing machine for further processing (for instance for packing and to discharge the stack to a machine for further processing (for instance a packing machine) in which the individual stacks are packed in plastic film sleeves, for example.
[0040] In the shown exemplary embodiment the transfer device 1 according to the invention is fashioned like a box, with a base 2 as well as longitudinal and transverse walls 3 , 4 as side walls, while the sixth side of the transfer device 1 (opposite the base 2 ) is open, and the product stack 5 can be received and dispensed through this open side.
[0041] The base 2 and the side walls 3 , 4 are provided with openings therein.
[0042] Slits are provided in the side walls 4 , in which slits 4 . 1 engagement elements for external sliders are directed, the engagement elements being connected with plates 12 that can be displaced in the transfer device 1 in the length direction of the guide elements 8 , 9 .
[0043] A connection unit 6 in the form of a tool exchanger is provided on the outside of the floor 2 , by means of which tool exchanger the transfer device according to the invention can be accepted by or decoupled from a transport device (for instance a manipulation apparatus), such as the hand flange of a robot.
[0044] Inside the transfer device 1 according to the invention are multiple receiver regions (in the embodiment of FIGS. 1-6 there are sixteen receiver regions 7 ) for the product stacks 5 that are bounded by rod-shaped guide elements 8 , 9 , wherein closure elements 10 that can each be pivoted on an axle 10 . 1 are located at the free ends of the guide elements 8 that face away from the base 2 . The closure elements 10 are—in their closed position shown in FIGS. 1 , 3 , 4 , and 6 —pressed in a spring-loaded manner against a stop (not shown). In this closed position a nose 10 . 2 of the closure elements 10 engages under the edge 5 . 1 of the frontmost of the products forming the product stack 5 .
[0045] In the shown embodiment, two guide elements 8 fashioned in such a manner are associated with one side of the product stack 5 , and only one is associated with the respective product stack on the other side.
[0046] In this preferred embodiment, the guide elements 9 leading the product stacks towards their other sides possess no such closure elements engaging below the products.
[0047] Furthermore, for illustration releasing units 11 are shown in the drawings, in particular in FIGS. 1 , 3 , which releasing units 11 are, however, not part of the transfer device 1 but rather are arranged stationary at the discharge stations for the product rods for the product stacks 5 and there can be activated to release the product stacks 5 . They press on the closure elements 10 so that each is pivoted in its axis 10 . 1 so the nose 10 . 2 retreats from the edge region 5 . 1 of the product of the product stack 5 and accordingly releases the product and the entire product stack so that it can be removed from the transfer unit. Insofar as the alignments of the stacks 5 or of the guide elements 8 , 9 has a vertical component (downward), this can take place under the force of gravity. Plates 12 are additionally provided on the base side of the product stack 5 , and can initially be displaced into the region of the base 2 . The plates 12 are likewise advantageously elastically held in this position shown in FIGS. 1 and 2 and can be displaced along the guide elements 8 , 9 towards their free ends by means of external sliders 13 likewise provided (opposite the transfer device 1 ) at the receiver station ( FIG. 10 ) in order to actively slide off the product stacks upon ejection of the product stacks 5 from the transfer devices 1 , and to act as a pressure pad during the acceptance of the products in the deep-draw machine in order to ensure that the product stacks formed there do not fall apart or, respectively, that the uppermost product does not rotate or tilt.
[0048] It is significant to the invention, and results from the preceding, which the transfer device possesses or requires no active units of its own but rather is fashioned to be entirely passive. Movements of its elements—closure elements 10 , plates 12 —are produced exclusively by external elements or even by elastic force (return into the initial position). Accordingly, no active electrical, pneumatic or hydraulic devices are required at the transfer device itself, and accordingly are not even present in the embodiment that is shown and explained. However, in principle it would also be possible to provide corresponding active elements at the transfer device itself.
[0049] FIG. 6 shows a section through a transfer device 1 according to the invention. It is clear that a respective tension spring 12 . 2 that can be encapsulated in a tube (not shown) is arranged between the outer floor 2 and the movable plate 12 that serves as a pressure pad and slider plate, wherein such a plate 12 is respectively associated with a respective product stack row. The ends 12 . 1 a and 12 . 1 b of the draw spring 12 . 2 are connected with sheathed cables 12 . 3 whose ends 12 . 3 a that face away engage at the movable plate 12 . The sheathed cables 12 . 3 are deflected via deflection rollers 12 . 4 and 12 . 5 , wherein the first deflection is by 90°, the second by 180°.
[0050] A force is thus exerted on the plates 12 in the direction of the arrow F due to the force of the spring 12 . 2 in the direction of the arrow F′, such that these plates 12 are moved in the direction of the free ends of the guide elements 8 , 9 and elastically held there if no product stack is located in the transfer device 1 . If products are shifted into the receiving regions 7 , the corresponding plate 12 is pressed back towards the floor 2 , counter to the effect of the draw spring 12 . 2 . Due to the closure elements 10 holding back an inserted product stack 5 , the plate 12 is held at a position corresponding to the level of the stack 5 .
[0051] If, after transport of the transfer device 1 to a discharge station, the closure elements 10 are unlocked by releasing elements there and therefore release the product stack 5 , these can be slid out of the transfer device 1 under the effect of the spring 12 . 2 , in particular given the vertical design shown in FIG. 6 . In particular when the stacks 5 is not vertical but rather are arranged at an angle or horizontally, such a sliding can be assisted by electrically or pneumatically actuated sliders engaging the plates 12 at the projecting noses 12 . 1 ( FIG. 10 ).
[0052] FIGS. 7 a and 7 b schematically show two possibilities to receive product stacks 5 in transfer devices 1 according to the invention. A production machine 14 , for instance a plastic deep-draw machine that produces (for example) deep-drawn plastic products such as plastic bowls or the like, which are stacked as stacks 5 in stack magazines 15 .
[0053] In the embodiment of FIG. 7 a , the transfer device 1 according to the invention is arranged above the stack magazine 15 , for example is brought there by a robot engaging at its connection unit 6 , and after production of a desired number of products in product stacks these are slid out of the stack magazines 15 into the transfer device 1 according to the invention by sliders (not shown) corresponding to the shown arrows, wherein said product stacks press the closure elements 10 (which are borne elastically such that they can pivot) to the side upon insertion until these then engage below the edge of the lowermost product of the product stack 5 . The transfer device 1 with the accommodated product stacks 5 is subsequently transported to a processing station ( FIG. 10 ).
[0054] In the embodiment of FIG. 7 b , the transfer device 1 according to the invention is driven in a comb-like manner into the stack magazines present at the production machine 14 . Upon insertion of respective finished products, closure elements 10 that are elastically supported such that they can pivot, are respectively pivoted or pressed to the side until they in turn engage below the edge of the lowermost product of the product stack 5 . The transfer device 1 with stacked product stacks 5 can likewise subsequently be transported for additional processing. The separation of a finished product stack 5 to be dispensed from additional inserted products is described in the following using FIGS. 8 a through 9 b.
[0055] FIGS. 8 a and 8 b show in side view and FIGS. 9 a and 9 b show in plan view a production machine with a stationary stack magazine located at this, into which stack magazine 15 the produced products are slid and in which such product stacks are formed. Barriers 21 with which a completely formed and to-be-dispensed product stack 5 can be separated from products subsequently produced by the deep-draw machine 14 that form an additional stack are directed into the guide rods of the stack magazine 15 . The barriers 21 or spacer elements are borne via a sliding guide on or in the guide rods of the stack magazine 15 . The barriers 21 or spacer elements are introduced into the movement region of the products or, respectively, product stacks 5 via 90° rotation of the guide rods. The point in time at which the product stack 5 in the stack magazine possesses the desired product count is marked in FIG. 8 a . At this point in time the barriers 21 are pivoted into the region of the products or, respectively, of the product stacks 5 so that the subsequently produced products inserted into the stack magazine 15 are, as stated, separated from the finished product stack 5 . While the release position in which the product stack is formed unhindered is shown in FIG. 9 a , this pivoted position 9 a of the barriers 21 is shown in FIG. 9 b.
[0056] In the situation shown in FIG. 8 b , the situation is depicted after three additional machine actions in which three additional products have thus respectively been inserted into the stack magazine 15 .
[0057] The barriers 21 or spacer elements can even be activated by gravity in the case of a vertical stack magazine 15 . Given an angled or horizontal arrangement of the stack magazine, the barriers 21 or spacer elements are pretensioned via a spring (not shown). The spring itself is then integrated into the guide rods.
[0058] As an alternative to the shown embodiment in which the barriers are directed in the guide rods of the stack magazine, a separate, additional guide system could also be provided for the barriers.
[0059] For example, the additional processing contains a packaging of the individual product stacks 5 at a packing machine 16 into plastic bags or sleeves accommodating said stacks 5 . For this purpose, the transfer device 1 according to the invention is initially deposited on its side, for example, i.e. with a side wall 3 or 4 on a lifting station 17 ( FIG. 10 ) that is moved to such a height that in this horizontal position the lower region of the product stack 5 is arranged approximately at the height of a receiving surface 16 . 1 of the packing station 16 . The releasing elements 11 (already mentioned above) provided at the packing station 16 move against the closure elements 10 so that these release the edges of the products of the corresponding product stack 5 so that this can be slid out by an external slider acting on the plates located at the floor 2 of the transfer device 2 (which slider is located at the receiver plate 16 . 1 ) into the packing station 16 or, respectively, onto the receiver plate 16 . 1 of said slider. The sliders 16 . 2 thereby engage at the engagement elements 12 . 6 (described above) arranged at the plates 12 overlapping the contour of the transfer device 1 .
[0060] In the exemplary embodiment shown in FIG. 10 , the lifting station 17 is subsequently lowered until the middle stack 5 shown there arrives at the level of the receiving surface 16 . 1 and this stack (and finally the uppermost stack after further lowering of the lifting station 17 ) is slid out in the same manner.
[0061] FIGS. 11 and 12 show complete layouts for the implementation of the method according to the invention. In the embodiment of FIG. 11 , two complete product lines are arranged next to one another. Each product line consists of a production machine (such as a deep-draw machine 14 ) with a respective stack magazine 15 , a robot 18 that bears a transfer device 1 , a packing machine 16 to accept the transfer devices 1 , and a discharge station 19 to discharge the packaged product stack 5 . If the transfer device 1 is continuously coupled to the robot 18 , a separate lifting station ( FIG. 10 ) is not required. The lifting movement ensues via the robot 18 . An external slider 16 . 2 (not shown) is additionally required.
[0062] Such an arrangement in which a packing machine is associated with every production machine is reasonable for production machines (deep-draw machines) of high capacity. If the production machines or, respectively, deep-draw machines 14 do not have a high capacity, it is also possible to associate one packing machine 16 with multiple deep-draw machines 14 , as this is shown in FIG. 8 where four deep-draw machines are associated with one packing machine 16 . Here a linear axle 20 along which a manipulation apparatus (such as a robot 18 ) can be moved is provided along the stack magazines 15 of the deep-draw machines 14 arranged next to one another, which manipulation apparatus moves the transfer devices back and forth between the deep-draw machines 14 and the packing machine 12 , wherein an intermediate storage (not shown) in the region of the packing machine 16 can also possibly be present so that the robot 18 can already retrieve an additional transfer device 1 filled with product stacks while a previously deposited transfer device 1 is emptied at the packing machine, which previously deposited transfer device 1 the robot can then pick up again to receive additional product stacks at one of the deep-draw machines 14 .
[0063] Although modifications and changes may be suggested by those skilled in the art, it is the intention of the inventors to embody within the patent warranted heron all changes and modifications as reasonably and properly come within the scope of their contribution to the art.
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A transfer device for transferring product stacks has a connecting element for connecting the transfer device to a transport device, and the transfer device has a number of receiver regions therein, that each receive a product stack. Each receiver region has guide elements with spring-loaded closure elements, and a plate that is movable in a spring-loaded manner toward the closing elements along the direction of the guide elements. When the transfer device with the product stacks therein reaches its transfer destination, the product stacks are pushed from the transfer device by the plates by spring force.
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BACKGROUND
[0001] This application claims the priority benefit of U.S. provisional application Ser. No. 61/904,998, filed Nov. 15, 2013.
[0002] Mount performance is significantly affected by the amount of air trapped under a decoupler. Determining the position of the decoupler and the relative timing of the state switching of the mount increases the performance characteristics of the mount as well as the repeatability/consistency of this performance. More particularly, one of the key performance metrics of an engine mount is phase or frequency offset. The amount of phase is affected by the amount of air trapped under the decoupler, i.e., the rubber barrier between fluid and air chambers in the mount. Air under the coupler in a first state (State 1) is allowed to vent to atmosphere. In a second state (State 2), air is trapped under the decoupler because an evacuation port is closed or blocked.
[0003] In prior applications, air under the decoupler is evacuated via a vacuum system. However, in some applications, vacuum is no longer present. Air is trapped beneath the coupler when the evacuation port is closed or plugged via an electrical actuator.
[0004] It is been determined that an ideal scenario for peak phase is a condition with the decoupler bottomed out (i.e., biased toward maximum travel in a downward direction against a lower cage of an inertia track). Detection of the decoupler position is therefore desirable for optimizing mount performance.
[0005] Many technologies are available for “position sensing” but the functional requirements, short distance, sealed chamber, and/or hostile environment, for example, of a switchable mount design make these technologies undesirable or difficult to use for this application in a vehicle. It is also important to keep in mind that a decoupler moves quickly, i.e., typically at a low amplitude and high frequency. Again, position sensing technology must be capable of detecting such movement.
[0006] For example, ultrasonic sensing uses high frequency sounds waves, and can work with a solid panel in front of the sound transducer. Although ultrasonic sensing technology may be acceptable where the target is stationary or slow-moving, the decoupler environment is fast-moving and results in a poor signal/indication of the sensed position of the decoupler.
[0007] Infrared (IR) sensing needs an optically clear window between the chambers, and generally cannot detect extremely short distances. As a result, infrared sensing is not generally conducive to sensing decoupler position in this environment.
[0008] Capacitance sensing does not work well sensing through a plastic wall and/or fluid environment when the target is rubber. The volume of fluid in the mount environment is not sufficient to make capacitance sensing a viable option.
[0009] Radio frequency sensing (RF) requires too close a distance to be useful in certain environments.
[0010] One of the key performance metrics of a vibration isolation mount or engine mount is phase (frequency offset). In this specific application, the amount of phase is affected by the amount of air trapped under the decoupler (rubber barrier between fluid and air chambers). Air under the decoupler in a first state or state 1 is allowed to vent to atmosphere. In a second state or state 2, the evacuation port is blocked, trapping air under the decoupler.
[0011] In prior applications, air under the decoupler would be evacuated via a vacuum system. In this specific application, vacuum is no longer present, and air is trapped by plugging the evacuation port via an electrical actuator.
[0012] Accordingly, a need exists to address, for example, the air trapped under the decoupler in an engine mount, and the need to provide an accurate, dependable or reliable sensing arrangement that confirms the state of the decoupler.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is cross-sectional view (and an enlarged cross-sectional view thereof) of an engine mount or vibration isolation mount that uses an inductive sensing assembly of the decoupler in order to provide opening or closing of a vent used in the engine mount according to the present disclosure.
[0014] FIG. 2 is an enlarged view of a portion of FIG. 1 .
[0015] FIG. 3 is a graphical representation of the frequency and phase due to trapped air under a fixed decoupler relative to decoupler position.
[0016] FIGS. 4-6 show different positions of the decoupler.
[0017] FIG. 7 is a plan view of a portion of the inductive sensor assembly.
[0018] FIGS. 8 and 9 are enlarged views of the inductive sensor assembly.
DETAILED DESCRIPTION
[0019] The Figures show a novel structure and method of detecting the position of a switchable hydro mount decoupler. This arrangement advantageously uses a signal from the decoupler and inductive sensor to determine when the decoupler is down against the lower decoupler cage (i.e., thus no air underneath is underneath the decoupler to be able to compress) and then use that information or signal to activate a solenoid (actuator) to plug the port thereby maximizing the mount stiffness, phase and damping.
[0020] Without this ability, the stiffness, damping, and phase can vary depending on what position the decoupler is in when the solenoid actuator closes off as in prior arrangements. If the decoupler is up, then air that is trapped underneath the decoupler when the solenoid closes reduces the mount performance.
[0021] Inductive sensing in a switchable vibration isolation mount or engine mount is utilized to determine the position of a rubber decoupler. When the decoupler is detected as being in an optimal position, via inductive sensing, the mount will be switched to an active state (blocking of an air transfer passage) thereby changing the mount performance to isolate/damp certain vibrational behaviors, and improving overall ride comfort.
[0022] Mount performance is significantly affected by the amount of air trapped under the decoupler. Determining the position of the decoupler and the relative timing of the state switching of the mount increases the performance characteristics of the mount as well as the repeatability/consistency of this performance.
[0023] The inductive sensor is capable of detecting various metals and the capability of the inductive sensor to detect metals through rubber (which are common in the vibration isolation assembly/engine mount environment). Previous testing has demonstrated that a best scenario for peak phase is the condition with the decoupler bottomed out (biased toward the maximum travel in the downward direction, against the inertia track lower cage).
[0024] Detection of the decoupler position is therefore a requirement for optimizing mount performance. Use of an inductive sensor assembly with a slightly metallic decoupler (via metallic insert such as metallic sheets that are flexible, an overmolded assembly where the metal in the center of the decoupler is exposed, and/or infusion of metallic particles in the rubber compound of the decoupler) provides positional consistency of the decoupler when switching the state of the mount. Without position detection, the location of the decoupler at the time of state switching cannot be predicted or guaranteed and performance characteristics of the engine mount are potentially reduced because of the air trapping issue described above.
[0025] With inductive sensing, as a metallic object (in this case a rubber decoupler with metallic characteristics) approaches an inductive coil sensor, a measure of inductance is generated and converted to a digital reading (e.g., a higher value indicates close proximity to a metallic object). Application of this technology in the mount would provide the positional accuracy and repeatability to guarantee the desired mount performance.
[0026] In an exemplary embodiment, it is preferred that an inductive sensing coil be integrated in a lower plastic housing (inertia track assembly cage) of an engine mount, along with integration of a metallic compound or metal insert into a rubber decoupler. Preferably the inductive sensor is internal to a vibration isolation mount. As a result, optimization of the performance of the vibration isolation mount during state switching through the accuracy and repeatability of component positioning can be achieved.
[0027] FIG. 1 shows a mount assembly 100 that includes a restrictor or external housing 102 dimensioned to receive a first or elastomeric component, sometimes referred to as the main rubber element or compliant member 104 . The main rubber element 104 has a general shape of a truncated cone and is made of an elastomeric material such as elastic rubber. A fastener 106 extends outwardly from a metal bearing member 108 that is at least partially encapsulated within the first elastomeric member 104 . As best shown in FIG. 1 , a lower portion of the rubber element 104 includes a stiffener such as metallic stiffener 110 that is typically molded within the rubber element to add rigidity and support at desired locations.
[0028] The rubber element 104 is received within the restrictor housing 102 so that the fastener 106 extends through a central opening 112 of the restrictor. An internal shoulder 114 of the restrictor 102 abuttingly engages the lower portion of the main rubber element 104 . Further, a lower portion of the main rubber element 104 is hollowed out to define a surface of a first or upper fluid chamber 116 . A dividing wall or inertia track assembly 130 seals along an outer perimeter region with a lower surface of the main rubber element 104 . In this manner, the first fluid chamber 116 is defined by the cavity formed between the main rubber element 104 and the inertia track 130 . The inertia track has a first or upper surface 132 that faces the first chamber and a second or lower surface 134 that cooperates with a movable wall or diaphragm 136 preferably formed from a flexible rubber material that is sealed along an outer periphery with the inertia track assembly 130 . In this manner, the inertia track assembly 130 , namely the lower surface 134 thereof, and the diaphragm 136 define a second or lower fluid chamber 138 .
[0029] The structure and operation of this portion of the mount is well known to those skilled in the art so that further description is unnecessary to a full and complete understanding of the present disclosure. The basic technology for switchable hydraulic engine mounts has been known in the industry for several years. As is well known in the art, a switch mechanism allows the mount 100 to switch between two states, typically one with fluid effect damping, and the other with no, or reduced, fluid effect damping. Physical switching of the hydraulic mount 100 from a fluid damped state to a non-damped state by way of opening and closing a port is well understood so that further description of the conventional portions of the mount and their operation are omitted for purposes of brevity.
[0030] A decoupler 150 is received in what is commonly referred to as a cage 152 of the inertia track assembly. More specifically, the decoupler 150 is received between a first or upper portion 154 of the cage 152 and a second or lower portion 156 of the cage (which is oftentimes a plastic structure). The decoupler 150 is typically a rubber structure but for purposes of the present disclosure incorporates at least one of a metallic insert such as a flexible metallic sheet or an infusion of metallic particles in the rubber compound that forms (at least in part) the decoupler. An air chamber 160 is provided beneath the decoupler 150 . An electronic actuator 170 has a sealing tip or plunger 172 that selectively engages/seals a primary air vent 180 that communicates with vent passage 182 to atmosphere beneath the decoupler 150 ( FIG. 2 ).
[0031] FIG. 3 illustrates the effect of air on the phase due to the air being trapped beneath a fixed decoupler relative to the position of the decoupler 150 . For example, four graphical representations are shown in FIG. 3 , namely, the decoupler 150 in the neutral position (graphical representation # 3 of FIG. 3 and as illustrated in FIG. 4 ), the up position (graphical representation # 2 of FIG. 3 and as illustrated in FIG. 5 ), and the downward decoupler position (graphical representation # 4 of FIG. 3 and as illustrated in FIG. 6 ) relative to a baseline graphical representation of a vacuum pulled on the decoupler. In the decoupler up position of FIG. 5 , air is pulled in from the exterior environment through vent passage 182 as the decoupler 150 moves upwardly. In the decoupler down representation of FIG. 6 , air is forced from the chamber beneath the decoupler 150 and exits through the side vent passage 182 .
[0032] With continued reference to FIGS. 1-6 , and additional reference to FIGS. 7-9 , an inductive sensor assembly 200 will be shown and described in greater detail. Specifically, and as noted previously, the decoupler 150 includes at least one of metallic particles infusing the rubber compound to form the decoupler, or a metallic insert such as flexible metallic metallic sheets to define a slightly metallic decoupler. An inductive coil 202 senses a metallic object, i.e., the rubber decoupler with metallic characteristics, as the decoupler approaches. A measure of inductance is generated by the coil 202 and fed via inductive sensor/microcontroller interconnect 204 to microcontroller 206 and converted to a digital reading. The microcontroller 206 also communicates with the actuator 170 via actuator/microcontroller interconnect 208 and external power is supplied via an external connector 210 ( FIG. 9 ). In this manner, inductive sensing is used to detect the decoupler as the decoupler approaches the inductive coil sensor. A measure of inductance is generated and the technology is advantageously located in the mount to provide positional accuracy and repeatability that improve desired mount performance. Positional consistency of the decoupler when switching the state of the mount in response to the decoupler position can be accurately predicted or achieved with this arrangement. Overall performance characteristics of the mount are increased because of the ability to determine the position of the decoupler and the relative timing of the state switching of the mount, as well as the repeatability/consistency of this performance.
[0033] This written description uses examples to describe the disclosure, including the best mode, and also to enable any person skilled in the art to make and use the disclosure. The patentable scope of the disclosure is defined by the description, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the disclosure if they have structural elements that do not differ from the literal description of the disclosure, or if they include equivalent structural elements with insubstantial differences from the literal description of the disclosure. It is also noted that each feature of each specific embodiment disclosed herein is not considered essential to that specific embodiment, and that features disclosed in one embodiment can be added or substituted with another embodiment.
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A mount assembly for vibration isolation or an engine includes a housing having first and second fluid chambers that are selectively connected through an elongated, first path, and a shorter, second path. A decoupler is received in the housing, and an inductive sensor assembly senses a position of the decoupler. An associated method of inductively sensing a decoupler position to improve switchable mount performance is provided. Metallic particles or a metal inserts are provided in the decoupler to cooperate with an induction coil mounted adjacent the decoupler.
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U.S. PATENT DOCUMENTS
[0001]
6378866
April 2002
Graham-Ward
273/153
5649703
July, 1997
Kanbar
273/157
4583742
April 1986
Slinn
273/260.
4568082
February 1986
Musolino
273/157.
4548410
October 1985
Morrone
273/153
4494756
January 1985
Winer
273/156
4418915
December 1983
Calebs
273/159
4257609
March 1981
Squibbs
273/241
4216964
August 1980
Gans
273/153
4040630
August 1977
Brattain
273/157
3966209
June 1976
Gambardellla
273/153
3633913
January 1972
Solimene
273/153
FIELD OF THE INVENTION
[0002] The present invention relates to game and puzzles devices. Specifically, the present invention relates to a device for number puzzle and associated methods of using this device to construct number puzzles.
BACKGROUND OF THE INVENTION
[0003] There are many inventions on number puzzle games, but most of them are either too complicated to play, or too inconvenient to reset, such as having to lookup the some references or instructions. Also, the sizes of the prior arts are either too big to carry around in travel or the like, or have too many pieces to play with. The well-known SuDoKu number puzzle, which became world-wide popular, shows such shortages, wherein the puzzle setting-up has to refer to a complex-computed puzzle from a booklet, meanwhile a player has to either use pencil and paper, or operate eighty-nine pieces elements on a large game board.
[0004] A wide variety of puzzles devices is currently available on the commercial market and an even larger number of these types of devices are known in the art of puzzle devices, for example, the puzzle disclosed by Thurston in U.S. Pat. No. 490,689; the puzzle disclosed by Brown in U.S. Pat. No. 1,532,875; the puzzle disclosed by Haswell in U.S. Pat. No. 1,558,165; the puzzle disclosed by Clark in U.S. Pat. No. 4,410,180; the color match board game disclosed by Rowbal in U.S. Pat. No. 4,463,952; the matching puzzle with multiple solutions disclosed by Vogeler in U.S. Pat. No. 5,692,749; the twelve-sided polygon tile game and method of playing in U.S. Pat. No. 6,402,151; and the combined puzzle and container therefore in U.S. Pat. No. D353,167.
[0005] In U.S. Pat. No. 4,018,445, an educational game for playing a game of skill and judgment, the game comprising, at least one game board divided into a plurality of rows and columns of four in number, a plurality of numbered tokens for placing at each of the sixteen spaces defined on the game board by the rows and columns, each of said game boards having a numerical solution, the solution being as obtained by addition of the numbered tokens on the board after all spaces are filled, the addition being in any desired direction of any four of the tokens in abutting relationship or in squares. In playing the game, numerical tokens are selected and placed on the game board until all spaces on each player's board are filled, the object of the game being to obtain the correct solution indicated for that particular game. Optionally, random number selector means may be used to select the order of playing the numbered tokens.
[0006] In U.S. Pat. No. 4,216,964, a number puzzle comprises a playing board having a planar surface with an odd number of squares arranged horizontally and vertically intersecting each other on the playing board, and a plurality of playing elements with each element having a different numbered indicia thereon. The elements being arrangeable on the squares of the playing board to satisfy a predetermined value which is defined by the arithmetical equations so that when the plurality of elements are properly positioned on the squares, the sum of the numbered indicia on the elements on each of the horizontal and vertical rows is equal to the predetermined value in accordance with the arithmetical equations.
[0007] In U.S. Pat. No. 4,548,410, a number puzzle comprises a series of nine tiles, number from “1” to “9” in seriatim are arrangeable in a three-times-three relationship and slidably disposed one recess of a housing, with the housing having an auxiliary recess to accommodate one of the tiles so as to slidably move the other tiles. The object of the game is to arrange the tiles so that when the numbers are added horizontally, vertically or diagonally, the sum is “15”.
[0008] In U.S. Pat. No. 490,689, another two dimensional type puzzle is shown which discloses a two dimensional puzzle played with a playing board or box and individual tablets each of which contain a plurality of numerical indicia and a plurality of color indicia thereon. The various tablets are assembled within the box so that the number and color indicia appearing along each edge or quadrant of the tablets will match a corresponding set of indicia on the adjacent tablet. Thus, this reference simply teaches a matching type game in which no arithmetic solutions are provided, the numbers and colors simply serving as objects to be matched. A somewhat similar puzzle that also teaches a matching type solution is shown in British Patent Specification No. 173,588.
[0009] In summary, many conventional number puzzles, being either too difficult or too easy to solve for the average person, do not provide the personal reward or satisfaction that a person seeks in such puzzles. The present invention is designed for player's convenience. A two-dimensional five-times-five relationship square grid, which forms twenty-five square recesses arranged in five horizontal and five vertical rows intersecting each other, developed as an apparatus primarily for the purpose of providing a means for holding, laying, placing, positioning, and scattering number-indicia cubes, and a means for laying, inserting, swapping and matching the pattern cards that is set as background pattern of the puzzle playing surface, so that numerical indicia on each five cubes in the grid are unique horizontally, vertically and within each section of the background pattern, and the color indicia of the cubes match the background pattern's color indicia. This game also provides different levels of challenge, so that players at different ages can choose their own levels from the easiest to the most challenging.
SUMMARY OF THE INVENTION
[0010] The principal object of the present invention is to provide an apparatus and methods for players' easily constructing number puzzles themselves in accordance with three simply rules specified in this invention, without referring to any complex formulas, equations, or booklets.
[0011] Another object is to provide a number puzzle that is in hand-held mode and simple to play, readily to be carried and operated by a player during travel or the like, and economical in cost to manufacture.
[0012] Another object is to provide a number puzzle that can be reset without requiring complex and numerous rules and instructions.
[0013] Another object is to provide a number puzzle that is amusing and fascinating for either adults or young kids with different levels of challenge.
[0000] The Methods of Constructing the Puzzle
[0014] Firstly, select the five startup cubes in such a way that
a) Each cube has a unique number; b) Only one cube is with central background color indicia; c) Two cubes are with the first background color indicia and the other two cubes with the second background color indicia, or four cubes are with the same color indicia;
[0018] Secondly, place the cube with central color indicia into the center square recess of grid, and randomly place the rest of four cubes into the recesses in such a way that each pair of cubes with the same color indicia having 180-degree rotational symmetry about a central point of said grid center;
[0019] Thirdly, select one pattern card that can match the color indicia of the startup cubes in the grid and insert it into the pattern card slot as the puzzle background pattern, and arrange rest of twenty cubes to match the playing background color pattern, and flip the blank side of each of twenty cubes at the surface of the grid.
[0000] The Rules of Playing the Game
[0020] The five cubes with startup color indicia are initially scattered and positioned into the puzzle's playing surface, the five-times-five grid, in accordance with the methods described in the present invention, and they can not be moved, replaced, nor flipped over during the game.
[0021] In order to achieve the game's object, the rest of twenty cubes are rearranged and flipped over in the playing grid, displaying the numerical indicia so that each can remain unique horizontally, vertically and within the section with its background color indicia. These cubes can be moved, replaced and flipped over during the game, and the pattern cards can also be rotated, replaced and flipped over during the game in order to solve the puzzle.
[0022] The objects of the puzzle solution is that the numerical indicia displayed on each five cubes are unique, horizontally, vertically as well as within each section with the same color indicia of the selected pattern, and the color indicia of said cubes also need to match those of the background patterns.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a top plan view of the playing box accordance with the present invention.
[0024] FIG. 2 is a diagram of the three types of playing cubes.
[0025] FIG. 3 is a diagram of the front side of the first pattern card.
[0026] FIG. 4 is a diagram of the back side of the first pattern card.
[0027] FIG. 5 is a diagram of the front side of the second pattern card.
[0028] FIG. 6 is a diagram of the back side of the second pattern card.
[0029] FIG. 7 is a diagram of the front side of the third pattern card.
[0030] FIG. 8 is a diagram of the back side of the third pattern card.
[0031] FIG. 9 is a diagram of the front side of the fourth pattern card.
[0032] FIG. 10 is a diagram of the back side of the fourth pattern card.
[0033] FIG. 11 is a diagram of the front side of the fifth pattern card.
[0034] FIG. 12 is a diagram of the back side of the fifth pattern card.
[0035] FIG. 13 is a plan view of a setup puzzle for a selected pattern card.
[0036] FIG. 14 is a intersection view of the playing box with positioned-in and housed-in cubes.
LIST OF REFERENCE NUMBERS
[0037] With regard to reference numerals used, the following numbering is used throughout the drawings and descriptions.
[0038] 10 the Numbered Cubes with the Center Background Color Indicia
[0039] 12 the Numbered Cubes with the First Background Color Indicia
[0040] 14 the Numbered Cubes with the Second Background Color Indicia
[0041] 16 the First Pattern Card
[0042] 18 the Second Pattern Card
[0043] 20 the Third Pattern Card
[0044] 22 the Fourth Pattern Card
[0045] 24 the Fifth Pattern Card
[0046] 26 Recesses of the Grid on the Playing Box
[0047] 28 Pattern Card Slot
[0048] 30 Playing Box Lid
[0049] 32 Cube Position Holders
[0050] 34 Cube Seats
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0051] As shown in FIG. 1 , FIG. 11 and FIG. 12 , the five-number puzzle game comprising a flat box that has twenty-five square recesses 26 , in the five-times-five relationship, in the grid on its surface, in which twenty-five cubes 10 , 12 and 14 can be laid on, positioned-in with flexible connection of cube position holders 32 , or can be pushed-in to the cube seats of each recess 34 , and a pattern card slot 28 at the bottom of the playing box into which the pattern cards 16 , 18 , 20 , 22 and 24 can be inserted and slid into said slot so as to become a playing pattern background of said flat box. The grid is made of transparent material so that the player can view the inserted playing background patterns. The box opens by sliding the card out of the slot so that the player can push out the positioned-in or housed-in cubes for resetting the new puzzle games. The grid forms twenty-five square recesses arranged in five horizontal and five vertical rows intersecting each other. The lid of the box 30 is for holding the playing cubes during the game.
[0052] As shown in FIG. 2 , the present apparatus also comprises twenty-five cubes, among which five of said cubes 10 having the background color indicia identical with the color indicia of the center section of the pattern cards, ten of said cubes 12 having the first background color indicia, same as the first background color indicia of the pattern cards, and the other ten of said cubes 14 having the second background color indicia, same as the second background color indicia of the pattern cards. All the twenty-five cubes are imprinted with the numbered indicia from “1” to “5” in the five of six sides of said cubes, and with the sixth side blank without any imprint.
[0053] The pattern cards are the key elements to setup number puzzles. On the pattern cards, there are three colors, the center color, the first background color and the second background color, that divide twenty-five squares into the five sections. Mathematically, the first and the second color indicia are not mutual exchangeable when manufacturing a particular pattern card because of the puzzle solutions are associated with each other among these ten patterns. The squares of each section are adjacent one another. The sections with the same color indicia have 180-degree rotational symmetry about a central point of the pattern. The pattern on each card with different literal indicia represents a level of puzzle difficulty. The five described patterns are such designed that any puzzle setup in accordance with methods of puzzle construction in present invention is always solveable when the appropriate puzzle-associated pattern is selected as its playing background. In another words, there is a definite solution for any puzzle within the scope of these five pattern cards.
[0054] The five preferably designed patterns are described by using the A, B, C, D and E as their horizontal index, and 1, 2, 3, 4 and 5 as their vertical index.
[0055] As shown in FIG. 3 , in the pattern on the front side of the first pattern card 16 , A 1 , B 1 , C 1 , D 1 , E 1 , A 5 , B 5 , C 5 , D 5 and E 5 are in the first background color indicia; A 2 , B 2 , D 2 , E 2 , A 3 , E 3 , A 4 , B 4 , D 4 , and E 4 are in the second background color indicia; C 2 , B 3 , C 3 , D 3 , and C 4 are in the center color indicia.
[0056] As shown in FIG. 4 , in the pattern on the back side of the first pattern card 16 , A 1 , B 1 , C 1 , D 1 , E 1 , A 5 , B 5 , C 5 , D 5 and E 5 are in the second background color indicia; A 2 , B 2 , D 2 , E 2 , A 3 , E 3 , A 4 , B 4 , D 4 , and E 4 are in the first background color indicia; C 2 , B 3 , C 3 , D 3 , and C 4 are in the center color indicia.
[0057] As shown in FIG. 5 , in the pattern on the front side of the second pattern card 18 , A 1 , B 1 , A 2 , B 2 , A 3 , E 3 , D 4 , E 4 , D 5 , and E 5 are in the first background color indicia; D 1 , E 1 , D 2 , E 2 D 3 , B 3 , A 4 , B 4 , A 5 , and B 5 are in the second background color indicia; C 1 , C 2 , C 3 , C 4 and C 5 are in.the center color indicia.
[0058] As shown in FIG. 6 , in the pattern on the back side of the second pattern card 18 , A 1 , B 1 , A 2 , B 2 , B 3 , D 3 , D 4 , E 4 , D 5 , and E 5 are in the first background color indicia; D 1 , E 1 , D 2 , E 2 E 3 , A 3 , A 4 , B 4 , A 5 and B 5 are in the second background color indicia; C 1 , C 2 , C 3 , C 4 and C 5 are in the center color indicia.
[0059] As shown in FIG. 7 , in the pattern on the front side of the third pattern card 20 , A 1 , B 1 , C 1 , D 1 , A 2 , E 4 , B 5 , C 5 , D 5 , and E 5 are in the first background color indicia; E 1 , C 2 , D 2 , E 2 A 3 , E 3 , A 4 , B 4 , C 4 , and A 5 are in the second background color indicia; B 2 , B 3 , C 3 , D 3 , and D 4 are in the center color indicia.
[0060] As shown in FIG. 8 , in the pattern on the back side of the third pattern card 20 , A 1 , A 2 , B 2 , C 2 , A 3 , E 3 , C 4 , D 4 , E 4 , and E 5 are in the first background color indicia; B 1 , C 1 , D 1 , E 1 , E 2 , A 4 , A 5 , B 5 , C 5 , and D 5 are in the second background color indicia, D 2 , B 3 , C 3 , D 3 , and B 4 are in the center color indicia.
[0061] As shown in FIG. 9 , in the pattern on the front side of the fourth pattern card 22 , B 1 , C 1 , D 1 , E 1 , C 2 , C 4 , A 5 , B 5 , C 5 , and D 5 are in the first background color indicia; A 1 , A 2 , A 3 , A 4 B 4 , D 2 , E 2 , E 3 , E 4 , and E 5 are in the second background color indicia; B 2 , B 3 , C 3 , D 3 , and D 4 are in the center color indicia.
[0062] As shown in FIG. 10 , in the pattern on the back side of the fourth pattern card 22 , A 1 , B 1 , C 1 , D 1 , C 2 , C 4 , B 5 , C 5 , D 5 , and E 5 are in the second background color indicia; A 2 , B 2 , A 3 , A 4 , A 5 , E 1 , E 2 , E 3 , D 4 , and E 4 are in the first background color indicia; D 2 , B 3 , C 3 , D 3 , and B 4 are in the center color indicia.
[0063] As shown in FIG.11 , in the pattern on the front side of the fifth pattern card 24 , A 1 , A 2 , A 3 , B 1 , C 1 , E 3 , E 4 , E 5 , D 5 , and C 5 are in the first background color indicia; A 4 , A 5 , B 3 , B 4 , B 5 , D 1 , D 2 , D 3 , El and E 2 are in the second background color indicia; B 2 , C 2 , C 3 , C 4 , and D 4 are in the center color indicia.
[0064] As shown in FIG. 12 , in the pattern on the back side of the fifth pattern card 24 , A 1 , A 2 , B 1 , B 2 , B 3 , D 3 , D 4 , D 5 , E 4 and E 5 are in the first background color indicia; A 3 , A 4 , A 5 , B 5 , C 1 , C 5 , D 1 , E 1 , E 2 and E 3 are in the second background color indicia; B 4 , C 2 , C 3 , C 4 , and D 2 are in the center color indicia.
[0065] While preferred specific embodiments of the present invention are hereinbefore set forth, it is to be clearly understood that the invention is not to limited to the exact constructions, materials, devices, symbols and colors illustrated and described hereinbefore because various modifications of these details may be provided in putting this invention into practice.
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An apparatus and method for constructing the two-dimensional five-number puzzle is provided wherein the twenty-five cubes, each with numbered indicia from “1” to “5”, are positionable in a five-times-five relationship grid that forms twenty-five square recesses arranged in five horizontal and five vertical rows intersecting each other, and a plurality of pattern cards can be chosen and positioned as the puzzle's background pattern that divides the five-times-five grid into five sections with three color indicia. The object of the game is to arrange the cubes so that the numerical indicia whereon are unique from “1” to “5” horizontally, vertically, as well as in each section, and the color indicia match those indicia of each section on the pattern card.
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This application claims the priority of German Patent Document DE 199 50 504.7, filed Oct. 20 1999, the disclosure of which is expressly incorporated by reference herein.
BACKGROUND AND SUMMARY OF THE INVENTION
The invention relates to a process and apparatus for the control of the light distribution of a headlight arrangement of a vehicle. Preferred embodiments relate to such process and apparatus which includes at least one first light sensor which senses light emissions acting on a driver of the vehicle from an area (I) of the opposite side of the road, a comparator device which compares the intensity of the light emissions in each area with a threshold value, a control device for the light distribution of the headlight arrangement as a function of a signal of the comparator device, where the control device, on overshoot of the threshold value in an area (I) sensing the opposite side of the road, sets the light distribution so that the illumination of an edge of the road of the driver's own side of the road is increased wherein the light distribution in the sense of an increase of the illumination of the edge of the road of the driver's own side of the road a turn-off delay is provided.
In the case of a generic process for the control of the light distribution of a headlight arrangement according to German Patent Document DE 38 44 364 C2, the driver's own side of the road is illuminated at an increased light level to avoid a reduction of the ability of the driver of a vehicle to see when oncoming traffic is present. For this purpose a light sensor registers various areas of a visual field of the driver and the light level for the illumination the driver's own side of the road is increased if a threshold value for the light emissions from the area of the opposite side of the road is exceeded. If, however, a threshold value for the light emissions from the area of the driver's own side of the road is exceeded or a threshold value for the light emissions for an area above the road is exceeded, then the light level is reduced once again. For the increase of the light level, an additional headlight is provided for dimmed light, said additional headlight being switched on in the previously described manner. Alternatively a movable shutter is provided in a headlight already present with which the light distribution can be changed. Instead of the movable shutter the light source can also be shifted, so that the position of the point of highest light intensity shifts.
With respect to this state of the art it is an objective of the invention to provide an improved process and an improved apparatus for the control of the light distribution of a headlight arrangement of a vehicle.
According to the invention this objective is realized by providing a turn-off delay for the light distribution in the sense of an increase of the illumination of the edge of the road of the driver's own side of the road. By this measure the light intensity in the area of the driver's own side of the road is not increased discontinuously but rather gradually. Thereby it is avoided in an advantageous manner that for the driver, whose eyes during the increased illumination had become accustomed to the greater amount of light, a dark space arises after the passing of the oncoming traffic by a sudden withdrawal to the increased illumination in the area of the driver's own side. In addition the number of the switching processes recognizable for the driver is reduced in the case of moderately dense oncoming traffic.
Advantageous extensions of the invention are described below and in the claims.
Thus it is proposed to perform the turn-off delay with a delay of approximately 2 to 10 seconds. This measure is based on the recognition that this time is sufficient so that the eye of the driver can accustom itself to the reduction of illumination. If, in this case, the upper limit is chosen, then the reduction of the illumination for the driver is hardly still perceptible. An additional increase of the delay time then leads to no additional improvement of the adaptation.
Furthermore, it is proposed in addition to the turn-off delay to provide also a turn-on delay. This should then preferably have a delay time of at most 2 seconds. By this measure the turn-on of the additional light acts less irritatingly on the driver. On the other hand it must be noted that a noticeable turn-on is desirable in order to divert the gaze of the driver to the right edge of the road.
Before the turn-off delay a deadtime of up to 3 seconds can be provided in addition in order to compensate for that time span which lies between the point in time at which the oncoming vehicle leaves the sensing area of the light sensor and the point in time at which the oncoming vehicle leaves the area visible to the driver.
For this purpose a light sensor senses various areas of a field of vision of the driver and the light level for the illumination of the driver's own side of the road is increased if a threshold value for the light emissions from the area of the oncoming traffic is exceeded.
Furthermore, it is advantageous if the threshold value for the light emissions from the area of the opposite side of the road at which the illumination of the edge of the road is increased, is determined as a function of ambient brightness. In this case the threshold value should increase with increasing ambient brightness so that the increase of the illumination of the edge of the road is only done when the light emissions from the area of the opposite side of the road lie by a certain amount or percentage above the ambient brightness in order thus to avoid an unnecessary increase of the illumination of the edge of the road.
Also it can be provided to perform the increase of the illumination of the edge of the road only within a predetermined range of speed. The lower limit of this range should be chosen so that it is characteristic for city traffic. In Germany this value can lie around 30 km/h. Thereby it is prevented that within the area of the city (usually illuminated anyway) with partially heavier oncoming traffic, in stop-and-go traffic, in standing traffic (for example, before a stop light) or in congestion by blinking lights, taillights, or reflections a frequent or even continuous additional illumination is triggered in the vehicle traveling forward.
The upper limit of this range should on the contrary be chosen so that it is characteristic for freeway travel. In Germany this value could lie at around 120 km/h. Thereby the illumination of the edge of the road will not be increased unnecessarily on the freeway, on which there can be no oncoming traffic in the direct sense. The limited range would offer moreover no real help at higher speeds.
According to advantageous features of preferred embodiments of the process, it is further proposed to turn headlights on or off for the setting of a light distribution. This setting of the light distribution distinguishes itself by a particularly simple setup and lower control expenditure. In particular it is proposed to provided a dimmed light known in itself for the illumination of the driver's own side of the road and an additional headlight for the illumination of the edge of the road.
Finally, it is proposed according to the apparatus to dispose the light exit area of the additional headlight in the light exit area of a headlight already present. By this measure in an advantageous manner on turning on of the additional headlight no new surface to be illuminated is provided which could distract or even irritate the oncoming driver. For such a common light exit for example, the additional headlight can be disposed in the area of the dimmed light or can be combined with a parking light.
For this purpose a dimmed light and an additional headlight or parking light could, for example, be disposed in a common reflector. It is also contemplated to dispose the additional headlight and the dimmed light under a common cover plate and to illuminate in addition the space formed around the two headlights with the aid of an additional source of illumination, such as, for example, the parking light, so that despite the separate light generation systems the goal of a single headlight is maintained.
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 schematic overview representation of a headlight arrangement of a vehicle. constructed according to preferred embodiments of the invention;
FIG. 2 is a schematic representation of a field of vision of a driver of a vehicle;
FIG. 3 is a schematic representation from a bird's-eye view of a light distribution for vehicles on a highway;
FIG. 4 is a time curve of an output signal generated by a turn-on and turn-off delay for a second headlight of an arrangement constructed according to preferred embodiments of the invention;
FIG. 5A is a schematic depiction of an arrangement for headlights constructed according to a preferred embodiment of the invention;
FIG. 5B is a schematic depiction of the headlight of FIG. 5A taken in the direction of arrow B;
FIG. 6A is a schematic depiction of an alternative arrangement of the headlight in FIG. 5A;
FIG. 6B is a schematic depiction of the headlight of FIG. 6A taken in the direction of arrow B;
FIG. 7A is a schematic depiction of an additional alternative arrangement for the headlight of FIG. 5A;
FIG. 7B is a schematic depiction of the headlight of FIG. 7A taken in the direction of arrow B;
FIG. 8 is a schematic representation of a device for pivoting the headlight of an arrangement constructed according to preferred embodiments of the invention; and
FIG. 9 is a detail representation of hinges according to FIG. 8 .
DETAILED DESCRIPTION OF THE INVENTION
The headlight arrangement 1 represented in FIG. 1 of a vehicle not shown in more detail includes a light sensor 2 disposed in the direction of travel of the vehicle which senses light emissions in a field of vision of the driver. The light sensor 2 consists of an imaging optics 3 and a light-sensitive layer disposed in the imaging plane 4 . The output signals of the light sensor 2 arrive over a signal line 6 at a control device 7 . An output signal 8 of the control device 7 is present on a switching device 9 which acts on a first headlight 11 . Thereby the headlight 11 is provided with an additional headlight for the illumination of an edge 24 of the road (represented in FIG. 2) while a second headlight 12 driven by a light switch 10 is a dimmed headlight known in itself. The light switch 10 acts on both headlights 11 and 12 . Instead of a positioning motor 34 , a solenoid or the like can be provided.
The control device 7 can have on the input side an amplifier 13 for the preparation of the signal coming in over the signal line 6 . Connected thereafter is a comparator device 14 which compares the output signal of the amplifier 13 to a signal supplied by a headlight coder 15 . The threshold value coder 15 is in this case connected to a sensor 35 which supplies a signal U for the ambient brightness. The sensor 35 is in this case directed upwards. A sliding average calculation is already done within the sensor 35 in order to compensate for short-term influences such as are generated by street lamps, for example. The threshold value coder adapts threshold value supplied to the comparator device to the ambient brightness U in the manner that this threshold value always increases with increasing ambient brightness U. A turn-on and turn-off delayer 16 is connected behind the comparator device 14 and with preset delay times TE for the turn-on delay, TA for the turn-off delay, TO for a deadtime connected before the turn-off delay finally generates the continuously adjustable (dimmable) output signal 8 .
The reproduction of the output signal 8 at the switching device 9 is in this case controlled by a switch 37 which is connected to a coder 36 for a speed v. The output signal 8 is in the present example only reproduced when the speed sensed by the coder 36 lies within a range from 30 km/h to 120 km/h. It is also possible to activate the entire control device 7 only within this range of speed v. In addition it can be insured that a turn-off of the control device 7 or the reproduction of the output signal 8 can only be done when the output signal 8 has the value zero. Thus the additional headlight 11 on leaving the range of speed cannot be turned off while operating but rather only the turning on of the additional headlight 11 is suppressed on leaving the range of speed.
FIG. 2 shows the field of vision of the driver received by the light-sensitive field 4 . The area I bordered by dash lines stands for the area of the opposite side 20 of the road. The area I is chosen so large that oncoming vehicles are sensed. It has been shown that in this case also a section of the driver's own side of the road should be sensed in order also to be able to recognize oncoming vehicles on curved stretches.
FIG. 3 shows the light distribution of the headlights 11 and 12 from a bird's-eye view. The vehicle 17 is located on the side 21 of the road appropriate to its direction. An additional vehicle 18 is located on the opposite side 20 of the road. The dimmed headlight 12 of the driver's own vehicle 17 generates the light cone 22 while the additional headlight 11 generates in its starting position the light cone 23 . By the positioning motor 34 the additional headlight 11 can be pivoted into a second position 23 ′ in which it can be used as additional high-beam headlight, as a range support for the dimmed light (for example, in freeway driving), or for flashing headlights (advantageous, for example, in connection with a discharge lamp as first headlight 11 for the generation of dimmed light and high-beam light).
The control device 7 continuously compares the signal supplied by the light-sensitive field for the range I with a threshold value stored in the threshold value coder 15 for the range I, said threshold value being adapted continuously to the ambient brightness with the aid of the signal U. If in the comparator device 14 it is recognized that in the range I, i.e. in the range of the opposite side 20 of the road, the light intensity exceeds the limiting value predetermined by the threshold value coder 15 , then the control device 7 outputs an output signal 8 which causes the first switching device 9 to turn on the additional headlight 11 . By this measure the light cone 22 is expanded by the light cone 23 and an area 24 of the edge of the road is illuminated more strongly (see FIG. 2 ).
By the—in the area sensed by the light cone 23 —clearly increased illumination, the gaze of the driver is automatically drawn away from the opposite side 20 of the road to the now more brightly illuminated edge of the road 24 . Thereby blinding caused by a vehicle 18 coming on the opposite side 20 of the road is reduced without the blinding of the oncoming vehicles 18 being increased. The light cone 23 is for this purpose aligned so that no scattered light goes in the direction of the opposite side 20 of the road.
FIG. 4 shows the time curve of the output signal 8 , the signal U for the ambient brightness, and the signal L 1 for the brightness in the area I. In each of the time intervals t 1 and t 2 as well as t 3 and t 4 an oncoming vehicle 18 is located on the opposite of the road 20 , to be recognized in the signal levels of the signal L 1 . For the first point in time t 1 a first oncoming vehicle 18 is so near to the driver's own vehicle 17 that there is danger of blinding. At that point in time the comparator 14 issues a signal 25 to the turn-on and turn-off delayer 16 . Through the turn-on and turn-off delayer 16 the output signal 8 does not immediately reach the value 100% thereupon, but rather only after a preset delay time TE of 0.2 sec. At the point in time t 2 the oncoming vehicle 18 passes the driver's own vehicle 17 so that there is no more danger of blinding. At this point in time the signal 25 is cleared. The output signal 8 on the contrary does not fall off immediately to 0%, but rather is first of all held for a deadtime TO of 2 seconds preset in the turn-on and turn-off device 16 and then slowly taken back over a delay time TA, here 3 seconds also preset.
At the third point in time t 3 a second vehicle has approached so far that in turn there is danger of blinding. At this point in time t 3 the output signal 8 (and thus also the amount of light of the additional headlight 11 ) has sunk only to 70% and is then raised once again to 100% with the delay time TE preset for the turn-on delay. At the fourth point in time t 4 the second vehicle passes the driver's own vehicle 17 . Since in the present example no additional vehicle approaches, the output signal 18 then sinks after the expiration of the deadtime TO within the preset delay time TA to 0%, that is, the additional headlight 11 is turned off completely.
The threshold value supplied to the comparator 14 by the threshold value coder 15 in this case is a function of the (average) ambient brightness determined by the sensor 35 . The threshold value rises in this case with rising ambient brightness so that as a result the brightness determined for the monitored range I must always lie by a certain amount or percentage above the ambient brightness in order to trigger a turning on of the additional headlight 11 .
Possible configurations of the headlights 11 and 12 are represented in the FIGS. 5A, 5 B; 6 A, 6 B; and 7 A, 7 B.
Expediently the headlights 11 and 12 can be disposed under a common cover glass 27 in a common housing 28 . In addition to the headlights 11 and 12 a parking light 26 is provided.
In the first exemplary embodiment according to FIGS. 5A and 5B the second headlight 12 is provided with its own reflector 29 while an additional reflector 30 is utilized by the additional headlight 11 as well as by the parking light 26 .
On the other hand, in the second exemplary embodiment according to FIGS. 6A and 6B, both headlights 11 and 12 are disposed in a common reflector 31 . The additional headlight 11 (more precisely the light source of the additional headlight 11 ) is in this case disposed offset with respect to the light source for the dimmed headlight 12 in order to generate the desired light bundle 23 . The parking light 26 can also be disposed in the single reflector 31 .
In the third exemplary embodiment according to FIGS. 7A and 7B, the headlights 11 and 12 are implemented as separate projection headlights. These generate on the common cover plate 27 separate surfaces 32 and 33 for the passage of light. The parking light 26 is disposed in this case between the headlights 11 and 12 or at another suitable point within the housing 28 so that the light exiting from the parking light 26 illuminates the area lying outside of the surfaces 32 and 33 for the passage of light and represented with hatching of the common cover plate 27 . Alternatively, light scattered from the dimmed headlight 12 can be used for illumination. The parking light 26 can be disposed in this case at another point.
In the exemplary embodiments according to FIGS. 5 to 7 it is significant that the additional headlight 11 , always in connection with an additional headlight, here the dimmed headlight 12 or the parking light 26 , is disposed so that common exit surfaces for the light result. Thus in the exemplary embodiment according to FIGS. 5A and 5B the additional headlight 11 as well as the parking light 26 , in the second exemplary embodiment according to FIGS. 6A and 6B the additional headlight 11 and the dimmed headlight 12 and in the third exemplary embodiment according to FIGS. 7A and 7B the additional headlight 11 (or its light-transmitting surface 33 ) and the parking light 26 each have a common light exit area.
FIG. 8 shows schematically a device 35 for the pivoting of the additional headlight 11 . As already shown in FIG. 1, the additional headlight 11 is driven from the standpoint of illumination technology via the switching device 9 and the output 8 of the (not represented here) control device 7 while the positioning motor 34 is connected to an output 8 ′ of the control device 7 . The additional headlight 11 is mounted in the headlight housing 28 so that it can be pivoted with the aid of two hinges 36 ′ and 36 ″ and can be pivoted via the positioning motor 34 which for this purpose is connected to the additional headlight 11 . The range of pivoting is only a few degrees. In its represented starting position the additional headlight 11 generates the light cone 23 (cf. FIG. 3) while in its second position, into which it is pivoted by the positioning motor 34 , it generates the light cone 23 ′.
In FIG. 9 the arrangement of the hinges 36 ′ and 36 ″ is represented schematically which is chosen so that a diagonal pivot axis results whose length is chosen so that the additional headlight 11 can be pivoted between it starting position and its second position. The point of engagement of the positioning motor 34 must in this case merely be chosen so that a force engagement axis of the positioning motor 34 does not intersect the pivot axis.
The control device 7 will then drive the positioning motor 34 (and thus pivot the additional headlight 11 in its second position) if, for example, the driver activates flashing lights or if the high beam is turned on. If the control device 7 recognizes freeway travel, the additional headlight 11 can be turned on with the corresponding layout of the illumination (this is a hard light-dark limit in connection with an inclination of approximately −0.2%) also as range support for the dimmed light. As starting position the illumination of the area 24 of the edge of the road is chosen so that in case of a failure of the positioning motor 34 oncoming vehicles 18 are not blinded by the headlight 11 located in the second position.
The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.
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A process and apparatus are provided for the control of the light distribution of a headlight arrangement of a vehicle with at least one first light sensor which senses light emissions acting on a driver from the field of vision in the direction of travel for various areas of the field of vision. A comparator device compares the intensity of the light emissions for each area with a threshold value. A control device controls the light distribution of the headlight arrangement as a function of a signal of the comparator device. In order to provide an improved process and an improved apparatus for the control of the light distribution of a headlight arrangement of a vehicle, it is proposed for the light distribution in the sense of an increase of the illumination of the edge of the road of the driver's own side of the road to provide a turn-off delay combined with a deadtime connected before it. The threshold value for the comparator device is a function of the ambient brightness which is determined over a certain time.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to hold down devices, and more particularly to apparatus for securing objects to the ground.
2. Description of the Prior Art
Various products have been developed to secure posts, poles, and the like to the ground. For example, U.S. Pat. Nos. 3,286,962; 3,317,168; and 4,454,824 show devices that support posts vertically on the ground by means of components that include skewers or augers embedded into the ground. U.S. Pat. No. 4,593,872 discloses a post holding sleeve that is held in a bayonet fashion to a screw that is turned into the ground.
U.S. Pat. No. 3,840,203 shows a base plate and tube for supporting non-vertical posts on the ground. The base plate of the U.S. Pat. No. 3,840,203 is retained to the ground by a pin driven into the ground and hooked into the base plate.
Prior hold down devices are also capable of securing items other than posts and the like to the ground. For instance, U.S. Pat. No. 4,072,286 describes a hoop type clamp retained flat on the ground by a screw or auger. U.S. Pat. No. 3,743,289 shows a skewer used to secure a baseball base in place on the ground.
Although the prior hold-down devices are generally suitable for their intended purposes, they nevertheless possess certain disadvantages. Most of the known hold downs are composed of two or more components that require assembly or other manipulation in order for them to hold a desired object in place. Other devices are designed to secure only specific objects, thereby limiting their usefulness. Consequently, the prior devices are either undesirably expensive to manufacture and complicated to use, or they are unsuitable for the particular purpose at hand.
Thus, a need exists for improvements in products for securing objects to the ground.
SUMMARY OF THE INVENTION
In accordance with the present invention, a versatile and inexpensive ground anchor is provided that is capable of securing a variety of objects to the ground. This is accomplished by apparatus that includes a coarse screw extending from one surface of a flat plate and a selected retaining member attached to the other surface of the plate.
The flat plate may be of any size and shape to suit the object to be secured to the ground and the contour of the ground surface. The screw is made as a long rod wound into a helix and having a longitudinal axis. One end of the rod is bent into a section that lies in a plane perpendicular to the screw axis. Preferably, the bent end section is formed into a generally semi-circular loop. The semi-circular loop is welded to the plate bottom surface, thereby creating a rigid joint between the plate and screw. Depending on the soil type and the application for the ground anchor, the screw may be from approximately seven inches to nine inches long and have an outer diameter of approximately two inches.
In one embodiment of the invention, the retaining member is in the form of a tube welded or otherwise attached to the plate second surface. The tube may be round and have its longitudinal axis at an angle to the plate. That embodiment is especially suitable for receiving the end of a pole associated with a swing set or a boat dock.
In another embodiment, the retaining member is a tube having its axis substantially perpendicular to the plane of the plate. The retaining member cross section may be rectangular or round for receiving a fence post, mail box post, or deck post. A rectangular retaining member may be made as two upstanding channels having the free ends of their respective side legs abutting and welded together.
A third embodiment employs a retaining member that is in the form of a ring attached to the flat plate second surface. The ring may be rigidly fixed to the plate, or the ring may swivel on the plate. The ring is very convenient for tying lines associated with a wide variety of objects such as airplanes, tents, and trees.
In all embodiments, the ground anchor is used by rotating it to cause the screw to penetrate the ground until the plate first surface rests on the ground. The object to be secured by the ground anchor is set in place, either within the retaining member, or adjacent the ground anchor and tied to the retaining member. The ground anchor thus functions in an inexpensive and convenient manner to secure a wide variety of objects in place on the ground.
Other advantages, benefits, and features of the invention will become apparent to those skilled in the art upon reading the detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the ground anchor of the present invention.
FIG. 2 is a top view of FIG. 1.
FIG. 3 is a bottom view of FIG. 1.
FIG. 4 is a side view of a modified embodiment of the present invention.
FIG. 5 a top view of FIG. 4.
FIG. 6 a bottom view of FIG. 4.
FIG. 7 is a side view of a further modified embodiment of the present invention.
FIG. 8 is a top view of FIG. 7.
DETAILED DESCRIPTION OF THE INVENTION
Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention, which may be embodied in other specific structure. The scope of the invention is defined in the claims appended hereto.
Referring to FIGS. 1-3, a ground anchor 1 is illustrated that includes the present invention. The ground anchor is particularly useful for securing a wide variety of objects, typically represented by pole 27, to the ground 3 in an economical and convenient fashion.
The ground anchor 1 is comprised of a flat plate 5, which, in the illustrated construction, is round in shape and has a diameter of approximately seven inches. Fourteen gauge sheet steel works very well for the plate 5. Attached to the top surface 7 of the plate is a retaining member in the form of a round tube 9. I prefer that the tube 9 have an outer diameter of approximately 1.75 inches, an eleven gauge wall thickness, and a three inch length. One end 11 of the tube 9 is cut at 30 degrees to the tube longitudinal axis 13. The tube end 11 is welded to the plate surface 7. A hole 15 extends transversely through the tube near its free end 17.
To secure the plate 5 and tube 9 to the ground, the ground anchor 1 further comprises a helical rod or screw 19 extending from the plate bottom surface 21. In the preferred embodiment, the screw 19 has a first end section 23 that is generally in the form of a semi-circle. The semi-circular end section 23 lies in a plane that is generally perpendicular to the screw longitudinal axis 24. The end section 23 lies flat against and is welded to the plate bottom surface 21. The screw second end 25 may be sharpened. The screw may be of any size and shape that suits the particular soil and application. I have found that a screw made of a 0.31 inches diameter rod coiled into a helix with a two inch outer diameter and with a finished length of approximately seven inches works very well for many installations.
In use, the screw point 25 is placed on the surface of the ground 3 with the plate 5 parallel to the ground surface. The plate is rotated such that the screw point 25 and the entire screw 19 enters the ground in auger fashion until the plate bottom surface 21 contacts the ground. The plate is rotated for adjustment until the tube axis 13 is oriented in the desired direction. The ground anchor is then firmly in place to receive a pole 27 of a swing set, boat dock, or similar member in the tube. The pole 27 may be positively held in place by a pin passing through the pole and the tube holes 15. Once in place, the ground anchor 1 will not pull out or shift under normal use, nor will it work out of the ground due to frost related soil movements. On the other hand, when the ground anchor is no longer needed, it can be intentionally removed from the ground merely by rotating it in a reverse direction until the screw is free. The ground anchor is then ready to be used again in a new location.
FIGS. 4-6 show a modified ground anchor 29 that is designed to support a selected object 31 in a vertical attitude. The ground anchor 29 has a flat plate 33 with top and bottom surfaces 35 and 37, respectively. The plate 33 may be square, as shown, or round or rectangular to suit a particular application and the ground contour.
To the plate top surface 35 is welded a retaining member 39. The retaining member 39 is shown as a tube with a square cross section, but, like the plate 33, the tube may have a round or rectangular cross section. The tube axis 41 is perpendicular to the plane of the plate. A preferred construction for the tube consists of two channels 43 and 45 with the free ends of their respective side legs 47 and 49 abutting and stitched together with welds 51.
The ground anchor 29 includes a screw 53 that has a semi circular end section 55 welded to the plate bottom surface 37. The screw 53 may be generally similar to the screw 19 described previously in connection with the ground anchor 1 of FIGS. 1-3. Other suitable components for the ground anchor 29 include a plate 33 that is 4.63 inches square and made of fourteen gauge sheet steel, two 1.81 by 3.63 inch channels six inches long, and a 0.31 inch diameter rod formed into a helix having a 2.50 inch outer diameter and a finished length of 9.5 inches.
The ground anchor 29 is used in generally the same manner as the ground anchor 1. When the ground anchor 29 is in place in the ground, the selected object 31 is inserted into the retaining member 39. The ground anchor 29 is especially suitable for holding fence posts, mail box posts, and the like vertically in place on the ground. Drain holes 57 in the plate 33 prevent water from accumulating within the retaining member.
Turning to FIGS. 7 and 8, a further modified ground anchor 57 has a flat plate 59, which may be round, with top and bottom surfaces 61 and 63, respectively. To the top surface 61 of the plate 59 is attached a ring, such as a D-ring 65. The D-ring 65 may be welded in one position to the plate. I prefer, however, that the D-ring be swivelable within a pair of journals 67 that are welded to the plate and that receive the opposite ends 69 of the D-ring. The semi circular end section 70 of a helical rod or screw 71 is welded to the plate bottom surface 63. Satisfactory shapes and dimensions for the ground anchor 57 include a round fourteen gauge plate with a six-inch diameter, a D-ring made of 0.25 inch diameter rod, and a screw 71 made of 0.31 inch diameter rod configured into a helix having a finished length of approximately nine inches and an outer diameter of approximately two inches.
One end of a rope 73 is tied to the D-ring 65. The other end of the rope 73 may be tied to such diverse objects as airplanes, nursery stock, and tents. In that manner, ropes tied to the D-ring secure those objects to the ground.
Thus, it is apparent that there has been provided, in accordance with the invention, a ground anchor that fully satisfies the aims and advantages set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims.
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A ground anchor comprises a flat plate and a helical rod extending at a right angle from one surface of the plate. A retaining member for removably receiving a selected object is permanently attached to the plate second surface. The retaining member may be a receptacle for holding a fence post or the like, or the retaining member may be a ring for typing a rope thereto for holding down such items as tents and nursery stock.
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CROSS REFERENCE
This application is a continuation-in-part application based on the copending application Ser. No. 490,229 filed July 22, 1974 and now abandoned, of same title and same applicant, Donald E. Ford, and priority of the original application is claimed.
BACKGROUND OF THE INVENTION
The cleaning of drainage ditches alongside roadways and highways is generally undertaken by using direct man power of several men employing shovels and rakes to collect debris in spaced piles. These are later shoveled into a dirt truck, which is slowly driven by the piles of debris. Also sometimes, in addition, backhoes and road graders are used. Considerable manpower is used and the cost varies from $600 to $2,000 per mile. Consequently, the overall cleanup is not undertaken too often. Between cleanings sufficient debris may collect causing blockage of the drainage ditch and this blockage is sometimes a contributing cause to a wash out along a road often destroying significant portions of the road.
Although machinery has been designed to create ditches, such as illustrated and described in U.S. Pat. No. 1,183,706 issued in 1916 to D. B. and M. C. Williams, and to create trench excavations, such as illustrated and described in U.S. Pat. No. 3,645,020, issued in 1972 to D. Beslin and B. Beherano, and to plow in a rotary motion, such as illustrated and described in U.S. Pat. No. 2,533,793 issued in 1950 to H. W. Hamlett, and to sweep streets, as illustrated and described in U.S. Pat. No. 1,363,502, issued to Steven Duich in 1920; and to dig and to clean ditches as set forth by E. Heuman in his U.S. Pat. No. 1,721,392 of 1929, and by W. Baker, in his U.S. Pat. No. 3,309,802 of 1967; machinery has not been provided to automatically clean drainage ditches already made and in use, which are not to be basically altered except to be cleaned and the debris removed is fully controlled to be deposited, preferably in the dirt collecting chamber of a dirt truck, on which the ditch cleaning machine is preferably mounted, and such cleaning occurs regardless of the variable spacing of the ditch away from the side of the road on which the truck must remain.
SUMMARY OF INVENTION
The cleaning of drainage ditches alongside roadways and highways without substantially changing their original contour is now undertaken by operating what is to become known, in a short description, as a ditch cleaner. In one embodiment, it is installed on a self-dumping dirt truck with a drivers cab ahead of it, and in another embodiment with a drivers cab behind it. The truck has many standard components, on which an assembly of the ditch cleaner components are mounted, powered, and operated: to loosen debris in a ditch; collect the debris; clean the debris from the ditch; continue raising the debris cleaned from the ditch; redirecting the debris to the rear of the truck and dumping it into the dirt collecting chamber or bed of the truck, before departing from the ditch cleaning operation to travel to the main dumping site. The controls of the truck itself and the controls of the ditch cleaning assembly are located closely nearby so the truck driver will also operate the ditch cleaning assembly while driving the truck as the debris is removed from the ditch and placed in the truck.
Moreover, the essentially automatic ditch cleaner components, in another embodiment, are mounted on a tractor, in an additional embodiment at the rear of a caterpillar vehicle, and in still another embodiment on a trailer, having its auxiliary power unit and connectable to a pickup truck. In regard to these embodiments, they are arranged so a dirt truck may be driven up closely and filled with the debris coming from the ditch. As soon as that dirt truck is filled another is driven up for loading.
In the arrangement and operation of all embodiments, the purpose is to clean ditches thoroughly at a substantially lower cost, as the truck mounted ditch cleaner, per se, cleans the debris from the ditches, completely controlling the debris, keeping it off the road shoulders, and the road itself, as the debris is controllably redeposited in the dirt collecting chamber of the truck or at a designated location, well clear of the ditch, road shoulder, and road. As a result ditches may be cleaned more often avoiding the dam up of debris and the unwanted costly wash out of a road section.
DRAWINGS
The heart of the overall vehicle mounted ditch cleaner, or the cleaning unit itself, is essentially a self-contained unit and has a base member which is bolted or welded to the frame of a vehicle at a preselected location in different embodiments. For movement back and forth in a lateral or transverse direction the ditch cleaner has a slide which moves on a stationary base secured to the vehicle frame. All the other components are thereafter mounted directly or indirectly to the slide.
FIG. 1 is a perspective view of a dirt dump truck with the cab at the front and the automated ditch cleaner mounted on the truck frame behind the cab and forward of the dirt collecting box or chamber, indicating the positioning of the ditch cleaner when a ditch is being cleaned;
FIG. 2 is a perspective view similar to FIG. 1, however, the ditch cleaner is moved to its non use position for highway travel to a ditch cleaning job area;
FIG. 3 is a perspective view of another dirt dump truck with the automated ditch cleaner mounted on the truck frame which is extended beyond the hood of the truck engine, the cab therefore being behind the ditch cleaner; and the motion arrows indicate the operation of the ditch cleaner in removing debris from a roadside ditch and conveying it to the box or debris collecting chamber of the truck;
FIG. 4 is a partial cross sectional view of parts of one embodiment of a ditch cleaner further indicating how the loosened debris is handled in the cleaner conveyer commencing its upward travel, and also showing the bucket conveyor raising the debris, the motion arrows showing the conveyor movements, the raising of the cleaner conveyor, and the translation or lateral movement of the ditch cleaners slide along its base, in turn secured to the frame of a vehicle, to move the cleaning conveyor away from and back to a vehicle frame, to reach the centerlines of ditches located at different distances from road edges;
FIG. 5 is a side view somewhat schematically showing how some portions of the ditch cleaner are mounted on the frame of a trailer vehicle which is equipped to be pulled by a pickup truck and which loads dirt trucks as they travel alongside or nearby the trailer;
FIG. 6 is a side view somewhat schematically showing how some portions of the ditch cleaner are mounted on the rear portions of a frame of a caterpillar type vehicle when, for example, irrigation ditches are being cleaned.
FIGS. 7, 8 and 9 show schematically in front views, the appearance of the front cab truck and ditch cleaner, with FIG. 7 illustrating the cleaning of a nearby ditch, FIG. 8, illustrating the cleaning of a ditch that is farther from the edge of the road, and FIG. 9, illustrating the ditch cleaner stored for regular speed highway travel;
FIGS. 10, 11 and 12, are partial views of the cleaner-conveyor's continuous movable chain showing respective embodiments of the paddles, FIG. 10 illustrating a steel paddle, FIG. 11 illustrating a part steel and part resilient, rubber or rubberlike paddle; and FIG. 12, illustrating a cleaning brush used in lieu of a paddle, but serving a like conveying-cleaning function, where concrete or other hard surface ditches are to be cleaned;
FIG. 13 is a somewhat schematic left side view or the auger side view of the preferred embodiment of the ditch cleaner, and portions of a vehicle, indicating the mounting of its base to the frame of the vehicle and the positioning of the ditch cleaner with respect to the box or debris collecting chamber of the vehicle;
FIG. 14 is a somewhat schematic front view of the preferred embodiment of the ditch cleaner with portions removed, with motion arrows, for example, to indicate the direction of motion of the auger, cleaner-conveyor, and bucket conveyor, and showing how the ditch cleaner is secured to the frame of the vehicle;
FIG. 15 is a somewhat schematic right side view, or the opposite auger side view, of the preferred embodiment of the ditch cleaner, and portions of a vehicle, indicating the mounting of its base to the vehicle frame and its position with respect to the box or debris collecting chamber of the vehicle;
FIG. 16 is a somewhat schematic rear view of the preferred embodiment of the ditch cleaner, with motion arrows, for example, to indicate the direction of motion of the auger, the pivoting of the cleaner-conveyor, and the transverse positioning of the slide relative to the base.
FIG. 17 is a rear view of the base of the ditch cleaner bolted to the vehicle frame shown in section;
FIG. 18 is a rear view of the slide before its mounting on the base of the ditch cleaner;
FIG. 19 is a top view of the slide before its mounting on the base of the ditch cleaner;
FIG. 20 is a side view, partially in section of the subassembly of the slide on the base of the ditch cleaner, with the base bolted to a vehicle frame, shown in part;
FIGS. 21 and 22 are somewhat schematic exploded views, respectively, of the auger end or intake end of the cleaner-conveyor, or digging conveyor, or digging arm, and the end opposite the auger end or discharge end of this same conveyor, to illustrate how this conveyor is made, assembled, and mounted on the slide of the ditch cleaner;
FIGS. 23, 24 and 25 are somewhat schematic views, respectively, of the hydraulic system controls operated by the person running the ditch cleaner from his control position above, and of the hydraulic system components located below and secured directly and indirectly to the frame of the vehicle, FIG. 24 being a top schematic view and FIG. 25 being an elevational schematic view.
FIG. 26 is a partial elevational view and FIG. 27 is a partial top view, both views indicating how an operational and/or warning light is continually switched on and off by the rotation of a cam which deflects the actuating arm of a light switch.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
THE DITCH CLEANER IS MOUNTABLE ON THE FRAMES OF MANY DIFFERENT TYPES OF VEHICLES
As illustrated in FIGS. 1, 2, 3, 5 and 6, the ditch cleaner 30, as an assembly of components to be powered, and then upon movement of a vehicle, to become automated machinery to clean debris from roadside ditches, is mountable on different types of vehicles. When the ditch cleaner 30, is mounted on front cab truck 32, behind the cab 34 as shown in FIGS. 1 and 2, or mounted at the front 36 of a hood 38 of the truck 40, illustrated in FIG. 3, then the debris loosened and withdrawn from the roadside ditches is collected in the respective collecting chambers 42, or box 42, of these trucks 32, 40 and transported to disposal areas. When the ditch cleaner 30 is mounted on the trailer 44, illustrated in FIG. 5, or the caterpillar vehicle 46, shown in FIG. 6, the debris removed from the ditch, either a roadside ditch or an irrigation ditch, will be redeposited adjacent to the ditch or deposited in another vehicle or trailer pulled alongside having a collecting chamber or box 42.
THE SIMILAR BASIC OPERATION OF ALL EMBODIMENTS OF THE DITCH CLEANER
Whether the ditch cleaner 30, is mounted on the vehicles shown in FIGS. 1, 2, 3, 5, and 6, or other vehicles, the overall function is essentially the same, as shown in FIGS. 1, 3, 4, 7, 8, and 9. As schematically illustrated in FIGS. 7, 8 and 9, the ditch cleaner 30, mounted on a front cab truck 32, is respectively at low speed cleaning a ditch nearer to the roadside, at low speed cleaning a ditch farther from the roadside, and compactly stored away for higher speed travel to or from a ditch cleaning location or area.
As shown in FIGS. 3 and 4, with motion arrows indicating translation motions to reach ditches farther away, pivoting motions to move down into deeper ditches and retract back upwardly, auger rotation motions, outboard, central, and longitudinal conveyor motions, the ditch cleaner 30, effectively and automatically, loosens the debris and raises it upwardly for rehandling, preferably depositing the debris in a collection chamber 42, for transport to a disposal area.
VARIOUS TYPES OF BLADES FOR VARIOUS TYPES OF DITCHES TO BE CLEANED
Most of the roadside and irrigation ditches to be cleaned will essentially be previously and initially formed from earth without further improvements, and later when these ditches are cleaned by the ditch cleaner 30, an all metal paddle 48 will be used to collect the debris loosened by the auger 90 and direct it within the cleaner conveyor 64. It will be welded to the endless chain 50 of an outward conveyor, as illustrated in FIG. 10. However, there will be times when the previously and initially formed ditch will have additional improvements such as concrete and/or metal drains, concrete and/or asphalt bottom and/or sidewall liners. When such improved ditches are to be cleaned, the combined metal 52 and resilient rubber or rubber like material 54 blade 56, shown in FIG. 11, or the brush 58, shown in FIG. 12, will be used at spaced locations along the endless chain 50 of a conveyor.
THE ENTIRE DITCH CLEANER ASSEMBLY MOUNTED ON A FRAME OF A TRUCK HAVING A FRONT CAB BEHIND THE CAB AND AHEAD OF ITS COLLECTING CHAMBER OR BOX
In FIGS. 13 through 24, a preferred embodiment of a full ditch cleaner assembly 30 is illustrated, which is particularly suited for installation on a front cab truck 32 and secured to the truck frame 60 behind the cab 34. FIGS. 13 through 16, show the full assembly of the ditch cleaner 30, respectively, viewed from the left side, front, right side, and rear. FIGS. 17 through 20, illustrate in more detail how the ditch cleaner 30 is secured to the frame 60 of truck 32 by using bolt and nut assemblies 62, and where the various supports and actuators are secured within the ditch cleaner assembly 30.
This same frame mounting using like components is utilized in mounting the ditch cleaner 30 to the front of the truck 40, illustrated in FIG. 3, when its frame 72 is extended forwardly to receive the ditch cleaner 30. Also, when necessary, an additional swiveling and pivoting guiding support 74 is secured to the frame 72 behind the cab 76 and ahead of the collecting chamber or box 42, to support the extended longitudinal or belt conveyor 78.
FIGS. 21 and 22, in exploded views, indicate preferred arrangements of the mounting and rotational parts of one conveyor, referred to as the outward, or cleaner, conveyor 64. The other conveyors are like conventional bucket conveyors and belt conveyors, and they are called the central, lifting, elevation, or bucket conveyor 66, and the longitudinal, distribution, or belt conveyor 68.
In FIGS. 23, 24, a preferred hydraulic control and hydraulic power distribution system is schematically illustrated based on taking the rotative power of a driven power take off shaft 82 of an engine, either the main engine 84 of a truck 32, 40 or caterpillar vehicle 46, or an auxiliary engine 86 of a trailer 44. The hydraulic cab controls are shown in FIG. 23, and the balance of the hydraulic control and hydraulic distribution components are illustrated in FIG. 24.
THE DITCH CLEANING AUGER AND THE OUTWARD, OR CLEANER, CONVEYOR
As illustrated, particularly, in FIGS. 13, 14, 16, 21 and 22, the ditch cleaning auger 90 and the outward conveyor 64, also referred to as the cleaner conveyor 64, are moved and powered together as a subassembly 92, using hydraulic motor 94 and its power drive chain 96 and drive sprocket 98 and driven sprocket 100, shaft 116 and sprocket 102. As particularly shown in FIGS. 10 and 14, metal paddles 48 are welded at spaced intervals along a continuous, endless digging chain 50 driven around the driven cleaning chain sprockets 102. As illustrated in FIGS. 3 and 4, as this outward, or cleaner, conveyor 64 operates, the auger 90 rotates to loosen the debris and the paddles 48 push and guide the debris upwardly through the housing 104 of conveyor 64.
To compensate for how far the metal paddles 48 may be directly effective in scraping the ground surfaces of the ditch and adjacent road shoulder, a ditch shoe 106 is translated in and out along the bottom of the housing 104 by a hydraulic actuator 108. At all times the purpose is to gather the debris up as soon as possible from the ditch and nearby road bank so it will be controllably conveyed away by the outward or cleaning conveyor 64, thereby eliminating any need for cleaning up unnecessarily the road bank or the road itself. Also attached to this ditch shoe 106 is a vertical shield 110 to combine with the ditch shoe in preventing a berm and to deflect rocks that might otherwise go on to damage the ditch cleaner 30 and/or hurt the operator.
To pivotally move the cleaning conveyor 64 down into a ditch or raise it up for higher speed highway travel, at the legal 8 foot overall width, as illustrated in FIGS. 1, 2, 8 and 9, it is pivotally attached to a slide frame member 114 using a mounting shaft 116, and it is moved using a pivoting arcuate lift beam subassembly 120 which in turn is powered by the lift hydraulic cylinder 122, the mounting shaft 116, being shown in FIG. 22, and the lift beam subassembly 120, being shown in FIG. 16. The lift beam subassembly 120 is pivotally secured by anchor 214, between the slide frame 114 and the housing 104 of the outward, cleaner, conveyor 64. The lift hydraulic cylinder 122 is secured between the slide frame 114 and the arcuate lift beam subassembly 120, as illustrated in FIG. 16.
To insure, during the cleaning conveyor pivotal movements, while ditch cleaning operations are underway, that debris will not be unwantedly dropped down on the road or shoulder, a spring loaded pivotal door 124 secured to the bucket, lifting, or elevator conveyor 66 continuously bears against the bottom of the housing 104 of the cleaning conveyor 64. Also above, a hinged cover 126, continuously bears against the top of the housing 104 of the cleaning conveyor 64 to also insure the debris will be pushed into the path of the bucket, lifting or elevator conveyor 66 and not elsewhere where it is not wanted. In addition along the bottom of the front side of the housing 104 is another movable member 112 to be opened up when dislodging any rock that may be jammed.
THE BUCKET, LIFTING, ELEVATION CONVEYOR
As shown in FIG. 16, the bucket conveyor, also referred to as a lifting, or elevation, conveyor 66, has its housing 130 secured to an upstanding frame 132 with offset leg 133, which in turn is removably secured by bolting assemblies 131, to the slide frame 114 by using receiving structures 220 which are welded to the slide frame 114. The members 114 and 132 together comprise a slide frame structure. A hydraulic motor 134 with its roller chain drive 136 and driving sprocket 138, powers the driven sprocket 140 inside the bucket conveyor 66, to thereby move the endless double pitch chain 142, its secured, spaced, plastic buckets 144, and the chain driven sprocket 146. These buckets 144 are moved through the debris being pushed and deposited by the cleaning conveyor paddles 48, to pick up a load of debris for its elevation and subsequent deposit on the longitudinal or belt conveyor 68.
The housing 130 of the bucket conveyor 66 is equipped with a lower clean out door 150 and a top inspection and access door 152. Also the housing 130 pivotally supports lower pivotal spring loaded door 124, which bears against the housing 104 of the digging conveyor 64, and it pivotally supports the hinged cover 126, which bears down on the top, shroud or cover, of the housing 104 of the cleaning conveyor 64.
THE BELT, LONGITUDINAL, CONVEYOR
As shown in FIGS. 13 through 16, when the debris that is elevated in the buckets 144 of the bucket conveyor 66, is to be guided further for deposit, such as in the debris collecting chamber 42 or box 42 of a truck 32, 40, a belt conveyor 68, also referred to as longitudinal conveyor 68, is operated. It is pivotally supported on shaft 154 in turn supported at one of its ends using a bearing socket 155 secured on an upstanding frame 156, which in turn is secured to the slide frame 114 and at its other end using a bearing socket 155 and a bracket 153 secured to the frame 132. A hydraulic motor 160 with its roller chain drive 162 and driving sprocket 164, powers the power roller 166 of the belt conveyor 68, and the movement of the belt 168 continues around its non power roller 170.
The power roller end or discharging end of this belt conveyor 68 is equipped with a protective cam shoe 174 to avoid damage by any contact made between this conveyor 68 and the box 42 of the truck 32. The angular or pivotal position of the belt conveyor 68 is adjusted upon operation of the hydraulic cylinder 176, which is pivotally secured between the frame 178 of the belt conveyor 68 and the slide frame 114. Before the debris collecting chamber 42 or box 42 of the truck 32 is pivotally raised to dump the collected debris, the hydraulic cylinder 176 must be actuated to pivotally raise the belt conveyor 68 clear of the path of the pivoting box 42. This sequence is assured by the arrangement of the overall hydraulic system. During this pivoting of the belt conveyor and at all times, a counter balance coiled tension spring 184 dampens and helps to control the positioning of the belt conveyor 68. This spring 184 is secured between the frame 178 of the belt conveyor and the vertical frame 132 supporting the bucket conveyor 66. To keep the debris falling down from the buckets 144 from occasionally spilling over and out of the path of the belt conveyor a shield 182 is secured to the housing 130 of the bucket conveyor 66, as shown in FIG. 15.
THE TRANSLATION OF SUBSTANTIALLY THE ENTIRE DITCH CLEANER TO CLEAN DITCHES LOCATED AT DIFFERENT DISTANCES FROM THE EDGE OF THE ROAD
As noted in FIGS. 7 and 8, ditches are not located at a standard distance away from the edges of the road, so as shown in FIGS. 3 and 4, with motion arrows, there is relative transverse movement between the ditch cleaner 30 and a truck 40. As illustrated in FIGS. 16, 17, 18, and 19, this transverse movement is taken care of in the ditch cleaner 30 itself. A slide frame 114 is made for controlled sliding movement along a base 188, in turn secured by brackets 190 or plates 190, which are welded to the base 188 and bolted to the frame of a vehicle, such as the frame 60 of truck 32, or frame 72 of truck 40.
In FIG. 16, the hydraulic actuator 192 is shown, which supplies the extending and retracting power to move the slide frame 114 relative to the base 188, and thereby to move the ditch cleaner over ditches located at different distances from the roadway edges. The hydraulic actuator 192 is secured to the base 188 by anchor 194 and secured to the slide frame 114 by anchor 196. Other than the anchor 194 for hydraulic actuator 192, the base 188 has no other securement places except for its continuous top and bottom flanges or rails 198, 200, which slidably interfit with the overlapping top and bottom guides 202, 204 welded to the slide 114.
In contrast, the slide 114 has several mounting places for all the translating components of the ditch cleaner 30, as illustrated in FIGS. 18, 19 and 20. There is a mounting hub 208 to receive the bearing mounting of the shaft 116, which supports, in turn, the cleaning conveyor 64. As noted before, anchor 196 on slide 114 receives the other end of the transverse extending and retracting hydraulic actuator 192. On slide 114, at its top, the lift hydraulic actuator 122 is secured to anchor 212. At its bottom, the slide 114 pivotally receives at its anchor 214, the lower end of the pivoting arcuate lift beam subassembly 120, which is used in rotating the outward cleaning conveyor 64 and avoiding any excessive bearing load pressure on the relative pivoting parts of the conveyor 64 and slide 114. A thrust plate 216 for receiving any thrust from the cleaning conveyor housing 104 is attached to slide 114. A hydraulic motor mounting plate 218 is welded to slide 114. Also projecting upwardly from slide 114 is upstanding vertical frame support 132, fitted to receiving structures 220/221. In addition the base of the hydraulic cylinder or actuator 176, which pivotally moves the belt conveyor 68, is secured to slide 114 at anchor 222. Therefore, when the hydraulic actuator 192 moves the slide 114 relative to the base 188, the slide moves together all the other cofunctioning components of the automatic ditch cleaner 30 to translate them to and from a ditch centerline.
PREFERRED EMBODIMENTS OF THE VARIOUS COMPONENTS MOUNTED AT THE OUTBOARD AND INBOARD HEADS OR ENDS OF THE CLEANING CONVEYOR
As noted earlier, the bucket and belt conveyors 66, and 68, are considered more conventional in function, although they are specifically designed for this ditch cleaner 30. However, the cleaner conveyor 64, because of its unusual function and its capability to be pivoted to reach different ditch locations and depths, and also to be pivoted to an upward higher speed high travel position, within the legal 8 feet highway width, is considered non conventional in function. Therefore, in FIGS. 21 and 22, in exploded views the various components of this cleaning conveyor 64 are illustrated in respect to the outboard head or end 228 and inboard head or end 230. From viewing these exploded views of FIGS. 21 and 22, the purpose and function of the components will be realized. Therefore they are listed by name and numeral as follows, in FIG. 21: tie rod 234, auger 90, driven cleaning chain sprockets 102, seal housing 236, seal 238, auger shaft 240, key way 242, key 244, shaft sleeve 246 for seal, bearing 248, bearing cup 250, lock 252, nut 254, end cap 256, and nut 258; and in FIG. 22: cap screw 262, washer 264, driven cleaning chain sprocket 102, nut 254, seal housing 236, seal 238, bearing 248, bearing cup 250, inboard head 230, digging conveyor 64, mounting shaft 116, hydraulic motor 94, drive chain 96, driving sprocket 98, driven sprocket 100, hub or bearing housing 208 shaft sleeve 246, key way 242, key 244, bolts 262, and slide 114, and also bolt 232 and cover 260.
HYDRAULIC SYSTEM FOR CONTROLLING, POWERING AND ACTUATING THE DITCH CLEANER
The preferred embodiment of a hydraulic system 266 for controlling, powering, and actuating the ditch cleaner 30 is schematically illustrated in FIGS. 23, and 24. In the respective cabs of trucks 32, 40, or other vehicles, there are, for example, eight hand actuated controls. Hand control 268 is an optional handle that can be used either as a replacement for one of the other controls in case of damage or for optional equipment, such as the debris load leveler 284 on collecting chamber or box 42, as shown in FIG. 3. It is to be noted now that valves 270, 272, 274 are automatic flow controls for the overall system and determine the selected flow direction at a selected volume of hydraulic oil. However, the other valves are controlled when the hand controls are moved or actuated. Hand control 276, via valve 278, controls the bucket conveyor hydraulic motor 134. Hand control 280, via valve 282, controls the belt conveyor hydraulic motor 160. Hand control 288, via valve 290, operates the hydraulic actuator 192, which moves the slide 114 relative to base 180 of the ditch cleaner 30. Hand control 292, via valve 294, controls movement of hydraulic actuator 122, in turn, moving the pivoting arcuate lift beam subassembly 120, which thereafter positions the cleaner conveyor 64. Hand control 296, via valve 298, operates hydraulic actuator 108 which moves the ditch shoe 106 on the cleaning conveyor 64. Hand control 300, via valve 302, operates the hydraulic motor 94 which drives both the cleaning conveyor 64 and the auger 90. Hand control 304, via valve assembly 306, first operates the hydraulic actuator 176 to pivot the belt conveyor, and then operates the vehicle's hoist to dump the debris collection chamber 42. The hydraulic fluid is circulated back and forth through tank 310, and filters 312, 312. The entire hydraulic system obtains its pressure via hydraulic pump 316, which is driven by the engine 84 of a vehicle, using a power take off shaft 82.
THE FEATURE OF THE HYDRAULIC SYSTEM OF SPECIFIC CONTROL WITH RESPECT TO FIRST MOVING THE BELT CONVEYOR OUT OF THE WAY, BEFORE RAISING THE DEBRIS COLLECTING CHAMBER
Upon movement of hand control 304, valve 306 is moved, and hydraulic pressure and flow are applied at the time to the box hoists cylinders 286, and through the box actuated valve 308, to the hydraulic actuator 176. Therefore, the belt conveyor, being the lightest is raised out of the way to the limit of travel of its actuator 176, where it stays, while the full hydraulic pressure operates the box hoist cylinders 286, in turn raising the box 42 to dump the debris. Also upon the box 42 raising, it clears a plunger 309 of the box actuated valve 308, shutting off the hydraulic oil circuit leading to the actuator 176 of the belt conveyor 68, thereby preventing the actuator 176 from lowering the belt conveyor 68 until after the box 42 is again back in place depressing the plunger 309 of valve 308, opening the hydraulic circuit releasing all pressure and lowering the belt conveyor 68.
OPTIONAL DEBRIS LEVELING ASSEMBLY
As shown in FIG. 3, an optional debris leveling assembly 284 is mounted on the top of collecting chamber or box 42 to drive leveling bars 283 into the forming debris pile to level their tops towards the rear of the box 42. It is driven by hydraulic motor 160, mounted on bracket 285, roller chain drive 162, driving sprocket 164. The driven sprockets 146 and driven chain 142 are similar to the driven sprockets 146 and driven chain 142 of the bucket conveyor. This optional debris leveling assembly 284 is controlled by moving the control handle 268.
OPERATIONAL LIGHTS TO INDICATE CONVEYORS ARE RUNNING AND/OR STOPPED
As viewed in FIG. 14, dual set of operational lights, 318, 320, are mounted on the housing 104 of the cleaning conveyor 64. Preferably during operation of the bucket conveyor 66 and the belt conveyor 68 respective, these green and amber lights 318 and 320 will be constantly blinking to indicate the conveyors correct operations. However when either conveyor stops because of plugging or overload, its respective light 318 or 320 will stop blinking informing the operator of trouble on ditch cleaner 30, so he may immediately take corrective action before trying to continue the ditch cleaning operations. These lights are positioned to be conveniently viewed by the operator, while he is also viewing the operation of auger 90 being simultaneously driven with the cleaner conveyor 64.
In FIGS. 14, 26, and 27, the cam-switch assembly 322 and circuit wires 324 to the belt conveyor and battery, and circuit wires 326 to bucket conveyor and battery, with respect to the operational lights 318, 320 are illustrated. As long as light 318 is blinking, the operator knows the belt conveyor 68 is running. As long as light 320 is blinking, the operator knows the bucket conveyor 66 is running. When respective shafts 328 and 330 of the belt conveyor 68 and bucket conveyor 66 are turning, then their eccentric cams 333 are turning. Their cam action moves their respective actuator arms 334 turning respective light switches 336 off and on. Respective wiring circuits 324, 326, carry the oscillating currents to the operational lights 318, 320, and both wiring circuits are connected to a battery of the truck 40. Other components shown in FIGS. 26 and 27 are shaft bearing 338, bearing mounting plate 340, bolt assemblies 342, cam bolt 344, a switch bracket 346, and housing 130 of conveyor 66.
SOME GENERAL SPECIFICATIONS OF A SPECIFIC EMBODIMENT OF A DITCH CLEANER MOUNTED ON THE FRAME OF A FRONT CAB TRUCK
The front cab truck has a diesel engine with a responder transmission and an electric operated hydraulic shift control of a power take off shaft. The tires sizes are 12:00 × 20 in front, 10:00 × 20 in back. The debris collection chamber or box has an 8 to 10 cubic yard capacity and twin telescope hoists are used to dump the box. The overall weight of the truck is 19,990 pounds, without the ditch cleaner.
The ditch cleaner weighs 4860 pounds, and has a hydraulic tank capacity of 85 gallons. A hydraulic fluid filter is installed in the tank suction line and optionally another filter is installed in the return line. A double hydraulic fluid pump is powered by rotation of the power take off shaft. Both the auger and cleaner conveyor are driven by the same reversible hydraulic motor developing 740 foot pounds of torque at 2000 pounds per square inch. Timken bearings are used in this digging conveyor. Both the bucket and belt conveyors are each driven by a reversible hydraulic motor developing 300 foot pounds of torque at 1500 pounds per square inch. Also these conveyors include self align ball bearings. The buckets of the bucket conveyor are made of a heavy duty plastic.
During operations the forward truck speed is generally between 0 and 2 miles per hour as the truck engine runs at 1200 revolutions per minute. The depth of the ditches being cleaned may be 21/2 feet deep and the lateral travel of the cleaning conveyor and the auger is 3 feet, with the extended reach from the truck wheel to the ditch centerline being 71/2 feet. The retracted height of the ditch cleaner is 12 feet -8 inches and its width is 8 feet -0 inch.
BRIEF SUMMARY OF MAJOR ADVANTAGES OF USING THE DITCH CLEANER MOUNTED ON A VEHICLE
By mounting a ditch, shoulder of the road, and the road cleaner on a vehicle and during its operation moving its rotating auger along in an established roadside or irrigation ditch, the ditch is reclaimed, as debris is automatically loosened, removed, conveyed, and deposited, at selected locations clear of the ditch. Substantial overall savings over current ditch cleaning costs are realized upon operating this ditch cleaner. Moreover, roadside ditches are maintained better and often more frequently, thereby, avoiding the related costs, for example, of otherwise having to rebuild a road, where a wash out or partial wash out has occurred because of an unwanted water flow dam created by accumulated debris.
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A vehicle, such as a self dumping dirt truck or a trailer, is equipped with a powered assembly of components to automatically clean debris from roadside ditches or irrigation ditches, preferably powered by the truck engine, a tractor engine, or an auxiliary engine, which in turn drives a hydraulic pump of a hydraulic system powering several hydraulic motors. The debris, dirt, gravel, and weeds, are loosened and collected from the ditches alongside a road and then conveyed to a dirt collecting chamber of the trailer or truck. At times if the debris is not objectionable it may be discharged back near the roadbank but removed from the ditch area. This powered assembly of components comprises: a leading powered auger for rotary and advancing movement in a ditch; a powered cleaner conveyor selectively positioned and operating just behind the auger, which it supports, to convey collected debris up and out of the ditch; a powered bucket elevator to continue conveying the collected debris to a higher elevation on the trailer or truck; a powered belt conveyor to move the collected debris from the bucket elevator to the dirt collecting chamber of the trailer or dirt truck, and an interrelated hydraulic drive system using a hydraulic pump and hydraulic motors, powered by the main engine of the dirt truck or tractor, or the auxiliary engine of a trailer. The powered assembly of the ditch cleaning components is adjustably mounted on the vehicle to be transversely or laterally moved relative to the truck to reach ditches located at different distances from a roadside. Also for legal highway travel, i.e., 8 feet wide, these ditch cleaning components are adjustable into such non-use legal width positions.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 09/801,370, filed on Mar. 7, 2001, now U.S. Pat. No. 6,728,375, which is a continuation of U.S. patent application Ser. No. 09/481,219, filed on Jan. 11, 2000, now U.S. Pat. No. 6,246,765, which is a continuation of U.S. patent application Ser. No. 09/075,685, filed on May 11, 1998, now U.S. Pat. No. 6,026,162, which is a continuation of U.S. patent application Ser. No. 08/335,008, filed on Nov. 7, 1994, now U.S. Pat. No. 5,940,503, which is a continuation of U.S. patent application Ser. No. 08/012,382, filed on Feb. 2, 1993, now abandoned. The entire disclosure of each of these applications is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The invention relates to telephones and more particularly to mobile cellular telephones for motor vehicular use.
Current mobile telephones are patterned after home and office equipment and are difficult to locate in motor vehicles. The crowded condition, which exists in vehicle interiors, results in a need for concepts in mobile telephones which can save space in the vehicle interiors. Moreover, the current telephone locations cause safety concerns. For example, the current locations on instrument panels and consoles require the driver to divert his attention from the road when utilizing the telephone and the telephones may impact, or be impacted by, the driver or passenger in a collision situation. The current locations are further deficient in that they fail to accommodate a wide range of vehicle designs and sizes. In some cases, the equipment designs have required substantial vehicle modifications to accommodate the equipment within the vehicle and these modifications have increased new model investment costs as well as manufacturing costs.
One improved method of locating a mobile telephone in a motor vehicle is shown in U.S. Pat. No. 4,707,273 wherein the telephone is mounted in the sunvisor of the vehicle. This location is an improvement over the instrument panel and console locations in the sense that the driver need not substantially divert his/her eyes from the road. However, the extremely close proximity of the telephone controls to the eyes of the driver can create focusing problems, especially when the driver is using vision correction devices such as eyeglasses or contact lenses.
SUMMARY OF THE INVENTION
This invention is directed to the provision of an improved mobile telephone system. More particularly, this invention is directed to the provision of a mobile telephone system which allows the driver to maintain a good view of the road while operating the telephone and which is located at a distance from the driver's eyes to allow easy focusing on the controls of the telephone.
This invention is further directed to the provision of an improved mobile telephone system which is inexpensive and which does not require any modification of the motor vehicle interior to accommodate the telephone system.
This invention is further directed to the provision of an improved portable telephone.
The invention relates to both a method and an apparatus for providing improved mobile telephone service.
The improved methodology relates to an improved method of providing mobile telephone service for a motor vehicle of the type including a windshield and a power source positioned in the motor vehicle. According to the invention methodology, an electrical connection to the power source is provided proximate the upper central region of the windshield and a telephone is electrically connected to the electrical connection. This methodology positions the telephone in an area that is readily visible by the driver, does not obstruct the driver's vision, and allows easy focusing on the telephone controls.
According to a further feature of the invention methodology, the motor vehicle further includes an inside rearview mirror positioned proximate the upper central region of the windshield, and the step of providing an electrical connection on the rearview mirror to the power source comprises providing an electrical connection to the power source. This methodology utilizes the existing rearview mirror to form the foundation for mounting the telephone.
According to a further feature of the invention methodology, the telephone is portable and includes external electrical connectors and the step of providing an electrical connection on the rearview mirror to the power source comprises providing connector means on the top of the rearview mirror for electrical connection to the telephone connectors. This methodology conveniently positions the portable telephone on top of the rearview mirror in electrical connection with the vehicular power source.
According to a further feature of the invention methodology, the step of providing an electrical connection to the power source further includes providing a socket on the rearview mirror including the electrical connectors, and the step of removably electrically connecting a portable telephone to the electrical connectors comprises positioning the portable telephone in the socket with the electrical connectors of the telephone connected to the electrical connectors of the socket.
According to a further feature of the invention methodology, the step of providing a socket on the rearview mirror comprises providing a holster sized to receive the portable telephone and positioning the holster on the rearview mirror.
According to a further feature of the invention methodology, the portable telephone further includes a battery and the method includes the further step of providing means on the rearview mirror to recharge the battery.
According to a further feature of the invention methodology, the step of providing a means on the rearview mirror to recharge the battery includes providing a pocket in the rearview mirror sized to receive the battery and providing an electrical connection in the pocket to the vehicular power source so as to electrically connect the vehicular power source to a battery inserted in the pocket.
According to a further feature of the invention methodology, the method includes the further steps of providing a separate speaker/microphone, providing an elongated flexible extension member, providing an input jack on the rearview mirror, positioning the speaker/microphone on one end of the elongated flexible extension member, and plugging the other end of the elongated flexible extension member into the input jack.
The invention further provides a mirror assembly for use with a motor vehicle of the type including a windshield and a power source positioned within the vehicle. The invention mirror assembly includes an inside rearview mirror adapted to be secured within the vehicle in a position proximate the upper central region of the windshield, a telephone on the mirror, and means establishing electrical connection between the telephone and the power source with the telephone mounted on the mirror.
In one embodiment of the invention mirror assembly, the telephone is removably mounted on the mirror by mounting means including a holster secured to the top of the mirror and defining a socket for receipt of the mobile telephone.
In further embodiments of the invention mirror assembly, at least one of the components of the telephone is built into the casing of the mirror.
According to a further feature of the invention mirror assembly, the mirror assembly further includes means for recharging the battery of the portable telephone. In the disclosed embodiment of the invention, the recharging means includes a pocket opening in the top of the mirror and sized to receive the battery.
According to a further feature of the invention mirror assembly, the mirror assembly further includes a separate speaker/microphone and means for physically and electrically connecting the speaker/microphone to the mirror with the speaker/microphone positioned remote from the mirror and proximate the driver of the vehicle. In the disclosed embodiment of the invention, the connecting means includes a flexible cable connected at one end to the mirror and mounting the speaker/microphone at its other, free end.
The invention also provides an improved portable or personal telephone. The improved portable telephone of the invention comprises an outgoing message microphone member, an incoming message speaker member, and means operative to vary the spacing between the members. This arrangement allows the microphone and speaker members to be positioned relatively close to each other for compactness to improve the portability and stowability of the telephone, and allows the microphone and speaker to be selectively spaced further apart to facilitate association of the microphone member with the mouth of the user and association of the speaker member with the ear of the user. In the disclosed embodiment of the invention, the telephone includes a housing, the microphone member is mounted in the housing, and the telephone further includes means operative to move the speaker member to a stored position proximate the housing and an operative position spaced from the housing. The operative means may comprise, for example, an arm pivotally mounted at one end on the housing and mounting the speaker member at its other end.
These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a fragmentary schematic view of a motor vehicle employing the invention mobile telephone system;
FIG. 2 is a fragmentary view of the motor vehicle of FIG. 1 looking forwardly from the driver's seat;
FIG. 3 is an exploded view of a mirror assembly according to the invention;
FIG. 4 is an assembled view of the invention mirror assembly looking from the front of the vehicle toward the rear of the vehicle;
FIG. 5 is an assembled view of the invention mirror assembly looking forwardly from the driver's seat;
FIGS. 6 and 7 are end and top views, respectively, of the invention mirror assembly;
FIG. 8 is a perspective view of a holster employed in the invention mirror assembly;
FIGS. 9–13 are detailed views of a personal telephone according to the invention;
FIG. 14 is a view showing the use of the invention personal telephone;
FIG. 15 is a cutaway view of a motor vehicle illustrating various ways in which the audio system of the vehicle may be utilized to receive incoming telephone calls;
FIG. 16 is a schematic view showing an arrangement for providing privacy for incoming telephone calls;
FIGS. 17–23 illustrate a microphone that may be utilized in association with the invention telephone and further illustrating various ways in which the microphone may be mounted within the vehicle;
FIGS. 24–27 illustrate embodiments of the invention in which the telephone is built into and forms a permanent part of the rearview mirror assembly; and
FIGS. 28–31 illustrate an alternate arrangement for mounting the invention personal telephone in the vehicle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention mobile telephone system is intended for use in a motor vehicle of the type including a windshield 10 , an instrument panel 12 , a steering wheel 14 , a pair of sunvisors 18 , a headliner 20 , A pillars 22 , and a trunk 24 .
A suitable power supply, such as, for example, a transceiver 26 , is positioned in the trunk 24 and coacts with an external antenna 28 to process outgoing and incoming telephone calls in a known manner.
The invention provides an inside rearview mirror assembly 30 to facilitate the provision of a mobile telephone system in the vehicle. Mirror assembly 30 includes an inside rearview mirror 32 , a bracket assembly 34 , and a speaker/microphone assembly 36 .
Mirror 32 includes a hollow casing 38 and a mirror glass 42 . Casing 38 includes a top wall 38 a , a front wall 38 b , a bottom wall 38 c , end walls 38 d , and a rim 38 e . Rim 38 e coacts with the main body of the casing to position mirror glass 42 at the rear face of the mirror.
An elongated slot 38 f is provided in top wall 38 a of casing 38 , a battery charging pocket 38 g opens in top wall 38 a on one side of slot 38 f , and an input jack 38 h opens in top wall 38 a on the other side of slot 38 f . Rear wall 38 b includes a raised mounting portion 38 i to facilitate securement of the mirror to the upper central region of the windshield 10 as, for example, by a bracket 46 adhesively secured at one end to the windshield and pivotally secured at its other end to the mirror. Alternatively, and in a known manner, the mirror may be secured to the windshield header.
A power cord 48 is connected at one end to transceiver 26 and passes at its other end through an opening 38 j in the front wall 38 b of the mirror casing. After passing through the opening 38 j , the power cord 48 splits electrically to form a series of parallel bundled leads 48 a which emerge from the casing through slot 38 f . A series of contacts 49 are provided at the bottom of pocket 38 g and these contacts are suitably connected via power cord 48 to a source of power such as the vehicle battery. It will be understood that jack 38 h is also suitably powered through cord 48 .
Bracket assembly 34 includes a bracket 50 , a holster 52 , and an angle plate 53 . Bracket 50 includes a pair of arm portions 50 a each defining a slot 50 b , a cross bar portion 50 c joining the arm portions 50 a , and journals 50 d . Bracket 50 is mounted for adjustable movement on casing 38 by a pair of screws 54 passing through slots 50 a for threaded engagement with nuts 56 slidably positioned in slot 38 f so that, by selective loosening and tightening of screws 54 , the bracket may be adjustably positioned along the length of the slot, may be adjustably positioned transversely of the slot (as seen in dashed outline A in FIG. 7 ), and may be positioned in a canted relation with respect to the slot (as seen in dashed outline B in FIG. 7 ) by positioning one screw 54 relatively forwardly in one slot 50 a and the other screw 54 relatively rearwardly in the other slot 50 a.
Holster 52 has a generally U configuration in cross section and includes a front wall 52 a , side walls 52 b and 52 c , a bottom wall 52 d , and a front wall 52 e coacting to define a socket 60 . Rear wall 52 e is in the form of a lip or a rim extending only partially across the width of the holster and having a vertical height that is only a minor fraction of the vertical height of the walls 52 a , 52 b , and 52 c . A plurality of contacts 62 is provided at the bottom of socket 60 . Holster 52 includes lugs 52 f coacting with screws 64 and journals 50 d to mount the holster for pivotal movement on bracket 50 . Coil springs 66 are connected at their respective ends to the holster and to the bracket and act in a known manner to resist pivotal movement of the holster 52 relative to the bracket. The holster normally assumes the generally upright position seen in FIG. 6 , but may be selectively pivoted rearwardly against the bias of spring 66 to facilitate insertion of a portable telephone 70 into the holster. Bundled leads 48 a extend through an opening 52 g in the front wall 52 a of the holster for respective electrical connection to contacts 62 .
Angle plate 53 includes journal portions 53 a and an angle plate portion 53 b . Angle plate 53 is positioned with its journals 53 a positioned immediately inboard of respective bracket journals 50 d . Nylon inserts or bushings 71 are received in journals 53 a and threaded inboard ends 64 a of screws 64 are threaded into bushings 71 . Screws 64 further include a shoulder 64 b so that tightening of the screws has the effect of clamping bracket journals 50 d inwardly against angle plate journals 53 a so as to maintain angle plate portion 53 b in any angular position to which it is adjusted. As best seen in FIG. 6 , the position of angular adjustment of angle plate portion 53 b determines the precise angular position in which holster 52 is maintained by springs 66 .
Speaker/microphone assembly 36 includes an elongated flexible cable 67 , a plug 68 on one end of cable 67 to allow the cable to be plugged into input jack 38 , and a speaker/microphone 69 mounted on the other, free end of cable 67 . The invention mobile telephone system may be used with or without the speaker/microphone assembly 36 .
The invention portable telephone 70 includes a housing 72 of generally rectangular configuration, a battery 74 adapted to be removably positioned in a cutout 72 a in the housing and including a plurality of contacts 76 to facilitate recharging of the battery, an outgoing message microphone 78 mounted in the housing, a power switch 80 mounted in the housing, a plurality of outgoing call pushbuttons 82 mounted in the housing and coacting with circuit board means (not shown) within the housing to generate outgoing telephone signals corresponding to the selected pushbutton sequence, a digital display 84 to display outgoing calls and other telephone functions, a volume control 86 mounted at the top of the housing, an arm 88 pivotally mounted at 90° to the housing for movement between a compact stowed position (as seen in FIG. 10 ) in which the arm is positioned in a recess 72 b in the housing and an extended operative position (as seen in FIG. 9 ) in which the arm is pivoted upwardly to position the free end 88 a of the arm in spaced relation to the housing, an incoming message speaker 92 mounted on the free end 88 a of arm 88 and positioned in a housing recess 72 c with arm 88 in its stowed position, and an antenna 94 telescopically mounted in arm 88 . Optionally, a pocket clip 96 may be secured to the housing by a screw 98 . Alternatively, clip 96 may be adjustably secured to the housing by a spring (not shown) positioned within the housing.
In the use of the invention telephone 70 as a portable or personal telephone, and as best seen in FIG. 14 , the telephone may ordinarily be conveniently stowed (as, for example, in the pocket 100 of a shirt 102 worn by a user) with the arm 88 in its lowered or stowed position. The telephone may be readily prepared for use as a personal or portable telephone by moving the arm 88 to its extended position so as to space the speaker 92 from the microphone 78 by a distance corresponding to the distance between the mouth and ear of a user so that the speaker 92 is positioned proximate the user's ear when the microphone 78 is positioned proximate the user's mouth. Antenna 94 may be selectively moved telescopically relative to arm 88 to fine tune the radio reception.
In the use of the invention personal telephone as part of the invention mobile telephone system, antenna 94 is moved to its stowed position within arm 88 , arm 88 is moved to its stowed position relative to the housing, clip 96 (if present) is removed, and the telephone is inserted into holster 52 to position external contacts 104 on the bottom of the housing 72 of the telephone as well as the contacts 76 on the bottom of battery 74 in respective electrical communication with contacts 62 at the bottom of the socket 60 defined by the holster 52 . Alternatively, the telephone may be mounted in the holster with the arm 88 in its raised position and/or clip 96 may remain on the housing and overlap the back of the holster. A light 105 mounted on the mirror casing is lit when the telephone has been positioned in the holster and electrical connection has been established with the transceiver 26 . Screws 54 may be selectively loosened and tightened to adjust holster 52 on mirror 32 (longitudinally along slot 38 f , transversely of slot 38 f , or obliquely with respect to slot 38 f ) to a position that is comfortable and convenient for use by the driver or a front seat passenger, and holster 52 may be pivoted rearwardly against the resistance of spring 66 to facilitate insertion of telephone 70 into the holster.
As the telephone slides into the holster, a rib 52 f on holster side wall 52 c slides into a groove on the telephone housing to positively locate the telephone relative to the holster and, as the telephone reaches its bottom position within the holster, the flexible upper portion 52 g of front wall 52 a snaps into engagement with a transverse groove 72 d in the telephone housing to preclude inadvertent displacement of the telephone from the holster. The telephone is now ready for use as the mobile telephone ingredient of the invention mobile telephone system.
When used as a mobile in-car telephone, the portable telephone 70 is powered via the electrical connection between the telephone contacts 76 and 104 and the holster contacts 62 whereby the telephone is connected to and powered by the transceiver 26 via the power cord 48 . In operation, depression of power button 80 actuates the system, depression of outgoing call push buttons 82 selects the outgoing call which is displayed in the digital display window 84 , the volume is adjusted by selective actuation of volume control 86 , microphone 78 serves as the outgoing message microphone, and speaker 92 serves as the incoming message speaker. It will be understood that, with the telephone positioned in the holster, the battery 74 secured to the telephone housing will receive a constant “trickle” charge from the vehicle power system via battery contacts 76 engaging holster contacts 62 .
When speaker/microphone assembly 36 is plugged into jack 38 h , the speaker/microphone 69 cooperates with the outgoing message microphone 78 to provide the outgoing message capability of the system and cooperates with incoming message speaker 92 to provide the incoming message capability of the system. The incoming message may thus be delivered with a stereo effect if incorporated with the car audio system or external speaker. Alternatively, the internal circuitry of the system may be arranged such that insertion of the speaker/microphone assembly into the input jack 38 has the effect of cutting out the outgoing message microphone 78 and/or the incoming message speaker 92 . As best seen in FIG. 2 , the flexible cable 36 enables the speaker/microphone 69 to be selectively positioned proximate the driver's head so as to readily pick up the driver's voice for outgoing message purposes and provide an incoming message signal that is readily discernable by the driver's ear.
As a further alternative arrangement, and as best seen in FIG. 15 , the incoming message signal may be transmitted to the driver via the existing motor vehicle audio system. FIG. 15 illustrates various locations where speakers might be placed within the vehicle interior (including instrument panel mounts, door mounts, roof mounts, pillar mounts and rear package shelf mounts) so as to selectively deliver the incoming message to various portions of the vehicle utilizing the existing motor vehicle audio system. FIG. 15 also illustrates that the transceiver, rather than being mounted in the luggage compartment of the vehicle according to the usual practice, may be mounted at other locations in the vehicle such as, for example, under the hood adjacent the vehicle battery 110 .
A further alternative arrangement is seen in FIG. 16 wherein the jack 38 h is utilized to receive a cord connected to a headset 114 worn by the driver so as to provide privacy with respect to incoming messages. That is, the system would be wired such that the driver, wearing the headphone set, would hear the incoming messages but the incoming messages would be inaudible to any other occupants of the vehicle.
FIGS. 17–23 illustrate further alternative arrangements whereby a clip-on microphone 120 may be utilized in combination with the mirror mounted telephone to facilitate the receipt of incoming messages or the transmission of outgoing messages. The microphone 120 in each case may be connected to a cord 116 plugged directly into the telephone, or may be connected to a cord 118 connected to jack 38 h . The microphone 120 may be clipped over the upper edge of the sunvisor, clipped over the lower edge of the sunvisor, clipped over the upper edge of the door glass of the vehicle door, clipped over or attached to interior trim moldings of the vehicle, or clipped onto the clothing of the driver or other occupant. The microphone may also be utilized in combination with a headband 122 wherein the microphone is clipped into an aperture 122 a in one end of the headband for direct contact with the ear of the user. The microphone is preferably a two-part construction including the microphone 120 , wired to the phone or to the jack on the mirror, and a spring clip 126 including a clip portion 126 a for fitting over the appropriate element of the motor vehicle or article of clothing and rippled prong portions 126 b arranged to coact with a series of sets of rippled holes in the upper face of the microphone to selectively position the clip relative to the microphone in a wide, medium or close setting relative to the main body portion of the microphone depending upon the element of the motor vehicle or article of clothing to be engaged.
The battery charger feature of the mirror may be utilized to charge a spare battery 74 while the mobile telephone system is in use (with the primary battery secured to the telephone housing receiving a trickle charge via the contacts in the holster) or may be used to recharge the primary battery 74 of the portable telephone when the mobile telephone system is not in use. It will be understood that when the battery 74 is positioned in the pocket 38 g , the external battery contacts 76 communicate with a source of power, such as, for example, the vehicle battery, via the contacts 49 and the power cord 48 . A light 110 on the mirror casing is lit when a battery is positioned in pocket 38 g and is undergoing charging.
The internal circuitry of the portable telephone is preferably arranged such that the transceiver built into the portable telephone is bypassed when the portable telephone is positioned in the holster 52 for use as a part of the invention mobile telephone system so that the incoming and outgoing signals are routed directly to the transceiver in the trunk of the vehicle where the 0.6 watt outgoing signal of the portable telephone is amplified to a 3 watt signal for transmission over the antenna 28 . Alternatively, the telephone circuitry may be arranged such that the outgoing and incoming signals pass through the built-in transceiver in the portable telephone and are suitably amplified for transmission purposes utilizing the external antenna. The system may be operated on either an analog or digital basis and the portable telephone may have voice actuation features whereby the telephone responds in a known manner to voice commands from the driver or passenger.
Although the invention has been illustrated and described in connection with a portable telephone which is removably mounted on the mirror, the invention is also applicable to an arrangement in which some or all of the components of the telephone are built into the mirror as a permanent part of the mirror assembly. Several arrangements in which the telephone is built into the mirror are shown respectively in FIGS. 24 , 25 , and 26 .
In the arrangement of FIG. 24 , the mirror frame 38 includes an outstanding portion 38 a housing the keypad of the telephone so that the keypad occupies the normal gap or space between the existing sunvisors 18 . The keypad is preferably tilted rearwardly to increase ceiling clearance and to better face the operator. The other controls/components of the telephone are built into the mirror casing along the upper edge of the casing on opposite sides of the upstanding portion 38 a and along the left side of the mirror casing where the microphone 78 and power switch 80 are housed.
In the arrangement of FIG. 25 , all of the telephone control/components are built directly into the mirror casing with all of the telephone components positioned either in the left portion of the mirror casing (the microphone 78 , speaker 80 , and volume control 82 ) or along the upper edge of the mirror casing (the keypad and the other telephone controls). Positioning of the volume and power controls on the left edge of the mirror casing allows these controls to be pushed without disturbing the position of the mirror.
In the arrangement of FIGS. 26 and 27 , the casing is enlarged to define a lefthand extension portion 38 b housing the keypad as well as the microphone 78 , power switch 80 , and volume control 82 and the remaining telephone controls are positioned along the upper edge of the mirror casing. Specifically, the “SEND,” “RECALL,” and “END” controls are positioned along the top of the mirror casing and are preferably arranged to be actuated by a squeezing action, as seen in FIG. 27 , rather than a pushing action so as to minimize the possibility of inadvertently moving the mirror and upsetting the preestablished rear vision field provided by the mirror.
As seen in FIGS. 28–31 , the invention personal telephone may also be mounted in the vehicle utilizing a holder 130 suitably secured to the inside of the windshield 10 . Holder 130 includes a holder body 132 , a pair of wire arms 134 slidably and rotatably mounted in tubular bosses 132 a formed along the rear vertical edges of the opposite sides of the holder body, and a pair of suction cups 136 arranged to grip the windshield and each including a lug 136 a pivotally receiving an upper cranked end 134 a of a respective arm 134 . Holder body 132 is sized to define a pocket to receive the telephone 70 with the side edges of the telephone positioned within the respective side walls 132 b , 132 c of the holder body and the lower end of the telephone supported on a bottom or shelf portion 132 d of the holder body. Cups 136 are preferably positioned on the windshield in a location such that the lower face of the bottom shelf 132 d of the holder body rests on top of the instrument panel 12 of the vehicle with rubberized treads 132 e on the lower face of the bottom shelf securely gripping the upper face of the instrument panel. As best seen in FIG. 28 , the holder 132 is preferably positioned proximate the central lower region of the windshield so as to position the telephone proximate the central lower region of the windshield immediately above the upper surface of the instrument panel. A cable 138 is plugged at one end into telephone jack 72 and is plugged at its other end into a suitable jack in the instrument panel connected to the vehicle electrical power system.
The invention telephone system will be seen to provide many important advantages. Specifically, the invention system positions the mobile telephone at a location that is readily accessible to the driver, that allows the driver to keep his vision focused primarily on the road while using the telephone, that allows “hands free” operation whereby the driver may keep both hands on the steering wheel when utilizing the telephone, and that allows the driver to achieve sharp focusing with respect to the indicia displayed on the face of the telephone. The mirror mounted location also minimizes the possibility that the telephone system will cause or exacerbate injury in a collision scenario. Further, the invention mobile telephone system does not require any modification of the vehicle to accommodate the system but rather the vehicle manufacturer may, depending on the build order of the particular vehicle, either supply the vehicle with a standard rearview mirror assembly or with the invention rearview mirror assembly. The plug-in speaker/microphone assembly further enhances the system by increasing the message receiving and transmitting capability of the system and yet does not pose any safety risk since it will be readily moved out of the way in a collision scenario. The invention further provides an improved personal or portable telephone which is extremely compact, to facilitate stowage of the telephone in small spaces such as shirt pockets, suitcases, briefcases, purses, etc., and yet which may be readily expanded to provide proper and comfortable spacing between the outgoing message microphone and the incoming message speaker.
The invention telephone system further readily provides original equipment installation or after-market installation, may be voice actuated, may be digital or analog, and may include a radio mute feature whereby the radio is automatically muted in response to incoming or outgoing calls. The invention telephone system also allows the telephone to be provided with two batteries, with one battery at all times secured to the telephone housing, and receiving a trickle charge when the telephone is positioned in the mirror holster, and the other battery positioned in the pocket 38 g for charging from the vehicle power system. With this arrangement, when the telephone is removed from the holster for portable usage, the battery attached to the telephone housing is fully charged, and the spare battery is also fully charged so that, during portable usage, the battery secured to the housing can be exchanged when depleted for the spare battery and, if desired, the depleted battery may then be placed in the pocket 38 g so as to be charging while the spare battery is utilized to power the telephone.
Whereas preferred embodiments of the invention have been illustrated and described in detail, it will be apparent that various changes may be made in the disclosed embodiment without departing from the scope or spirit of the invention.
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An improved rearview mirror mounted telephone system mounted in a vehicle comprises a rearview mirror assembly having a housing and a reflective member associated with the housing in such a manner as to enable said reflective member to properly function as a rearview mirror; and an RF transceiver mounted to, within or on the rearview mirror assembly for providing a communication link with the rearview mirror assembly. The RF transceiver may be in communication with a portable telephone when the portable telephone is connected to the RF transceiver. The RF transceiver may be a cellular telephone transceiver.
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BACKGROUND OF THE INVENTION
The present invention provides a novel composition of matter, 2-decarboxy-2-alkylcarbonyl-PG-type compounds. The present invention further provides for the use of these compounds as gastrointestinal cytoprotective agents. Moreover the present invention provides novel intermediates and processes for preparing such compounds.
The prostaglandins are a family of cyclic carboxylic acids, containing 20 carbon atoms. Typical of the prostaglandins is PGF 2 α, whose structure and carbon atom numbering are as depicted in formula I. ##STR1## For a discussion of the prostaglandins and their pharmacological effects, see Bergstrom, et al., Pharmacol. Review 20:1, and references cited therein.
The prostaglandins, such as PGF 2 α are all named according to the degree of unsaturation exhibited in the side chains at C-8 and C-12 and the functional groups and/or unsaturation present on the cyclopentane ring. Accordingly, PGF 2 α exhibits two double bonds (C-5 and C-13), while the corresponding PGF 1 α exhibits a single double bond at C-13. When the stereochemistry of PGF 2 α at C-9 is reversed, the resulting prostaglandins are of the PGFβ series, e.g., PGF 2 β. Likewise, a PGE compound such as PGE 2 is similar to PGF 2 α as depicted above except that the C-9 hydroxy is replaced by an oxo.
The various prostaglandins all exhibit one or more centers of asymmetry and thus can exist in either optically active or optically inactive (racemic) form. For example, PGF 2 α as depicted above contains five centers of asymmetry: C-8, C-9, C-11, C-12, and C-15. For formula I above and the various formulas hereinafter substituents of asymmetric carbon atoms above the plane of the cyclopentane ring are depicted by heavy solid lines (the beta configuration), while dotted lines represent substituents below the plane of the cyclopentane ring (the alpha configuration). Thus for PGF 2 α the asymmetric centers are respectively of the alpha, alpha, alpha, beta, and alpha configurations. When wavy lines are employed hereinafter (˜), the substituents thereby depicted are either in the alpha or beta configuration or in a mixture of alpha and beta configurations.
The side chain hydroxyl at C-15 of PGF 2 α is in the "S" configuration according to the Cahn-Ingold-Prelog sequence rules. See J. Chem. Ed. 41:16 (1964). Also, Nature 212:38 (1966) provides a discussion of the stereochemistry of the prostaglandins. Expressions such as C-8, C-9, C-11, C-12, C-15, and the like will hereinafter refer to the carbon atom in any prostaglandin or prostaglandin analog which is in the position corresponding to the position of the same number in PGF 2 α above.
For convenience hereinafter the use of the term prostaglandin ("PG") will mean the optically active form of the prostaglandin thereby referred to with the same absolute configuration as PGF 2 α obtained from mammalian sources. The term prostaglandin-type of PG-type product, as used herein, will refer to any monocyclic or bicyclic cyclopentane derivative herein which is pharmacologically useful. The formulas as drawn herein which depict a prostaglandin-type product or an intermediate useful in the preparation of a prostaglandin-type product each represent a particular stereoisomer which is of the same relative stereochemical configuration as the corresponding prostaglandin obtained from mammallian sources, or the particular stereoisomer of the intermediate which is useful in preparing the above stereoisomer of the PG-type product. The term prostaglandin analog, as used herein, represents that stereoisomer of a prostaglandin-type product which is of the same relative stereochemical configuration as a corresponding prostaglandin obtained from mammalian tissues or a mixture comprising that stereoisomer and the enantiomer thereof. In particular, where a formula is used to depict a prostaglandin-type product herein, the term "prostaglandin analog" refers to the compound of that formula or a mixture comprising that compound and the enantiomer thereof.
In addition to the naturally-occurring prostaglandins, certain chemical analogs thereof have been prepared and are known in the art. Among the prostaglandin analogs known in the art are the PGD-type, 9β-PGD-type, and 9-deoxy-9,10-didehydro-PGD-type compounds of U.S. Pat. Nos. 4,016,184; the PGC-type compounds of 3,993,686, the 9-deoxy-9-methylene-PGF-type compounds of 4,021,467 and 4,060,534; the 11-deoxy-PG-type compounds of 4,029,693 and 3,987,072; the 8β,12α-PG-type compounds of 3,979,483; the 2,2-difluoro-PG-type compounds of 4,001,300; the cis-4,5-didehydro-PG-type compounds of 4,032,561 and 3,933,889; the inter-phenylene-PG-type compounds of 4,020,097 and 3,997,566; the 5,6-didehydro-PG 2 -type or 4,4,5,5-tetradehydro-PG 1 -type compounds of 4,013,695; the 5-oxa-PG 1 -type compounds of 3,931,279 and 3,864,387; the 4-oxa-PG 1 -type and 3-oxa-PG 1 -type compounds of 3,944,593,; the 13-cis-PG-type compounds of 4,026,909; the 13,14-didehydro-PG-type compounds of 4,029,681 and 4,018,803; the ω-aryl-PG-type compounds of 3,987,087; the ω-aryloxy-PG-type compounds of 3,864,387; the 16-alkyl-PG-type compounds of 3,903,131; the 16-fluoro-PG-type compounds of 3,962,293; and 15-methyl-PG-type compounds of 3,728,382.
While the naturally-occurring prostaglandins are carboxylic acids, numerous derivatives thereof are known in the art. For example, ester derivatives, including especially aromatic and phenacyl esters, are known in the art. See U.S. Pat. Nos. 3,069,332, 3,598,858, 3,979,440, and 3,984,062. Likewise, salts of these carboxylic acids are known in the art. See U.S. Pat. Nos. 3,069,332 and 3,958,858 cited above, as well as other references such as 3,657,327 and 3,888,916. Other derivatives of the prostaglandins, such as the amides thereof, are known in the art. See U.S. Pat. Nos. 3,853,941, 3,884,942, 3,903,299, 3,880,883, and 3,953,470.
Finally, there are also known macrocyclic lactone derivatives of the prostaglandins as is, for example, described by Corey, E. J. et al., JACS 97:653 (1975) and U.S. Pat. Nos. 3,931,206, 4,067,991, 4,049,648, 4,032,543, 4,045,449, and 4,049,678.
In addition to these various carbonyl-containing prostaglandin analogs, there are likewise known in the art acidic, non-carboxylic prostaglandin anlogs such as tetrazoles and sulfonates. See for example the 2-decarboxycarboxy-2-tetrazolyl-PG analogs described in U.S. Pat. Nos. 3,883,513, 3,932,389, 3,984,400, and 4,035,360. Also 2-decarboxy-2-sulfonyl-type compounds are described in U.S. Pat. No. 3,922,301.
Among the various other modifications at the C-2 position of the known prostaglandin analogs is the replacement of the carboxyl with an amine, as is for example described in U.S. Ser. No. 719,055, filed Aug. 30, 1976 and Derwent Farmdoc CPI No. 46957Y (abstracting Belgian Pat. No. 849,963).
Numerous references also describe primary alcohols corresponding to the known prostaglandins and analogs thereof as are described in U.S. Pat. Nos. 4,028,419, 4,055,602, 4,032,576, 3,931,207, 3,878,239, 3,966,792, 4,024,174, 3,962,312, 3,636,120, 3,723,528, 3,895,058, 3,954,881, 4,004,021, and 3,962,218. In addition to these 2-decarboxy-2-hydroxymethyl-PG compounds, there are known the corresponding C-2 aldehydes as described in U.S. Pat. Nos. 3,931,296 and 3,953,435. See also Derwent Farmdoc CPI No. 35953X and at 93049X for a description of further 2-decarboxy-2-carboxaldehyde-PG analogs. Finally, the C-2 acetals thereof are described at Derwent Farmdoc CPI No. 94924X.
SUMMARY OF THE INVENTION
The present invention particularly provides: a prostaglandin analog of the formula ##STR2## wherein D is ##STR3## wherein R 1 is alkyl of one to 4 carbon atoms, inclusive; wherein L 1 is ##STR4## a mixture of ##STR5## wherein R 3 and R 4 are hydrogen, methyl, or fluoro, being the same or different, with the proviso that one of R 3 and R 4 is methyl only when the other is hydrogen or methyl;
wherein M 1 is ##STR6## wherein R 5 is hydrogen or methyl; wherein R 7 is ##STR7## wherein h is zero to three, inclusive, wherein m is one to 5, inclusive, s is zero, one, 2, or 3 and T is chloro, fluoro, trifluoromethyl, alkyl of one to 3 carbon atoms or alkoxy of one to 3 carbon atoms, the various T's being the same or different, with the proviso that not more than two T's are other than alkyl;
wherein Y 1 is
(1) trans--(CH═CH--
(2) cis--CH═CH--,
(3) --ch 2 ch 2 --, or
(4) --C.tbd.C--; and
wherein Z 1 is
(1) cis--CH═CH--CH 2 --(CH 2 ) g --CH 2 --,
(2) cis--CH═CH--CH 2 --(CH 2 ) g --CF 2 --,
(3) cis--CH 2 --CH═CH--(CH 2 ) g --CH 2 --,
(4) --(ch 2 ) 3 --(ch 2 ) g --CH 2 --,
(5) --(ch 2 ) 3 --(ch 2 ) q --CF 2 --,
(6) --ch 2 --o--ch 2 --(ch 2 ) g --CH 2 --,
(7) --(ch 2 ) 3 --o--(ch 2 ) g --CH 2 --,
(8) --(ch 2 ) 3 --o--(ch 2 ) g --, ##STR8## (11) --C.tbd.C--CH 2 --(CH 2 ) g --CH 2 --, (12) --CH 2 --C.tbd.C--(CH 2 ) g --CH 2 --, or
(13)trans--(CH 2 ) 2 --(CH 2 ) g --CH═CH--,
wherein g is one, two, or three.
By virtue of the ketone function in the C-8 side chain, all of the novel prostaglandin analogs herein are named as 2-decarboxy-2-alkylcarbonyl-PG-type compounds. Accordingly, when R 1 is methyl, the novel prostaglandin analogs herein are named as 2-decarboxy-2-methylcarbonyl-PG-type compounds.
Further, the novel 2-decarboxy-2-alkylcarbonyl-PG-type compounds herein are further categorized according to their cyclopentane ring structure. This cyclopentane ring structure, providing a "parent-type" for each of the novel prostaglandin analogs herein is associated with the nomenclature indicated in the following table:
______________________________________CLASSIFICATION OF 2-DECARBOXY-2-ALKYLCARBONYL PG ANALOGS BYCYCLOPENTANE RING STRUCTURERing Structure Nomenclature______________________________________A. ##STR9## PGFα-type compoundsB. ##STR10## 8β,12α-PGFα-type compoundsC. ##STR11## PGFβ-type compoundsD. ##STR12## 8β,12α-PGFβ-type compoundsE. ##STR13## PGE-type compoundsF. ##STR14## 8β,12α-PGE-type compoundsG. ##STR15## 11-Deoxy-PGFα-type compoundsH. ##STR16## 11-Deoxy-8β,12α-PGFα- type compoundsI. ##STR17## 11-Deoxy-PGFβ -type compoundsJ. ##STR18## 11-Deoxy-8β,12α-PGFβ- type compoundsK. ##STR19## 11-Deoxy-PGE-type compoundsL. ##STR20## 11-Deoxy-8β,12α-PGE- type compoundsM. ##STR21## PGA-type compoundsN. ##STR22## 8β,12α-PGA-type compoundsO. ##STR23## PGB-type compoundsP. ##STR24## 9-Deoxy-9-methylene- PGF-type compoundsQ. ##STR25## 9-Deoxy-9-methylene-8β,12α- PGF-type compoundsR. ##STR26## PGD-type compounds-S. ##STR27## 8β,12α-PGD-type compoundsT. ##STR28## 9β-PGD-type compoundsU. ##STR29## 8β,9β,12α-PGD-type compoundsV. ##STR30## 9-Deoxy-9,10-didehydro- PGD-type compoundsW. ##STR31## 9-Deoxy-9,10-didehydro- 8β,12α-PGD-type compounds______________________________________
Those novel prostaglandin analogs herein wherein Z 1 is cis--CH═CH--CH 2 --(CH 2 ) g --CH 2 -- or cis--CH═CH--CH 2 --(CH 2 ) g --CF 2 -- are named as PG 2 -type compounds. The latter compounds are further characterized as 2,2-difluoro-PG-type compounds.
Further when Z 1 is --(CH 2 ) 3 --(CH 2 ) g --CH 2 -- or --(CH 2 ) 3 --(CH 2 ) g --CF 2 , wherein g is as defined above, the compounds so described are PG 1 -type or 2,2-difluoro-PG 1 -type compounds.
When Z 1 is --CH 2 --O--CH 2 --(CH 2 ) g --CH 2 -- the compounds so described are named as 5-oxa-PG 1 -type compounds. When Z 1 is --(CH 2 ) 2 --0--(CH 2 ) g --CH 2 --, wherein g is as defined above, the compounds so described are named as 4-oxa-PG 1 -type compounds. When Z 1 is --(CH 2 ) 3 --O--(CH 2 ) g --, wherein g is as defined above, the compounds so described are named as 3-oxa-PG 1 -type compounds.
When Z 1 is cis--CH 2 --CH═CH--(CH 2 ) g --CH 2 --, wherein g is as defined above, the compounds so described are named as cis-4,5-didehydro-PG 1 -type compounds.
For the novel compounds of this invention wherein Z 1 is ##STR32## there are described, respectively, 3-oxa-3,7-inter-m-phenylene-4,5,6-trinor or 3,7-inter-m-phenylene-4,5,6-trinor-PG-type compounds.
When Z 1 is --C.tbd.C--CH 2 --(CH 2 ) g --CH 2 --, wherein g is as defined above, the compounds so described are named as 5,6-didehydro-PG 2 -type compounds. When Z 1 is --CH 2 --C.tbd.C--(CH 2 ) g --CH 2 --, wherein g is as defined above, the compounds so described are named as 4,4,5,5-tetradehydro-PG 1 -type compounds.
When Z 1 is trans--(CH 2 ) 2 --(CH 2 ) g --CH═CH--, wherein g is as defined above, the compounds so described are named as trans-2,3-didehydro-PG 1 -type compounds.
When g is 2 or 3, the prostaglandin analogs so described are 2a-homo- or 2a,2b-dihomo-PG-type compounds, since in this event the carboxy terminated side chain contains 8 or 9 carbon (or carbon and oxygen) atoms, respectively, in place of the 7 carbon atoms contained in PGF 2 α. These additional carbon atoms are considered as though they were inserted between the C-2 and C-3 positions. Accordingly, these additional carbon atoms are referred to as C-2a C-2b, counting from the C-2 to the C-3 position.
The novel prostaglandin analogs of this invention which contain a cis--CH═CH--, --CH 2 CH 2 -- or --C.tbd.C-- moiety at the C-13 to C-14 position, are accordingly, referred to as 13-cis-, 13,14-dihydro-, or 13,14-didehydro-PG-type compounds. respectively.
When R 7 is --(CH 2 ) m --CH 3 , wherein m is as defined above, the compounds so described are named as 19,20-dinor-, 20-nor-, 20-methyl-, or 2-ethyl-PG-type compounds when m is one, 2, 4, or 5, respectively.
When R 7 is ##STR33## wherein T and s are as defined above, the neither R 3 nor R 4 is methyl, the compounds so described are named as 16-phenyl-17,18,19,20-tetranor-PG-type compounds, when s is zero. When s is one, 2, or 3, the corresponding compounds are named as 16-(substituted phenyl)-17,18,19,20-tetranor-PG-type compounds. When one and only one of R 3 and R 4 is methyl or both R 3 and R 4 are methyl, then the corresponding compounds wherein R 7 is as defined in this paragraph are named as 16-phenyl- or 16-(substituted phenyl)-18,19,20-trinor-PG-type compounds or 16-methyl-16-phenyl- or 16-(substituted phenyl)-18,19,20-trinor-PG-type compounds, respectively.
When R 7 is ##STR34## wherein T and s are as defined above, the compounds so described are named as 17-phenyl-18,19,20-trinor-PG-type compounds, when s is zero. When s is one, 2, or 3, the corresponding compounds are named as 17-(substituted phenyl)-18,19,20-trinor-PG-type compounds.
When R 7 is ##STR35## wherein T and s are as defined above, the compounds so described are named as 18-phenyl-19,20-dinor-PG-type compounds, when s is zero. When s is one, 2, or 3, the corresponding compounds are named as 18-(substituted phenyl)-19,20-dinor-PG-type compounds.
When R 7 is ##STR36## wherein T and s are as defined above, the compounds so described are named as 19-phenyl-20-nor-PG-type compounds, when s is zero. When s is one, 2, or 3, the corresponding compounds are named as 19-(substituted phenyl)-20-nor-PG-type compounds.
When R 7 is ##STR37## wherein T and s are as defined above, and neither R 3 nor R 4 is methyl, the compounds so described are named as 16-phenoxy-17,18,19,20-tetranor-PG-type compounds, when s is zero. When s is one, 2, or 3, the corresponding compounds are named as 16-(substituted phenoxy)-17,18,19,20-tetranor-PG-type compounds. When one and only one of R 3 and R 4 is methyl or both R 3 and R 4 are methyl, then the corresponding compounds wherein R 7 is as defined in this paragraph are named as 16-phenoxy- or 16-(substituted phenoxy)-18,19,20-trinor-PG-type compounds or 16-methyl-16-phenoxy- or 16-(substituted phenoxy)-18,19,20-trinor-PG-type compounds, respectively.
When at least one of R 3 and R 4 is not hydrogen then (except for the 16-phenyl 16-phenoxy-PG-type compounds discussed above) there are described the 16-methyl- (one and only one of R 3 and R 4 is methyl), 16,16-dimethyl- (R 3 and R 4 are both methyl), 16-fluoro- (one and only one of R 3 and R 4 is fluoro), or 16,16-difluoro-PG-type (R 3 and R 4 are both fluoro) compounds. For those compounds wherein R 3 and R 4 are different, the prostaglandin analogs so represented contain an asymmetric carbon atom at C-16. Accordingly, two epimeric configurations are possible: "(16S)" and "(16R)". Further, there is described by this invention the C-16 epimeric mixture: "(16RS)".
When R 5 is methyl, the compounds so described are named as 15-methyl-PG-type compounds.
With the exception of the 13-cis-PG-type compounds described above, all the above compounds exhibiting a hydroxy in the beta configuration at C-15 are additionally referred to as 15-epi-PG-type compounds. For the 13-cis-PG-type compounds herein, only compounds exhibiting the hydroxy in the alpha configuration at C-15 are referred to as 15-epi-PG-type compounds. The rationale for this system of nomenclature with respect to the natural and epimeric configurations at C-15 is described in U.S. Pat. No. 4,016,184, issued Apr. 5, 1977.
Examples of alkyl of one to 4 carbon atoms, inclusive, are methyl, ethyl, propyl, butyl, and isomeric forms thereof.
Examples of ##STR38## wherein T is alkyl of one to 3 carbon atoms, inclusive, fluoro, chloro, trifluoromethyl, or alkoxy of one to 3 carbon atoms, inclusive; and s is zero, one, 2, or 3, with the proviso that not more than two T's are other than alkyl, are phenyl, (o-, m-, or p-)tolyl, (o-, m-, or p-)ethylphenyl, 2-ethyl-p-tolyl, 4-ethyl-o-tolyl, 5-ethyl-m-tolyl, (o-, m-, or p-)propylphenyl, 2-propyl-(o-, m-, or p-)tolyl, 4-isopropyl-2,6-xylyl, 3-propyl-4-ethylphenyl, (2,3,4-, 2,3,5-, 2,3,6-, or 2,4,5-trimethylphenyl, (o-, m-, p-)fluorophenyl, 2-fluoro-(o-, m-, or p-)tolyl, 4-fluoro-2,5-xylyl, (2,4-, 2,5-, 2,6-, 3,4-, or 3,5-)difluorophenyl, (o-, m-, or p-)chlorophenyl, 2-chloro-p-tolyl, (3-, 4-, 5-, or 6-)chloro-o-tolyl, 4-chloro-2-propylphenyl, 2-isopropyl-4-chlorophenyl, 4-chloro-3,5-xylyl, (2,3-, 2,4-, 2,5-, 2,6-, 3,4-, or 3,5-(dichlorophenyl, 4-chloro-3-fluorophenyl, (3-, or 4-(chloro-2-fluorophenyl, o-, m-, or p-trifluoromethylphenyl, (o-, m-, or p-methoxyphenyl, (o-, m-, or p-)-ethoxyphenyl, (4- or 5-)chloro-2-methoxyphenyl, and 2,4-dichloro(5- or 6-)methylphenyl.
The novel prostaglandin analogs of the present invention are all useful pharmacological agents, exhibiting high potency as gastrointestinal cytoprotective agents. the gastrointestinal cytoprotective property of the novel prostaglandin analogs herein is evidenced by the ability of these compounds to inhibit the formation of ulcers or other lesions in standard laboratory animals treated with gastrointestinally erosive agents. For a discussion of such laboratory tests, describing the prevention of these gastric lesions by pre-treatment with prostaglandins, see Robert, et al., "Gastric Cytoprotective Property of Prostaglandins", Gastroenterology 72:1121 (1977); and a discussion of such laboratory tests, describing the reduction in intestinal lesions by pre-treatment with prostaglandins, see Robert, et al., Gastroenterology 69:1045 (1974), wherein, inter alia, PGE 2 is demonstrated to be effective in reducing indomethacin-induced intestinal lesions in the rat.
By virtue of the gastrointestinal cytoprotective property of the novel prostaglandin analogs herein, these compounds are highly useful in the prevention and treatment of inflammatory diseases of the stomach, duodenum, and large and small intestine. For example, the novel prostaglandin analogs herein are employed as gastric cytoprotective agents in the prevention and treatment of gastric erosive diseases, such as gastric ulceration and erosive gastritis. Moreover, the novel prostaglandin analogs herein are useful as intestinal cytoprotective agents in the treatment of numerous intestinal inflammatory diseases, included in which are Crohn's disease, inflammatory bowel disease, infectious enteritis, sprue, and intestinal inflammatory diseases secondary to radiation exposure or allergen exposure. While the novel prostaglandin analogs herein are useful for the present gastrointestinal cytoprotective purposes in a wide variety of mammals, including valuable domestic animals, the principal use of the novel prostaglandin analogs herein is in man.
Accordingly, by this preferred embodiment of the gastric cytoprotective use, the novel prostaglandin analogs herein are used in man for the treatment and prevention of gastric ulcer, duodenal ulcer, gastritis and other gastric inflammatory conditions (e.g., secondary to radiation exposure), by the systemic administration of a dose of a novel prostaglandin analog effective to treat or prevent the development of the disease. In the prophylactic use of these gastric cytoprotective prostaglandins, patients are selected for treatment who exhibit a high susceptibility to the acquisition of a gastric inflammatory disease. Examples of such patients include those with a previous history of gastric or duodenal ulcer; those persons subjected to chronic or acute and stressful environmental conditions, whether of a physical or emotional origin; those manifesting chronic and excessive ethanol consuption (e.g., especially persons diagnosed as alcoholics); and those persons for whom an acute exposure to a cytodestructive dose of ionizing radiation is contemplated. In the latter case, the use of the novel prostaglandin analogs herein in patients receiving therapeutic doses of radiation, for example in the treatment of neoplastic diseases, is particularly contemplated.
When the novel prostaglandin analogs herein are employed as enteric cytoprotective agents, the prophylactic or therapeutic use is undertaken when the animal or patient is in a state of high susceptibility to the development of an intestinal inflammatory disease or the diagnosis of such a disease has been made. Examples of patients exhibiting a high susceptibility to the development of enteric inflammatory diseases include, for example, patients subject to cytodestructive doses of radiation, as indicated above.
With regard to the systemic administration of the novel compounds of the present invention, any convenient systemic route is employed, although oral administration is the highly preferred route. While the oral route is preferred, for patients where this route of administration is inconvenient or unacceptable, other routes such as via a nasogastric tube or via suppositories and enemas are likewise preferred. For a description of the various methods of formulation and routes of administration by which the novel prostaglandin analogs herein are employed, see United States Patent 3,903,297.
The dosage regimen and duration of treatment for the novel prostaglandin analogs herein will depend upon a wide variety of factors, including the type, age, weight, sex, medication condition of the animal or patient being treated and the nature and severity of the gastric or enteric inflammatory disease to be treated or prevented. For example, oral doses between 25 mg/kg/day and 0.5 μg/kg/day will ordinarily be gastrointestinally cytoprotective. Once a minimum effective dose for the particular novel prostaglandin analog herein is determined for a particular animal or patient, that animal or patient is thereafter advantageously provided with a daily dosage schedule which will provide a substantially uniform level of the novel cytoprotective analog throughout the day.
Moreover, treatment with the novel prostaglandin analog herein should be continued therapeutically until the gastrointestinal inflammatory disease has been successfully arrested, and thereafter a prophylactic regimen with the prostaglandin analog should be maintained until susceptibility to the recurrence of the disease is no longer high. Thus, in the case of an acute exposure to a noxious atent, treatment for several days to several weeks will ordinarily be sufficient. However, in cases where a patient, for example, has a history of multiple recurrences of gastric or duodenal ucler, prophylactic treatment may be maintained indefinitely, based upon the continued tolerance to the drug.
______________________________________CHART A ##STR39## XXI ##STR40## XXII ##STR41## XXIII ##STR42## ##STR43## XXIV ##STR44## ##STR45## XXV ##STR46## ##STR47## XXVI ##STR48## XXXI XXXII4 ## XXXIII0## ##STR51## XLI XLIIR 2## XLIII5 ## XLIVR 4## XLVTR55## ##STR56## LI LIIT 57## LIIIR58## ##STR59## LXI LXIIR 0## LXIII61## ##STR62## LXXI LXXII6 ## LXXIII4 # LXXIV65## ##STR66## LXXXI LXXXII7 # LXXXIII# LXXXIV9 # LXXXV70## The charts herein provide exemplary methods by which the novel2-decarboxy-2-alkylcarbonyl-PG-type compounds of the present inventionare prepared. With respect to the charts, R.sub.18 is hydrogen orprotective group - derivatized hydroxyl, wherein said protective group isselected from among acetal-type ethers (e.g., tetrahydrofuran,tetrahydropyran, and 1-epoxyethyl) and stable silyl groups such ast-butyldimethylsilyl. For examples of protective groups apposite to theinstant purposes see U.S. Pat. No. 4,016,184. R.sub.8 is hydroxy ofhydrogen; R.sub.2 is alkyl of one to 4 carbon atoms, inclusive,preferably being methyl or ethyl; R.sub.11 and R.sub.12 are such thatmoiety --CHR.sub.11 R.sub.12 is primary or secondary alkyl of one to 4carbon atoms, inclusive; R.sub.9 is trialkylsilyl of the formula--S.sub.i (G.sub.1).sub.3, wherein G.sub.1 is alkyl of one to 4 carbonatoms, inclusive, the various G.sub.1 's being the same or different andpreferably all being methyl; and R.sub.13 is --OH, --NCONH.sub.2,--NCSNH.sub.2, or --NOR.sub.2. M.sub.6 and M.sub.7 are hydroxylderivatized forms of M.sub.1 wherein the hydroxyl group is replaced by anether-type derivative. For M.sub.6, the derivative is a protecting groupas in R.sub.18, while for M.sub.7 the derivative is a silyl group as
Aryl is an aromatic carbocyclic radical, preferably being phenyl. Hal is halogen, preferably being chloro or bromo.
R 1 , R 7 , M 1 , L 1 , and Z 1 are as defined above.
Chart A provides a method whereby the formula XXI PGFα- or 11-deoxy-PGFα-type 11,15-bis ether of 15-ether is transformed to the formula XXVI 2-decarboxy-2-alkylcarbonyl-PGFα- or 11-deoxy-PGFα-type compounds of the present invention.
The formula XXI compound is known in the art or readily prepared by methods known in the art. See for example the above references describing the preparation of PGFα- and 11-deoxy-PGFα-type compounds exhibiting the various C-8 and C-12 side chain modifications as evidenced by formula XXI.
The formula XXII compound is prepared from the formula XXI compound by silyl protection of the C-9 hydroxyl.
Methods for such monosilylation of PG-type products with the trialkylsilyl groups of R 9 are described in U.S. Pat. No. 4,016,184.
The formula XXII compound is thereafter transformed to the formula XXIII sulfoximine ester by reaction with an S-aryl-N-alkyl-S-alkylsulfoximine in the presence of a lower alkyl Grignard reagent (e.g., an alkyl magnesium chloride). The reaction ordinarily proceeds to completion in several minutes to an hour at low temperature, i.e., less than or equal to 0° C. For example, the reaction conveniently employs S-phenyl-N,S, dimethylsulfoximine with methyl magnesium chloride in a tetrahydrofuran solvent at 0° to -78° C. when preparing the formula XXIII compound wherein R 11 and R 12 are both hydrogen.
Thereafter, the formula XXIV ketone is prepared from the formula XXIII compound by an aluminum amalgam reduction. Conventional methods for the preparation of aluminum amalgams are employed and the reaction, being slightly exothermic, is ordinarily completed at about ambient temperature in about one hr after treatment of the formula XXIII compound with the amalgam. For a detailed description of the preparation of the aluminum amalgam and its instant reductive use, see the description in U.S. Pat. No. 3,950,363, wherein aluminum amalgams are employed in the preparation of 9-deoxy-9-methylene-PGF-type compounds.
Thereafter the formula XXV compound is prepared from the formula XXIV compound by selective hydrolysis of the C-9 silyl group. For example, the tri(primary alkyl) silyl group according to R 9 is hydrolyzed in the presence of citric acid and aqueous methanol at between 0° and 25° C., reaction conditions under which the acetal type protective groups according to R 18 or dialkyl-(tertiary alkyl) silyl groups according to R 18 are not so hydrolyzed. The formula XXV 2-carboxy-2-alkylcarbonyl-PGFα- or 11-deoxy-PGFα-type, 11,15-bis ether or 15-ether is then readily and efficiently oxidized to the corresponding 2-decarboxy-2-alkylcarbonyl-PGE- or 11-deoxy-PGE-type, 11,15-bis ether or 15-bis ether, in accordance with methods known in the art. Moreover, hydrolysis of these 2-decaroboxy-2-alkylcarbonyl-PGE- or 11-deoxy-PGE-type 11,15-bis ethers or 15 ethers is accomplished by methods hereinafter described for the preparation of the formula XXVI compounds, yielding the corresponding 2-decarboxy-2-alkylcarbonyl-PGE- or 11-deoxy-PGE-type products.
These 2-decarboxy-2-alkylcarbonyl-PGE- or 11-deoxy-PGE-type products are thereafter transformed to corresponding 2-decarboxy-2-alkylcarbonyl-PGA- or PGB-type products by acidic or basic dehydration, respectively, in accordance with methods known in the art. Further the 2-decarboxy-2-alkylcarbonyl-PGE- or 11-deoxy-PGE-type products are selectively reduced to the corresponding 2-decarboxy-2-alkylcarbonyl-PGFβ- or 11-deoxy-PGFβ-type products, in accordance with methods known in the art.
Finally, the 2-decarboxy-2-alkylcarbonyl-PGE-type 11,15-bis ethers are transformed to corresponding 2-decarboxy-2-alkylcarbonyl-9-deoxy-9-methylene-PGF-type 11,15-bis ethers employing methods described in U.S. Pat. No. 3,950,363. Accordingly, these 2-decarboxy-2-alkylcarbonyl-9-deoxy-9-methylene-PGF-type products are prepared by a sulfoximine addition, as described in the preparation of the formula XXIII compound from the formula XXII compound; and hydrolysis of the ether groups, as described in the preparation of the formula XXVI compound hereinbelow; and an aluminum amalgam reduction, as described in the preparation of the formula XXIV compound from the formula XXIII compound.
The formula XXVI compound is prepared from the formula XXV compound by hydrolysis of the dialkyl (tertiary alkyl) silyl or acetyl-type protective groups, employing methods known in the art. For example mixtures of acetic acid, water, and tetrahydrofuran at 40° C. are conveniently employed. See in particular the methods for hydrolysis described in U.S. Pat. No. 4,016,184.
The formula XXVI compound represents a 2-decarboxy-2-alkylcarbonyl-PGF -or 11-deoxy-PGF -type product of the present invention. Such formula XXVI products are transformed to the corresponding 2-decarboxy-2-alkylcarbonyl-PGD-9β-PGD- or 9-deoxy-9,10-didehydro-PGD-type products according to methods known in the art. For a description of such methodology see U.S. Pat. No. 4,016,184.
For each of the various 2-decarboxy-2-alkylcarbonyl-PG-type products exhibiting a PGFα, PGFβ, PGE, 11-deoxy-PGFα, 11-deoxy-PGFβ, 11-deoxy-PGE, PGA,9-deoxy-9-methylene-PGF, PGD, 9β-PGD, or 9-deoxy-9,10-didehydro-PGD parent structure, corresponding 8β,12α-PG-type products are prepared by employing the 8β,12α isomer of the formula XXII compound. Such 8β,12α-PGFα- or 11-deoxy-PGFα-type reactants according to formula XXI are known in the art or prepared by methods known in the art. Most particularly, methodology for the preparation of these stereoisomers is described in U.S. Pat. No. 3,979,438. Accordingly, there are prepared by procedures described hereinabove from these 8β,12α-PGFα- or 11-deoxy-PGFα-reactants of formula XXII 2-decarboxy-2-alkylcarbonyl-8β,12α-PGFα- PGFβ-, PGE-, 11-deoxy-PGFα-, 11-deoxy-PGFβ-, 11-deoxy-PGE-, PGA-, 9-deoxy-9-methylene-PGF-, PGD-, 9β-PGD-, or 9-deoxy-9,10-didehydro-PGD-type products.
Accordingly, there are prepared from the formula XXI - formula XXVI compounds of Chart A, or the 8,12-PG-type stereoisomers thereof 2-decarboxy-2-(primary alkyl)carbonyl- or 2-(secondary alkyl)carbonyl-PG-type products of the present invention.
Chart B provides a method analagous to that described in Chart A whereby the formula XXXI compound of Chart B (the formula XXII compound of Chart A) is transformed to a formula XXXIII 2-decarboxy-2-(primary or secondary)alkyl-PGFα- or 11-deoxy-PGFα-type intermediate according to formula XXXIII (the formula XXIV compound of Chart A). In accordance with the method of Chart B, the formula XXXI compound is reacted with an anion generated from a symmetrical bis(primary or secondary alkyl)sulfoxide to yield the formula XXXII sulfoxide ester. The bisalkylsulfoxide anion is generated from a symmetrical compound of the formula CHR 11 R 12 SOCHR 11 R 12 by reaction with a strong base. Appropriate bases include potassium t-butoxide and sodium hydride. The general methodology for preparing sulfoxide esters is known in the art. See for example Corey, E. J., et al., JACS 86:1639 (1964).
The formula XXXII compound is then reduced, employing an aluminum amalgum, to yield the formula XXXIII 2-decarboxy-2-(primary or secondary alkyl)carbonyl-PGFα- or 11-deoxy-PGFα- intermediate. Suitable reaction conditions are known in the art and are for example described by Corey, E. J., et al. JACS 86:1639 (1964). These formula XXXIII compounds of Chart B are then employed in the preparation in various 2-decarboxy-2-(primary or secondary alkyl)carbonyl-PG-type products of the present invention by methods described in Chart A from the preparation of such products from the formula XXIV compound.
Chart C provides yet a third method whereby 2-decarboxy-2-alkylcarbonyl-PGFα- or 11-deoxy-PGFα-type intermediates are prepared, which intermediates can thereafter be transformed to the various 2-decarboxy-2-alkylcarbonyl-PG-type products of the present invention. In distinction to the methods described in Chart A and B, the method described in Chart C provides for the preparation of intermediates which are ultimately transformed (by methods described above) to 2-decarboxy-2-(2-tertiary alkyl)carbonyl-PG-type products of the present invention.
The method of Chart C provides for the transformation of the formula XLI carboxylic acid, as known in the art or as is readily prepared by methods known in the art, to the formula XLV 2-decarboxy-2-(primary, secondary, or tertiary alkyl)carbonyl-PGFα- or 11-deoxy-PGFα-type intermediates.
In accordance with the method of Chart C, the formula XLI carboxylic acid is transformed to the formula XLII silyl ether - silyl ester by silylation methods described above for the preparation of the formula XXII compound of Chart A.
The formula XLIII compound is then prepared from the formula XLII compound by hydrolysis of the silyl esters. The hydrolysis of the esters proceed efficiently in an aqueous medium, especially aqueous media containing sufficient amounts of organic solvent (e.g., ethanol) to assure solubility of the formula XLII reactant. Having prepared the formula XLIII acid, the 2-pyridyl ester thereof is prepared by reacting the acid with 2,2'-dipyridyl disulfide in the presence of triphenylphosphine. Appropriate reaction conditions for such an esterification are known in the art. See for example Corey, E. J., et al., JACS 97:653 (1975).
Thereafter, an alkyl Grignard reagent is employed in the transformation of the formula XLIV compound to the corresponding formula XLV 2-decarboxy-2-(alkylcarbonyl-PGFα- or 11-deoxy-PGFα-type intermediate. This ketonization reaction is known in the art, being described by Mukaiyama, T., et al., JACS 95:4763 (1973).
Chart D provides yet a fourth method whereby the formula LIV 2-decarboxy-2-alkylcarbonyl-PGFα- or 11-deoxy-PGFα-type intermediate is prepared. By the method of Chart D, the formula LI compound, prepared as the formula XLIII compound in Chart A, is firstly transformed to the formula LII acid chloride. Methods known in the art for the generation of such acid chlorides are employed. For example, by one convenient method oxalyl chloride is employed. The formula LII acid chloride thusly prepared is then transformed to the formula LIII 2-decarboxy-2-alkylcarbonyl-PGFα- or 11-deoxy-PGFα-type intermediate by reaction with a dialkyl copper (I) lithium reagent corresponding to the formula III 2-decarboxy-2-alkylcarbonyl-PGFα- or 11-deoxy-PGFα-type intermediate to be prepared. The copper lithium reagent is generated by reaction of, for example, cuperous iodide with the desired alkyllithium compound and thereafter combining the reagent thusly prepared with the formula LII compound. The reaction is appropriately undertaken at low temperature (-20° to -78° C.) and is ordinarily complete within several minutes. For a description of the general reaction conditions employed herein, see Posner, G., et al. Tetrahedron Lett. 4676 (1970).
Chart E provides yet a fifth method whereby the formula LXIII 2-decarboxy-2-alkylcarbonyl-PGFα- or 11-deoxy-PGFα-type intermediate is prepared. By the method of Chart E, this intermediate is prepared from the formula LXII acid chloride, prepared as the formula LII compound of Chart D. The acid chloride is then reacted with Na 2 Fe(CO) 4 to yield the formula LII ester, which ester is thereafter reacted with an alkyl halide corresponding to the formula LXIII 2-decarboxy-2-alkylcarbonyl-PGFα- or 11-deoxy-PGFα-type intermediate to be prepared. The method for preparing ketones of the present type is known in the art. See for example Collman, J. P., et al., JACS 94:1788 (1972).
Chart F provides an especially convenient method whereby the preparation of the formula LXXIV 2-decarboxy-2-methylcarbonyl-9-deoxy-9-methylene-PGF-type products are prepared. Methods analagous to those in Chart F for preparing the carboxylic acids corresponding to the formula LXXIV ketones are described in U.S. Pat. Nos. 4,012,467 and 4,060,343, where the instant formula LXXIV ketones represent uncharacterized and unappreciated reaction side products of the preparation of the 9-deoxy-9-methylene-PGF-type compounds described therein. Accordingly, the silylation of the formula LXXXI compound to the formula LXXXII compound proceeds as is described in U.S. Pat. No. 4,021,467; and thereafter the silylated formula LXXXII compound is reacted with an S methyl-S-aryl-N-alkyl-sulfoxamine reagent in the presence of an alkyl Grignard reagent in a manner described in Chart A for the preparation of the formula XXIII compound therein. While substantial yields of the formula LXXII product can be obtained by allowing the reaction to proceed at from 0° to -78° C. by employing a single equivalent of the sulfoxamine reagent, the preferred reaction conditions for the preparation of the formula LXXIII compound are the employment of three to four equivalents of the sulfoxamine reagent with reaction proceeding at 0° C. to ambient temperature. While reaction conditions may be maintained for as short a period as 2 hrs, preferred reaction times are 4-6 hrs.
Thereafter the formula LXXIV product is prepared in the manner described above for the preparation of the formula XXVI compound of Chart A, e.g., the protection followed by aluminum amalgam reduction.
Chart G provides a method whereby the cyclopentanone products of formula LXXXV are prepared from the formula LXXXI PGFα- or 11-deoxy-PGFα-, 11,15-bis ethers or 15-ethers.
In accordance with the method of Chart D, the formula LXXXI compound is first oxidized to the formula LXXXII PGE- or 11-deoxy-PGE-, 11,15-bis ether or 15-ether by methods known in the art. For example, known reducing agents for transforming PGF-type compounds to the corresponding PGE derivatives such as the Collins reagent or the Jones reagent are employed. Thereafter, the cyclopentanone ring of the formula LXXXII compound is derivatized to the formula LXXXIII oxime, semicarbazone, thiosemicarbazone, or alkoxyoxime. The preparation of such derivatives of the formula LXXXII compound is readily accomplished by methods known in the art. See for example U.S. Pat. No. 3,723,528, describing the conversion of similar cyclopentanone compounds to corresponding nitrogen-containing derivatives.
The formula LXXXIII compound is then transformed to the formula LXXXIV 2-decarboxy-2-alkylcarbonyl derivative by any one of the methods described in Charts A-E above. Preferred among such methods described above for the present purpose is that described in Charts A and C.
Finally, the formula LXXXIV compound is hydrolyzed to the formula LXXXV product, employing, again, methods described in U.S. Pat. No. 3,723,528 for transforming the oxime, semicarbazone, thiosemicarbazone, or alkoxyoxime derivatives to corresponding cyclopentanones and other hydrolytic methods (e.g., for the removal of protective groups) as described above.
By a variation of the method described in Chart G, the various other novel prostaglandin analogs herein exhibiting a cyclopentanone or cyclopentanone ring are likewise prepared by the methods described in Chart G by substituting the corresponding carboxylic acids thereof in place of the formula LXXXII compound. For example, the 2-decarboxy-2-alkylcarbonyl-PGA-type compounds of the present invention are prepared in accordance with the method of Chart G by subjecting the corresponding PGA-type, alkyl ester, 15-ether to the sequence of reaction steps employed in the transformation of the formula LXXXII compound to the formula LXXXV products.
Further, as indicated above, when 8β,12α-PG-type products are desired, the respective procedures of Charts A-G are followed, with the exception that, corresponding 8β,12α-PG-type starting materials are employed. Such starting materials are known in the art or readily prepared by methods known in the art and indicated above.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention can be more fully understood by the following examples and preparations.
All temperatures are in degrees centigrade.
IR (infrared) absorption spectra are recorded on a Perkin-Elmer Model 421 infrared spectrophotometer. Except when specified otherwise, undiluted (neat) samples are used.
UV (Ultraviolet) spectra are recorded on a Cary Model 15 spectrophotometer.
NMR (Nuclear Magnetic Resonance) spectra are recorded on a Varian A-60, A-60D, or T-60 spectrophotometer in deuterochloroform solutions with tetramethylsilane as an internal standard (downfield).
Mass spectra are recorded on an CEG model 110B Double Focusing High Resolution Mass Spectrometer or an LKB Model 9000 Gas-Chromatograph-Mass Spectrometer. Trimethylsilyl derivatives are used, except where otherwise indicated.
"Brine", herein, refers to an aqueous saturated sodium chloride solution.
The A-IX solvent system used in thin layer chromatography is made up from ethyl acetate-acetic acid-2,2,4-trimethylpentane-water (90:20:50:100) according to M Hamberg and B. Samuelsson, J. Biol. Chem. 241, 257 (1955).
Skellysolve-B (SSB) refers to mixed isomeric hexanes.
Silica gel chromatography, as used herein, is understood to include elution, collection of fractions, and combination of those fractions shown by TLC (thin layer chromatography) to contain the pure product (i.e., free of starting material and impurities).
Melting points (MP) are determined on a Fisher-John or Thomas-Hoover melting point apparatus.
THF refers to tetrahydrofuran.
Specific Rotations, (α), are determined for solutions of a compound in the specified solvent at ambient temperature with a Perkin-Elmer Model 141 Automatic Polarimeter.
EXAMPLE 1 -- 2-Decarboxy-2-methylcarbonyl-16,16-dimethyl-9-deoxy-9-methylene-PGF 2 (Formula LXXIV: Z 1 is cis-CH═CH-(CH 2 ) 3 -, Y 1 is trans-CH═CH-, R 5 of the M 1 moiety is hydrogen, R 3 and R 4 of the L 1 moiety are both methyl, and R 7 is n-butyl).
Refer to Chart F.
A. A solution of 8.78 g of S-methyl-S-phenyl-N-methylsulfoximine in 150 ml of tetrahydrofuran was cooled to 0° C. and treated dropwise over 10 min with 16.9 ml of 2.9 M methylmagnesium chloride in tetrahydrofuran. After 15 min at 0° C. the resulting sulfoximine ion-solution was cooled to -78° C. and added dropwise over 15 min to a stirred solution of 13.8 g of 16,16-dimethyl-PGE 2 , methyl ester, 11,15-bis(tetrahydropyranyl ether) in 70 ml of tetrahydrofuran at -78° C. The resulting solution is then stirred at -78° C. for 2.5 hrs and thereafter treated with 20 ml of saturated aqueous ammonium chloride. After an additional 10 min, the resulting mixture is then poured into a mixture of ice, aqueous ammonium chloride, and diethyl ether. Extracting with diethyl ether, washing with brine, drying over sodium sulfate, and concentrating under reduced pressure yields a residue containing the formula LXXIII sulfoxamine ester.
B. Aluminum metal (20 g of 20 mesh) is washed with diethyl ether and methanol. The metal is then combined with 20 g of mercuric chloride in 150 ml of water. The resulting suspension is then swirled until appreciable hydrogen evolution is noted. The solution is then decanted and the resulting aluminum amalgam then washed with methanol and diethyl ether, rendering is suitable for immediate use.
C. The reaction product from Part A above is dissolved in 650 ml of tetrahydrofuran and diluted with water in acetic acid (100 ml each). Resulting mixture is then treated with about 28 g of the aluminum amalgam prepared in Part B, with the resulting suspension being stirred in a cool (15°-20° C.) water bath for 1 hr. Thereafter, 20 g of diatomaceous earth is added and the resulting mixture stirred an additional 10 min. The mixture is then filtered through a pad of diatomaceous earth and the filter solids washed with tetrahydrofuran. The filtrate is then concentrated under reduced pressure, thereby removing the tetrahydrofuran; diluted with brine (500 ml); extracted with ethyl acetate and hexane (1:1, 1400 ml); and backwashed with brine (1600 ml) and 0.5 M aqueous sodium phosphate (dibasic, ph 9), until the aqueous washes were at pH 8-9. The ethereal extracts are then washed with brine, dried over magnesium sulfate, and concentrated under reduced pressure to yield a 20.1 g mixture containing crude 2-decarboxy-2-methylcarbonyl-16,16-dimethyl-9-deoxy-9-methylene-PGF 2 , 11,15-bis(tetrahydropyranyl ether).
The crude product from Part C is then dissolved in a mixture of 50 ml of tetrahydrofuran, 100 ml of water, and 200 ml of acetic acid; stirred at 25° C. for 4.5 hrs; partially concentrated under reduced pressure at 40° C. (for removal of the tetrahydrofuran); diluted with brine (500 ml); and extracted with ethyl acetate and hexane (1:1; 1300 ml). The extracts are then washed with 0.5 M aqueous sodium phospate (dibasic, pH 9) under basic extracts are obtained, and brine (400 ml). Drying over magnesium sulfate and concentrating under reduced pressure yields a 12 g mixture containing crude title product. Chromatography on 1.5 kg of silica gel packed with 20% ethyl acetate and hexane and eluted with ethyl acetate and hexane (1:4, 5 l; 3:7, 5 l; 2:3; 15 l [fractions 1-40]; and 3:2, 5 l [fractions 41-52]). Fractions 11-23 yield 4.7 g of 9-deoxy-9-methylene-16,16-dimethyl-PGF 2 α. methyl ester, while fractions 27-40 yield 940 mg (9%) of pure 2-decarboxy-2-methylcarbonyl-16,16-dimethyl-9-deoxy-9-methylene-PGF 2 , the title product. Infrared absorptions are observed at 3400, 1710, 1650, 1355, 1155, 1070, 1020, 1000, 970, and 880 cm -1 . NMR absorptions are observed at 5.65-5.20, 4.9, 3.90-3.50, 2.13, 0.82, and 0.87 δ. The mass spectrum of the trimethylsilyl derivative exhibits a weak molecular ion at 520; a demethylated high resolution peak at 505.3525; other peaks at 421, 331, and 241.
Following the procedure of Example 1, there are prepared from each of the formula LXXII PGE-type compounds the corresponding formula LXXIV 2-decarboxy-2-methylcarbonyl-9-deoxy-9-methylene-PGF-type products of the present invention.
EXAMPLE 2 -- 2-Decarboxy-2-methylcarbonyl-cis-4,5-didehydro-16,16-dimethyl-9-deoxy-9-methylene-PGF 2 (Formula LXXIV: Z 1 is cis-CH 2 -CH═CH(CH 2 ) 2 -, Y 1 is trans-CH═CH-, R 5 of the M 1 moiety is hydrogen, R 3 and R 4 of the L 1 moiety are both methyl, and R 7 is n-butyl)
Refer to Chart F.
A. To a solution of 6.0 g of cis-4,5-didehydro-16,16-dimethyl-9-deoxy-9-methylene-PGF 1 , methyl ester in 180 ml of tetrahydrofuran is added 45 ml of hexamethyldisilazane and 18 ml of chlorotrimethylsilane. The resulting mixture is then stirred for 2 days at 25° C. under a nitrogen atmosphere. Thereafter the reaction mixture is concentrated under reduced pressure, removing the hexamethyldisilazane. The residue is then dissolved in xylene; filtered through diatomaceous earth, thereby removing ammonium chloride; concentrated under reduced pressure at 50° C.; and finally twice dissolved in zylane (50 ml) and concentrated under reduced pressure to a residue. The residue, consisting of about 70% formula LXXII compound, cis-4,5-didehydro-16,16-dimethyl-9-deoxy-9-methylene-PGF 1 , 11,15-bis(trimethylsilyl ether), and 30% cis-4,5-didehydro-16,16-dimethyl-9-deoxy-9-methylene-PGF, 11-(trimethylsilyl ether), is used in Part B without further purification.
B. Following the procedure of Example 1, Part A. 5.28 g of S-methyl-S-phenyl-N-methyl-sulfoxamine and the reaction product of Part A yield the formula LXXIII compound corresponding to the instant title product.
C. Following the procedure of Example 1, Part B, aluminum amalgam (13 g) and the crude formula LXXIII reaction product of Part B are reacted to yield 2.3 g of cis-4,5-didehydro-16,16-dimethyl-PGF 1 , methyl ester and 930 mg of pure title product, 2-decarboxy-2-methylcarbonyl-cis-4,5-didehydro-16,16-dimethyl-9-deoxy-9-methylene-PGF 1 . There is further obtained a 215 mg mixture of the methyl ester and title product. For the title product, infrared absorptions are observed at 3500, 3100, 1720, 1660, 1240, 1160, 1080, 1050, 975, 890, and 735 cm -1 . NMR absorptions are observed at 5.75-5.15, 5.0-4.75, 3.95-3.55, 2.65, 2.10, 0.87, and 0.84 δ. The mass spectrum for the trimethylsilyl derivative exhibits a weak molecular ion at 520; a demethylated high resolution peak at 505.3519; and other peaks at 463, 421, 331, 243, and 99.
EXAMPLE 3 -- 2-Decarboxy-2-methylcarbonyl-17-phenyl-18,19,20-trinor-9-deoxy-9-methylene-PGF 2 (Formula LXXIV: Z 1 is cis-CH═CH--(CH 2 ) 3 --, Y 1 is trans-CH═CH-, R 5 of the M 1 moiety and R 3 and R 4 of the L 2 moiety are all hydrogen, and R 7 is benzyl).
Refer to Chart F.
Following the procedure of Example 2, Part A, 1.7 g of 17-phenyl-18,19,20-trinor-PGE 2 , methyl ester and 1.5 ml of chlorotrimethylsilane are reacted to yield 2.1 g of crude formula LXXII compound, 17-phenyl-18,19,20-trinor-PGE 2 , methyl ester, 11,15-bis(trimethylsilyl ether). Silica gel TLC Rf is 0.5 in ethyl acetate and hexane (1:4).
Following the procedure of Example 2, Part B, 2.0 g of S-methyl-S-phenyl-N-methyl-sulfoxamine and the crude bis(trimethylsilyl ether) obtained above are reacted to yield a crude mixture containing the formula LXXIII compound corresponding to the title product.
Following the procedure of Example 2, Part C, the crude formula LXXIII product obtained above is transformed to the corresponding title product, 215 mg of 2-decarboxy-2-methylcarbonyl-17-phenyl-18,19,20-trinor-9-deoxy-9-methylene-PGF 2 , and 482 mg of the corresponding methyl ester (9-deoxy-9-methylene-17-phenyl-18,19,20-trinor-PGF 2 α, methyl ester). Infrared absorptions are observed at 3400, 3100, 1720, 1660, 1610, 1360, 1160, 1070, 970, 885, 750, and 700 cm -1 .
NMR absorptions are observed at 7.35-7.05, 5.70-5.25, 5.05-4.80, 4.3-3.4, and 2.05 δ. The mass spectrum for the trimethylsilyl derivative exhibits a high resolution molecular ion at 526.3290 and other peaks at 511, 436, 421, 401, 331, 311, 207, and 91.
EXAMPLE 4 -- 2-Decarboxy-2-methylcarbonyl-9-deoxy-9-methylene-PGF 2 (Formula LXXIV: Z 1 is cis-CH═CH--(CH 2 ) 3 --, Y 1 is trans-CH═CH--, R 3 and R 4 of the L 1 moiety and R 5 of the M 1 moiety are all hydrogen, and R 7 is n-butyl).
Refer to Chart F.
PGE 2 , methyl ester, 11,15-bis(trimethylsilyl ether), 25 g, and S-methyl-S-phenyl-N-methyl-sulfoxamine (13.25 g) are reacted according to the procedure of Example 2, Part B, yielding a crude product which is reduced with 35 g of aluminum amalgum according to the procedure of Example 2, Part C. There is obtained in this manner 10.84 g of pure 9-deoxy-9-methylene-PGF 2 , methyl ester and 1.42 g of pure title product, 2-decarboxy-2-methylcarbonyl-9-deoxy-9-methylene-PGF 2 . Infrared absorptions are observed at 3400, 3100, 1720, 1660, 1360, 1160, 1075, 1020, 970, and 885 cm -1 . NMR absorptions are observed at 5.65-5.25, 5.04-4.80, 4.3-3.50, and 2.21 δ. The mass spectrum for the trimethylsilyl derivative exhibits a high resolution molecular ion at 492.3479 and other peaks at 477, 421, 402, 367, 331, 312, 277, 243, 199, and 173.
Following the procedure of the Examples 1-4, but employing the appropriate PGE 2 -type or 8β,12α-PGE 2 -type starting material, there are prepared
2-decarboxy-2-methylcarbonyl-9-deoxy-9-methylene-PGF 2 - type compounds; or
2-decarboxy-2-methylcarbonyl-9-deoxy-9-methylene-8β,12α-PGF.sub.2 - type compounds;
which exhibit the following side chain characteristics:
15-Methyl;
16-Methyl;
15,16-Dimethyl-;
16,16-Dimethyl-;
16-Fluoro-;
15-Methyl-16-fluoro-;
16,16-Difluoro-;
15-Methyl-16,16-difluoro-;
17-Phenyl-18,19,20-trinor-;
17-(m-trifluoromethylphenyl)-18,19,20-trinor-;
17-(m-chlorophenyl)-18,19,20-trinor-;
17-(p-fluorophenyl)-18,19,20-trinor-;
15-Methyl-17-phenyl-18,19,20-trinor-;
16-Methyl-17-phenyl-18,19,20-trinor-;
16,16-Dimethyl-17-phenyl-18,19,20-trinor-;
16-Fluoro-17-phenyl-18,19,20-trinor-;
16,16-Difluoro-17-phenyl-18,19,20-trinor-;
16-Phenyl-17,18,19,20-tetranor-;
15-Methyl-16-phenyl-17,18,19,20-tetranor-;
16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-;
16-(m-chlorophenyl)-17,18,19,20-tetranor-;
16-(p-fluorophenyl)-17,18,19,20-tetranor-;
16-Phenyl-18,19,20-trinor-;
15-Methyl-16-phenyl-18,19,20-trinor-;
16-Methyl-16-phenyl-18,19,20-trinor-;
15,16-Dimethyl-16-phenyl-18,19,20-trinor-;
16-Phenoxy-17,18,19,20-trinor-;
15-Methyl-16-phenoxy-17,18,19,20-tetranor-;
16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-;
16-(m-chlorophenoxy)-17,18,19,20-tetranor-;
16-(p-fluorophenoxy)-17,18,19,20-tetranor-;
16-Phenoxy-18,19,20-trinor-;
15-Methyl-16-phenoxy-18,19,20-trinor-;
16-Methyl-16-phenoxy-18,19,20-trinor-;
15,16-Dimethyl-13,14-didehydro-;
16,16-Dimethyl-16-phenoxy-18,19,20-trinor-;
13,14-Didehydro-;
15-Methyl-13,14-didehydro-;
16-Methyl-13,14-didehydro-;
16,16-Dimethyl-13,14-didehydro-;
16-Fluoro-13,14-didehydro-;
16,16-Difluoro-13,14-didehydro-;
17-Phenyl-18,19,20-trinor-13,14-didehydro-;
17-(m-trifluoromethyl)-18,19,20-trinor-13,14-didehydro-;
17-(m-chlorophenyl)-18,19,20-trinor-13,14-didehydro-;
17-(p-fluorophenyl)-18,19,20-trinor-13,14-didehydro-;
16-Methyl-17-phenyl-18,19,2+-trinor-13,14-didehydro-;
16,16-Dimethyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
16-Fluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
16,16-Difluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
16-Phenyl-17,18,19,20-tetranor-13,14-didehydro-;
16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-didehydro-;
16-(m-fluorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
16-Phenyl-18,19,20-trinor-13,14-didehydro-;
16-Methyl-16-phenyl-18,19,20-trinor-13,14-didehydro-;
16-Phenoxy-17,18,19,20-tetranor-13,14-didehydro-;
16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
16-Phenoxy-18,19,20-trinor-13,14-didehydro-;
16-Methyl-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
13,14-Dihydro-;
15-Methyl-13,14-dihydro-;
16-Methyl-13,14-dihydro-;
16,16-Dimethyl-13,14-dihydro-;
16-Fluoro-13,14-dihydro-;
16,16-Difluoro-13,14-dihydro-;
17-Phenyl-18,19,20-trinor-13,14-dihydro-;
17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-didehydro-;
17-(m-chlorophenyl)-18,19,20-trinor-13,14-dihydro-;
17-(p-fluorophenyl)-18,19,20-trinor-13,14-dihydro-;
16-Methyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
16,16-Dimethyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
16-Fluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
16,16-Difluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
16-Phenyl-17,18,19,20-tetranor-13,14-dihydro-;
16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-dihydro-;
16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
16-Phenyl-18,19,20-trinor-13,14-dihydro-;
16-Methyl-16-phenyl-18,19,20-trinor-13,14-dihydro-;
16-Phenoxy-17,18,19,20-tetranor-13,14-dihydro-;
16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
16-Phenoxy-18,19,20-trinor-13,14-dihydro-;
16-Methyl-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
15-epi-13-cis-;
15-Methyl-15-epi-13-cis-;
16-Methyl-15-epi-13-cis-;
16,16-Dimethyl-15-epi-13-cis-;
16-Fluoro-15-epi-13-cis-;
16,16-Difluoro-15-epi-13-cis-;
17-Phenyl-18,19,20-trinor-15-epi-13-cis-;
17-(m-trifluoromethylphenyl)-18,19,20-trinor-15-epi-13-cis-;
17-(m-chlorophenyl)-18,19,20-trinor-15-epi-13-cis-;
17-(p-fluorophenyl)-18,19,20-trinor-15-epi-13-cis-;
16-Methyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
16,16-Dimethyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
16-Fluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
16,16-Difluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
16-Phenyl-17,18,19,20-tetranor-15-epi-13-cis-;
16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
16-(m-chlorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
16-(p-fluorophenyl-17,18,19,20-tetranor-15-epi-13-cis-;
16-Phenyl-18,19,20-trinor-15-epi-13-cis-;
16-Methyl-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
16-Phenoxy-17,18,19,20-tetranor-16-epi-13-cis-;
16-(m-trifluoromethylphenoxy-17,18,19,20-tetranor-15-epi-13-cis-;
16-(m-chlorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
16-(p-chlorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
16-Phenoxy-18,19,20-trinor-15-epi-13-cis-;
16-Methyl-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-;
2a,2b-Dihomo-16-methyl-;
2a,2b-Dihomo-16,16-dimethyl-;
2a,2b-Dihomo-16-fluoro-;
2a,2b-Dihomo-16,16-difluoro-;
2a,2b-Dihomo-17-phenyl-18,19,20-trinor-;
2a,2b-Dihomo-17-(m-trifluoromethylphenyl)-18,19,20-trinor-;
2a,2b-Dihomo-17-(m-chlorophenyl)-18,19,20-trinor-;
2a,2b-Dihomo-17-(p-fluorophenyl)-18,19,20-trinor-;
2a,2b-Dihomo-16-methyl-17-phenyl-18,19,20-trinor-;
2a,2b-Dihomo-16,16-dimethyl-17-phenyl-18,19,20-trinor-;
2a,2b-Dihomo-16-fluoro-17-phenyl-18,19,20-trinor-;
2a,2b-Dihomo-16,16-difluoro-17-phenyl-18,19,20-trinor-;
2a,2b-Dihomo-16-phenyl-17,18,19,20-tetranor-;
2a,2b-Dihomo-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-;
2a,2b-Dihomo-16-(m-chlorophenyl)-17,18,19,20-tetranor-;
2a,2b-Dihomo-16-(p-fluorophenyl)-17,18,19,20-tetranor-;
2a,2b-Dihomo-16-phenyl-18,19,20-trinor-;
2a,2b-Dihomo-16-methyl-16-phenyl-18,19,20-trinor-;
2a,2b-Dihomo-16-phenoxy-17,18,19,20-tetranor-;
2a,2b-Dihomo-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-;
2a,2b-Dihomo-16-(m-chlorophenoxy)-17,18,19,20-tetranor-;
2a,2b-Dihomo-16-(p-fluorophenoxy)-17,18,19,20-tetranor-;
2a,2b-Dihomo-16-phenoxy-18,19,20-trinor-;
2a,2b-Dihomo-16-methyl-16-phenoxy-18,19,20-trinor-;
2a,2b-Dihomo-15-methyl-13,14-didehydro-;
2a,2b-Dihomo-16-methyl-13,14-didehydro-;
2a,2b-Dihomo-16,16-dimethyl-13,14-didehydro-;
2a,2b-Dihomo-16-fluoro-13,14-didehydro-;
2a,2b-Dihomo-16,16-difluoro-13,14-didehydro-;
2a,2b-Dihomo-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-17-(m-chlorophenyl)-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-17-(p-fluorophenyl)-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-16-methyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-16-fluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-16-phenyl-17,18,19,20-tetranor-13,14-didehydro-;
2a,2b-Dihomo-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-didehydro-;
2a,2b-Dihomo-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
2a,2b-Dihomo-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
2a,2b-Dihomo-16-phenyl-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-16-methyl-16-phenyl-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-16-phenoxy-17,18,19,20-tetranor-13,14-didehydro-;
2a,2b-Dihomo-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
2a,2b-Dihomo-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
2a,2b-Dihomo-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
2a,2b-Dihomo-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-16-methyl-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-13,14-dihydro-;
2a,2b-Dihomo-15-methyl-13,14-dihydro-;
2a,2b-Dihomo-16-methyl-13,14-dihydro-;
2a,2b-Dihomo-16,16-dimethyl-13,14-dihydro-;
2a,2b-Dihomo-16-fluoro-13,14-dihydro-;
2a,2b-Dihomo-16,16-difluoro-13,14-dihydro-;
2a,2b-Dihomo-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-17-(m-chlorophenyl)-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-17-(p-fluorophenyl)-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-16-methyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-16-fluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-16-phenyl-17,18,19,20-tetranor-13,14-dihydro-;
2a,2b-Dihomo-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-dihydro-;
2a,2b-Dihomo-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
2a,2b-Dihomo-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
2a,2b-Dihomo-16-phenyl-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-16-methyl-16-phenyl-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-16-phenoxy-17,18,19,20-tetranor-13,14-dihydro-;
2a,2b-Dihomo-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
2a,2b-Dihomo-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
2a,2b-Dihomo-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
2a,2b-Dihomo-16-methyl-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-15-epi-13-cis-;
2a,2b-Dihomo-15-methyl-15-epi-13-cis-;
2a,2b-Dihomo-16-methyl-15-epi-13-cis-;
2a,2b-Dihomo-16,16-dimethyl-15-epi-13-cis-;
2a,2b-Dihomo-16-fluoro-15-epi-13-cis-;
2a,2b-Dihomo-16,16-difluoro-15-epi-13-cis-;
2a,2b-Dihomo-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13-cis-;
2a,2b-Dihomo-17-(m-chlorophenyl)-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-17-(p-fluorophenyl-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-16-methyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-16,16-dimethyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-16-fluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-16,16-difluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-16-phenyl-17,18,19,20-tetranor-15-epi-13-cis-;
2a,2b-Dihomo-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
2a,2b-Dihomo-16-(m-chlorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
2a,2b-Dihomo-16-(p-fluorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
2a,2b-Dihomo-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-16-methyl-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-16-phenoxy-17,18,19,20-tetranor-15-epi-13-cis-;
2a,2b-Dihomo-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
2a,2b-Dihomo-16-(m-chlorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
2a,2b-Dihomo-16-(p-fluorophenoxy-17,18,19,20-tetranor-15-epi-13-cis-;
2a,2b-Dihomo-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-16-methyl-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
5,6-Didehydro-;
5,6-Didehydro-16-methyl-;
5,6-Didehydro-16,16-dimethyl-;
5,6-Didehydro-16-fluoro-;
5,6-Didehydro-16,16-difluoro-;
5,6-Didehydro-17-phenyl-18,19,20-trinor-;
5,6-Didehydro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-;
5,6-Didehydro-17-(m-chlorophenyl)-18,19,20-trinor-;
5,6-Didehydro-17-(p-fluorophenyl)-18,19,20-trinor-;
5,6-Didehydro-16-methyl-17-phenyl-18,19,20-trinor-;
5,6-Didehydro-16,16-dimethyl-17-phenyl-18,19,20-trinor-;
5,6-Didehydro-16-fluoro-17-phenyl-18,19,20-trinor-;
5,6-Didehydro-16,16-difluoro-17-phenyl-18,19,20-trinor-;
5,6-Didehydro-16-phenyl-17,18,19,20-tetranor-;
5,6-Didehydro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-;
5,6-Didehydro-16-(m-chlorophenyl)-17,18,19,20-tetranor-;
5,6-Didehydro-16-(p-fluorophenyl)-17,18,19,20-tetranor-;
5,6-Didehydro-16-phenyl-18,19,20-trinor-;
5,6-Didehydro-16-methyl-16-phenyl-18,19,20-trinor-;
5,6-Didehydro-16-phenoxy-17,18,19,20-tetranor-;
5,6-Didehydro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-;
5,6-Didehydro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-;
5,6-Didehydro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-;
5,6-Didehydro-16-phenoxy-18,19,20-trinor-;
5,6-Didehydro-16-methyl-16-phenoxy-18,19,20-trinor-;
5,6-Didehydro-15-methyl-13,14-didehydro-;
5,6-Didehydro-16-methyl-13,14-didehydro-;
5,6-Didehydro-16,16-dimethyl-13,14-didehydro-;
5,6-Didehydro-16-fluoro-13,14-didehydro-;
5,6-Didehydro-16,16-difluoro-13,14-didehydro-;
5,6-Didehydro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
5,6-Didehydro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-didehydro-
5,6-Didehydro-17-(m-chlorophenyl)-18,19,20-trinor-13,14-didehydro-;
5,6-Didehydro-17-(p-fluorophenyl)-18,19,20-trinor-13,14-didehydro-;
5,6-Didehydro-16-methyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
5,6-Didehydro-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
5,6-Didehydro-16-fluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
5,6-Didehydro-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
5,6-Didehydro-16-phenyl-17,18,19,20-tetranor-13,14-didehydro-;
5,6-Didehydro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-didehydro-;
5,6-Didehydro-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
5,6-Didehydro-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
5,6-Didehydro-16-phenyl-18,19,20-trinor-13,14-didehydro-;
5,6-Didehydro-16-methyl-16-phenyl-18,19,20-trinor-13,14-didehydro-;
5,6-Didehydro-16-phenoxy-17,18,19,20-tetranor-13,14-didehydro-;
5,6-Didehydro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
5,6-Didehydro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
5,6-Didehydro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
5,6-Didehydro-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
5,6-Didehydro-16-methyl-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
5,6-Didehydro-13,14-dihydro-;
5,6-Didehydro-15-methyl-13,14-dihydro-;
5,6-Didehydro-16-methyl-13,14-dihydro-;
5,6-Didehydro-16,16-dimethyl-13,14-dihydro-;
5,6-Didehydro-16-fluoro-13,14-dihydro-;
5,6-Didehydro-16,16-difluoro-13,14-dihydro-;
5,6-Didehydro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
5,6-Didehydro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-dihydro-;
5,6-Didehydro-17-(m-chlorophenyl)-18,19,20-trinor-13,14-dihydro-;
5,6-Didehydro-17-(p-fluorophenyl)-18,19,20-trinor-13,14-dihydro-;
5,6-Didehydro-16-methyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
5,6-Didehydro-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
5,6-Didehydro-16-fluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
5,6-Didehydro-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
5,6-Didehydro-16-phenyl-17,18,19,20-tetranor-13,14-dihydro-;
5,6-Didehydro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-dihydro-;
5,6-Didehydro-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
5,6-Didehydro-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
5,6-Didehydro-16-phenyl-18,19,20-trinor-13,14-dihydro-;
5,6-Didehydro-16-methyl-16-phenyl-18,19,20-trinor-13,14-dihydro-;
5,6-Didehydro-16-phenoxy-17,18,19,20-tetranor-13,14-dihydro-;
5,6-Didehydro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
5,6-Didehydro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
5,6-Didehydro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
5,6-Didehydro-16-methyl-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
5,6-Didehydro-15-epi-13-cis-;
5,6-Didehydro-15-methyl-15-epi-13-cis-;
5,6-Didehydro-16-methyl-15-epi-13-cis-;
5,6-Didehydro-16,16-dimethyl-15-epi-13-cis-;
5,6-Didehydro-16-fluoro-15-epi-13-cis-;
5,6-Didehydro-16,16-difluoro-15-epi-13-cis-;
5,6-Didehydro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
5,6-Didehydro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-15-epi-13-cis-;
5,6-Didehydro-17-(m-chlorophenyl)-18,19,20-trinor-15-epi-13-cis-;
5,6-Didehydro-17-(p-fluorophenyl)-18,19,20-trinor-15-epi-13-cis-;
5,6-Didehydro-16-methyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
5,6-Didehydro-16,16-dimethyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
5,6-Didehydro-16-fluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
5,6-Didehydro-16,16-difluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
5,6-Didehydro-16-phenyl-17,18,19,20-tetranor-15-epi-13-cis-;
5,6-Didehydro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
5,6-Didehydro-16-(m-chlorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
5,6-Didehydro-16-(p-fluorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
5,6-Didehydro-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
5,6-Didehydro-16-methyl-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
5,6-Didehydro-16-phenoxy-17,18,19,20-tetranor-15-epi-13-cis-;
5,6-Didehydro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
5,6-Didehydro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
5,6-Didehydro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
5,6-Didehydro-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
5,6-Didehydro-16-methyl-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-;
2,2-Difluoro-16-methyl-;
2,2-Difluoro-16,16-dimethyl-;
2,2,16-Trifluoro-;
2,2,16,16-Tetrafluoro-;
2,2-Difluoro-17-phenyl-18,19,20-trinor-;
2,2-Difluoro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-;
2,2-Difluoro-17-(m-chlorophenyl)-18,19,20-trinor-;
2,2-Difluoro-17-(p-fluorophenyl)-18,19,20-trinor-;
2,2-Difluoro-16-methyl-17-phenyl-18,19,20-trinor-;
2,2-Difluoro-16,16-dimethyl-17-phenyl-18,19,20-trinor-;
2,2,16-Trifluoro-17-phenyl-18,19,20-trinor-;
2,2,16,16-Tetrafluoro-17-phenyl-18,19,20-trinor-;
2,2-Difluoro-16-phenyl-17,18,19,20-tetranor-;
2,2-Difluoro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-;
2,2-Difluoro-16-(m-chlorophenyl)-17,18,19,20-tetranor-;
2,2-Difluoro-16-(p-fluorophenyl)-17,18,19,20-tetranor-;
2,2-Difluoro-16-phenyl-18,19,20-trinor-;
2,2-Difluoro-16-methyl-16-phenyl-18,19,20-trinor-;
2,2-Difluoro-16-phenoxy-17,18,19,20-tetranor-;
2,2-Difluoro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-;
2,2-Difluoro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-;
2,2-Difluoro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-;
2,2-Difluoro-16-phenoxy-18,19,20-trinor-;
2,2-Difluoro-16-methyl-16-phenoxy-18,19,20-trinor-;
2,2-Difluoro-15-methyl-13,14-didehydro-;
2,2-Difluoro-16-methyl-13,14-didehydro-;
2,2-Difluoro-16,16-dimethyl-13,14-didehydro-;
2,2,16-Trifluoro-13,14-didehydro-;
2,2,16,16-Tetrafluoro-13,14-didehydro-;
2,2-Difluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-17-(m-chlorophenyl)-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-17-(p-fluorophenyl)-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16-methyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2,16-Trifluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2,16,16-Tetrafluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16-phenyl-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16-methyl-16-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16-phenoxy-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16-methyl-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-13,14-dihydro-;
2,2-Difluoro-15-methyl-13,14-dihydro-;
2,2-Difluoro-16-methyl-13,14-dihydro-;
2,2-16,16-dimethyl-13,14-dihydro-;
b 2,2,16-Trifluoro-13,14-dihydro-;
2,2,16,16-Tetrafluoro-13,14-dihydro-;
2,2-Difluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-17-(m-chlorophenyl)-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-17-(p-fluorophenyl)-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16-methyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2,16-Trifluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2,16,16-Tetrafluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16-phenyl-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16-methyl-16-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16-phenoxy-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-methyl-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-15-epi-13-cis-;
2,2-Difluoro-15-methyl-15-epi-13-cis-;
2,2-Difluoro-16,16-dimethyl-15-epi-13-cis-;
2,2,16-Trifluoro-15-epi-13-cis-;
2,2,16,16-Tetrafluoro-15-epi-13-cis-;
2,2-Difluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-17-(m-chlorophenyl)-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-17-(p-fluorophenyl)-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-16-methyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-16,16-dimethyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2,2,16-Trifluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2,2,16,16-Tetrafluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-16-phenyl-17,18,19,20-tetranor-15-epi-13-cis-;
2,2-Difluoro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
2,2-Difluoro-16-(m-chlorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
2,2-Difluoro-16-(p-fluorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
2,2-Difluoro-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-16-methyl-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-16-phenoxy-17,18,19,20-tetranor-15-epi-13-cis-;
2,2-Difluoro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
2,2-Difluoro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
2,2-Difluoro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
2,2-Difluoro-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-16-methyl-16-phenoxy-1-,19,20-trinor-15-epi-13-cis-.
Following the procedure of Examples 1-4, but employing the appropriate PGE 1 -type or 8β,12α-PGE 1 -type starting material, there are prepared
2-Decarboxy-2-methylcarbonyl-9-deoxy-9-methylene-PGF 1 -type compounds; or
2-Decarboxy-2-methylcarbonyl-9-deoxy-9-methylene-8β,12α-PGF.sub.1 -type compounds; which exhibit the following side chain characteristics:
15-Methyl;
16-Methyl;
15,16-Dimethyl-;
16,16-Dimethyl-;
16-Fluoro-;
15-Methyl-16-fluoro-;
16,16-Difluoro-;
15-Methyl-16,16-difluoro-;
17-Phenyl-18,19,20-trinor-;
17-(m-trifluoromethylphenyl)-18,19,20-trinor-;
17-(m-chlorophenyl)-18,19,20-trinor-;
17-(p-fluorophenyl)-18,19,20-trinor-;
15-Methyl-17-phenyl-18,19,20-trinor-;
16-Methyl-17-phenyl-18,19,20-trinor-;
16,16-Dimethyl-17-phenyl-18,19,20-trinor-;
16-Fluoro-17-phenyl-18,19,20-trinor-;
16,16-Difluoro-17-phenyl-18,19,20-trinor-;
16-Phenyl-17,18,19,20-tetranor-;
15-Methyl-16-phenyl-17,18,19,20-tetranor-;
16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-;
16-(m-chlorophenyl)-17,18,19,20-tetranor-;
16-(p-fluorophenyl)-17,18,19,20-tetranor-;
16-Phenyl-18,19,20-trinor-;
15-Methyl-16-phenyl-18,19,20-trinor-;
16-Methyl-16-phenyl-18,19,20-trinor-;
15,16-Dimethyl-16-phenyl-18,19,20-trinor-;
16-Phenoxy-17,18,19,20-tetranor-;
15-Methyl-16-phenoxy-17,18,19,20-tetranor-;
16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-;
16-(m-chlorophenoxy)-17,18,19,20-tetranor-;
16-(p-fluorophenoxy)-17,18,19,20-tetranor-;
16-Phenoxy-18,19,20-trinor-;
15-Methyl-16-phenoxy-18,19,20-trinor-;
16-Methyl-16-phenoxy-18,19,20-trinor-;
15,16-Dimethyl-13,14-didehydro-;
16,16-Dimethyl-16-phenoxy-18,19,20-trinor-;
13,14-Didehydro-;
15-Methyl-13,14-didehydro-;
16-Methyl-13,14-didehydro-;
16,16-Dimethyl-13,14-didehydro-;
16-Fluoro-13,14-didehydro-;
16,16-Difluoro-13,14-didehydro-;
17-Phenyl-18,19,20-trinor-13,14-didehydro-;
17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-didehydro-;
17-(m-chlorophenyl)-18,19,20-trinor-13,14-didehydro-;
17-(p-fluorophenyl)-18,19,20-trinor-13,14-didehydro-;
16-Methyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
16,16-Dimethyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
16-Fluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
16,16-Difluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
16-Phenyl-17,18,19,20-tetranor-13,14-didehydro-;
16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-didehydro-;
16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
16-Phenyl-18,19,20-trinor-13,14-didehydro-;
16-Methyl-16-phenyl-18,19,20-trinor-13,14-didehydro-;
16-Phenoxy-17,18,19,20-tetranor-13,14-didehydro-;
16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
16-Phenoxy-18,19,20-trinor-13,14-didehydro-;
16-Methyl-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
13,14-Dihydro-;
15-Methyl-13,14-dihydro-;
16-Methyl-13,14-dihydro-;
16,16-Dimethyl-13,14-dihydro-;
16-Fluoro-13,14-dihydro-;
16,16-Difluoro-13,14-dihydro-;
17-Phenyl-18,19,20-trinor-13,14-dihydro-;
17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-dihydro-;
17-(m-chlorophenyl)-18,19,20-trinor-13,14-dihydro-;
17-(p-fluorophenyl)-18,19,20-trinor-13,14-dihydro-;
16-Methyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
16,16-Dimethyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
16-Fluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
16,16-Difluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
16-Phenyl-17,18,19,20-tetranor-13,14-dihydro-;
16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-dihydro-;
16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
16-Phenyl-18,19,20-trinor-13,14-dihydro-;
16-Methyl-16-phenyl-18,19,20-trinor-13,14-dihydro-;
16-Phenoxy-17,18,19,20-tetranor-13,14-dihydro-;
16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
16-Phenoxy-18,19,20-trinor-13,14-dihydro-;
16-Methyl-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
15-epi-13-cis-;
16-Methyl-15-epi-13-cis-;
16,16-Dimethyl-15-epi-13-cis-;
16-Fluoro-15-epi-13-cis-;
16,16-Difluoro-15-epi-13-cis-;
17-Phenyl-18,19,20-trinor-15-epi-13-cis-;
17-(m-trifluoromethylphenyl)-18,19,20-trinor-15-epi-13-cis-;
17-(m-chlorophenyl)-18,19,20-trinor-15-epi-13-cis-;
17-(p-fluorophenyl)-18,19,20-trinor-15-epi-13-cis-;
16-Methyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
16,16-Dimethyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
16-Fluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
16,16-Difluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
16-Phenyl-17,18,19,20-tetranor-15-epi-13-cis-;
;b 16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
16-(m-chlorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
16-(p-fluorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
16-Phenyl-18,19,20-trinor-15-epi-13-cis-;
16-Methyl-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
16-Phenoxy-17,18,19,20-tetranor-15-epi-13-cis-;
16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
16-(m-chlorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
16-(p-fluorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
16-Phenoxy-18,19,20-trinor-15-epi-13-cis-;
16-Methyl-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-;
2a,2b-Dihomo-15-methyl-;
2a,2b-Dihomo-16-methyl-;
2a,2b-Dihomo-16,16-dimethyl-;
2a,2b-Dihomo-16-fluoro-;
2a,2b-Dihomo-16,16-difluoro-;
2a,2b-Dihomo-17-phenyl-18,19,20-trinor-;
2a,2b-Dihomo-17-(m-trifluoromethylphenyl)-18,19,20-trinor-;
2a,2b-Dihomo-17-(m-chlorophenyl)-18,19,20-trinor-;
2a,2b-Dihomo-17-(p-fluorophenyl)-18,19,20-trinor-;
2a,2b-Dihomo-16-methyl-17-phenyl-18,19,20-trinor-;
2a,2b-Dihomo-16,16-dimethyl-17-phenyl-18,19,20-trinor-;
2a,2b-Dihomo-16-fluoro-17-phenyl-18,19,20-trinor-;
2a,2b-Dihomo-16,16-difluoro-17-phenyl-18,19,20-trinor-;
2a,2b-Dihomo-16-phenyl-17,18,19,20-tetranor-;
2a,2b-Dihomo-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-;
2a,2b-Dihomo-16-(m-chlorophenyl)-17,18,19,20-tetranor-;
2a,3b-Dihomo-16-(p-fluorophenyl)-17,18,19,20-tetranor-;
2a,2b-Dihomo-16-phenyl-18,19,20-trinor-;
2a,2b-Dihomo-16-methyl-16-phenyl-18,19,20-trinor-;
2a,2b-Dihomo-16-phenoxy-17,18,19,20-tetranor-;
2a,2b-Dihomo-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-;
2a,2b-Dihomo-16-(m-chlorophenoxy)-17,18,19,20-tetranor-;
2a,2b-Dihomo-16-(p-fluorophenoxy)-17,18,19,20-tetranor-;
2a,2b-Dihomo-16-phenoxy-18,19,20-trinor-;
2a,2b-Dihomo-16-methyl-16-phenoxy-18,19,20-trinor-;
2a,2b-Dihomo-15-methyl-13,14-didehydro-;
2a,2b-Dihomo-16-methyl-13,14-didehydro-;
2a,2b-Dihomo-16,16-dimethyl-13,14-didehydro-;
2a,2b-Dihomo-16-fluoro-13,14-didehydro-;
2a,2b-Dihomo-16,16-difluoro-13,14-didehydro-;
2a,2b-Dihomo-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-17-(m-chlorophenyl)-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-17-(p-fluorophenyl)-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-16-methyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-16-fluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-16-phenyl-17,18,19,20-tetranor-13,14-didehydro-;
2a,2b-Dihomo-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-didehydro-;
2a,2b-Dihomo-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
2a,2b-Dihomo-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
2a,2b-Dihomo-16-phenyl-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-16-methyl-16-phenyl-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-16-phenoxy-17,18,19,20-tetranor-13,14-didehydro-;
2a,2b-Dihomo-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
2a,2b-Dihomo-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
2a,2b-Dihomo-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
2a,2b-Dihomo-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
2a,2b-Dihomo-16-methyl-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
2a.2b-Dihomo-13,14-dihydro-;
2a,2b-Dihomo-15-methyl-13,14-dihydro-;
2a,2b-Dihomo-16-methyl-13,14-dihydro-;
2a,2b-Dihomo-16,16-dimethyl-13,14-dihydro-;
2a,2b-Dihomo-16-fluoro-13,14-dihydro-;
2a,2b-Dihomo-16,16-Difluoro-13,14-dihydro-;
2a,2b-Dihomo-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-17-(m-chlorophenyl)-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-17-(p-fluorophenyl)-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-16-methyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-16-fluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-16-phenyl-17,18,19,20-tetranor-13,14-dihydro-;
2a,2b-Dihomo-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-dihydro-;
2a,2b-Dihomo-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
2a,2b-Dihomo-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
2a,2b-Dihomo-16-phenyl-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-16-methyl-16-phenyl-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-16-phenoxy-17,18,19,20-tetranor-13,14-dihydro-;
2a,2b-Dihomo-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
2a,2b-Dihomo-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
2a,2b-Dihomo-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
2a,2b-Dihomo-16-methyl-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
2a,2b-Dihomo-15-epi-13-cis-;
2a,2b-Dihomo-15-methyl-15-epi-13-cis-;
2a,2b-Dihomo-16-methyl-15-epi-13-cis-;
2a,2b-Dihomo-16,16-dimethyl-15-epi-13-cis-;
2a,2b-Dihomo-16-fluoro-15-epi-13-cis-;
2a,2b-Dihomo-16,16-difluoro-15-epi-13-cis-;
2a,2b-Dihomo-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-17-(m-trifluoromethylphenyl)-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-17-(m-chlorophenyl)-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-17-(p-fluorophenyl)-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-16-methyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-16,16-dimethyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-16-fluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-16,16-difluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-16-phenyl-17,18,19,20-tetranor-15-epi-13-cis-;
2a,2b-Dihomo-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
2a,2b-Dihomo-16-(m-chlorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
2a,2b-Dihomo-(p-fluorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
2a,2b-Dihomo-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-16-methyl-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-16-phenoxy-17,18,19,20-tetranor-15-epi-13-cis-;
2a,2b-Dihomo-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
2a,2b-Dihomo-16-(m-chlorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
2a,2b-Dihomo-16-(p-fluorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
2a,2b-Dihomo-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
2a,2b-Dihomo-16-methyl-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
cis-4,5-Didehydro-;
cis-4,5-Didehydro-15-methyl-;
cis-4,5-Didehydro-16-methyl-;
cis-4,5-Didehydro-16,16-dimethyl-;
cis-4,5-Didehydro-16-fluoro-;
cis-4,5-Didehydro-16,16-difluoro-;
cis-4,5-Didehydro-17-phenyl-18,19,20-trinor-;
cis-4,5-Didehydro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-;
cis-4,5-Didehydro-17-(m-chlorophenyl)-18,19,20-trinor-;
cis-4,5-Didehydro-17-(p-fluorophenyl)-18,19,20-trinor-;
cis-4,5-Didehydro-16-methyl-17-phenyl-18,19,20-trinor-;
cis-4,5-Didehydro-16,16-dimethyl-17-phenyl-18,19,20-trinor-;
cis-4,5-Didehydro-16-fluoro-17-phenyl-18,19,20-trinor-;
cis-4,5-Didehydro-16,16-difluoro-17-phenyl-18,19,20-trinor-;
cis-4,5-Didehydro-16-phenyl-17,18,19,20-tetranor-;
cis-4,5-Didehydro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-;
cis-4,5-Didehydro-16-(m-chlorophenyl)-17,18,19,20-tetranor-;
cis-4,5-Didehydro-16-(p-fluorophenyl)-17,18,19,20-tetranor-;
cis-4,5-Didehydro-16-phenyl-18,19,20-trinor-;
cis-4,5-Didehydro-16-methyl-16-phenyl-18,19,20-trinor-;
cis-4,5-Didehydro-16-phenoxy-17,18,19,20-tetranor-;
cis-4,5-Didehydro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-;
cis-4,5-Didehydro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-;
cis-4,5-Didehydro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-;
cis-4,5-Didehydro-16-phenoxy-18,19,20-trinor-;
cis-4,5-Didehydro-16-methyl-16-phenoxy-18,19,20-trinor-;
cis-4,5-Didehydro-15-methyl-13,14-didehydro-;
cis-4,5-Didehydro-16-methyl-13,14-didehydro-;
cis-4,5-Didehydro-16,16-dimethyl-13,14-didehydro-;
cis-4,5-Didehydro-16-fluoro-13,14-didehydro-;
cis-4,5-Didehydro-16,16-difluoro-13,14-didehydro-;
cis-4,5-Didehydro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
cis-4,5-Didehydro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-didehydro-;
cis-4,5-Didehydro-17-(m-chlorophenyl)-18,19,20-trinor-13,14-didehydro-;
cis-4,5-Didehydro-17-(p-fluorophenyl)-18,19,20-trinor-13,14-didehydro-;
cis-4,5-Didehydro-16-methyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
cis-4,5-Didehydro-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
cis-4,5-Didehydro-16-fluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
cis-4,5-Didehydro-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
cis-4,5-Didehydro-16-phenyl-17,18,19,20-tetranor-13,14-didehydro-;
cis-4,5-Didehydro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-didehydro-;
cis-4,5-Didehydro-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
cis-4,5-Didehydro-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
cis-4,5-Didehydro-16-phenyl-18,19,20-trinor-13,14-didehydro-;
cis-4,5-Didehydro-16-methyl-16-phenyl-18,19,20-trinor-13,14-didehydro-;
cis-4,5-Didehydro-16-phenoxy-17,18,19,20-tetranor-13,14-didehydro-;
cis-4,5-Didehydro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
cis-4,5-Didehydro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
cis-4,5-Didehydro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
cis-4,5-Didehydro-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
cis-4,5-Didehydro-16-methyl-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
cis-4,5-Didehydro-13,14-dihydro-;
cis-4,5-Didehydro-15-methyl-13,14-dihydro-;
cis-4,5-Didehydro-16-methyl-13,14-dihydro-;
cis-4,5-Didehydro-16,16-dimethyl-13,14-dihydro-;
cis-4,5-Didehydro-16-fluoro-13,14-dihydro-;
cis-4,5-Didehydro-16,16-difluoro-13,14-dihydro-;
cis-4,5-Didehydro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
cis-4,5-Didehydro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-dihydro-;
cis-4,5-Didehydro-17-(m-chlorophenyl)-18,19,20-trinor-13,14-dihydro-;
cis-4,5-Didehydro-17-(p-fluorophenyl)-18,19,20-trinor-13,14-dihydro-;
cis-4,5-Didehydro-16-methyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
cis-4,5-Didehydro-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
cis-4,5-Didehydro-16-fluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
cis-4,5-Didehydro-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
cis-4,5-Didehydro-16-phenyl-17,18,19,20-tetranor-13,14-dihydro-;
cis-4,5-Didehydro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-dihydro-;
cis-4,5-Didehydro-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
cis-4,5-Didehydro-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
cis-4,5-Didehydro-16-phenyl-18,19,20-trinor-13,14-dihydro-;
cis-4,5-Didehydro-16-methyl-16-phenyl-18,19,20-trinor-13,14-dihydro-;
cis-4,5-Didehydro-16-phenoxy-17,18,19,20-tetranor-13,14-dihydro-;
cis-4,5-Didehydro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
cis-4,5-Didehydro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
cis-4,5-Didehydro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
cis-4,5-Didehydro-16-methyl-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
cis-4,5-Didehydro-15-epi-13-cis-;
cis-4,5-Didehydro-15-methyl-15-epi-13-cis-;
cis-4,5-Didehydro-16-methyl-15-epi-13-cis-;
cis-4,5-Didehydro-16,16-dimethyl-15-epi-13-cis-;
cis-4,5-Didehydro-16-fluoro-15-epi-13-cis-;
cis-4,5-Didehydro-16,16-difluoro-15-epi-13-cis-;
cis-4,5-Didehydro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
cis-4,5-Didehydro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-15-epi-13-cis-;
cis-4,5-Didehydro-17-(m-chlorophenyl)-18,19,20-trinor-15-epi-13-cis-;
cis-4,5-Didehydro-17-(p-fluorophenyl)-18,19,20-trinor-15-epi-13-cis-;
cis-4,5-Didehydro-16-methyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
cis-4,5-Didehydro-16,16-dimethyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
cis-4,5-Didehydro-16-fluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
cis-4,5-Didehydro-16,16-difluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
cis-4,5-Didehydro-16-phenyl-17,18,19,20-tetranor-15-epi-13-cis-;
cis-4,5-Didehydro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
cis-4,5-Didehydro-16-(m-chlorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
cis-4,5-Didehydro-16-(p-fluorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
cis-4,5-Didehydro-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
cis-4,5-Didehydro-16-methyl-16-phenyl-18,19,20-tetranor-15-epi-13-cis-;
cis-4,5-Didehydro-16-phenoxy-17,18,19,20-tetranor-15-epi-13-cis-;
cis-4,5-Didehydro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
cis-4,5-Didehydro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
cis-4,5-Didehydro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
cis-4,5-Didehydro-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
cis-4,5-Didehydro-16-methyl-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-;
2,2-Difluoro-15-methyl-;
2,2-Difluoro-16-methyl-;
2,2-Difluoro-16,16-dimethyl-;
2,2,16-Trifluoro-;
2,2,16,16-Tetrafluoro-;
2,2-Difluoro-17-phenyl-18,19,20-trinor-;
2,2-Difluoro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-;
2,2-Difluoro-17-(m-chlorophenyl)-18,19,20-trinor-;
2,2-Difluoro-17-(p-fluorophenyl)-18,19,20-trinor-;
2,2-Difluoro-16-methyl-17-phenyl-18,19,20-trinor-;
2,2-Difluoro-16,16-dimethyl-17-phenyl-18,19,20-trinor-;
2,2,16-Trifluoro-17-phenyl-18,19,20-trinor-;
2,2,16,16-Tetrafluoro-17-phenyl-18,19,20-trinor-;
2,2-Difluoro-16-phenyl-17,18,19,20-tetranor-;
2,2-Difluoro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-;
2,2-Difluoro-16-(m-chlorophenyl)-17,18,19,20-tetranor-;
2,2-Difluoro-16-(p-fluorophenyl)-17,18,19,20-tetranor-;
2,2-Difluoro-16-phenyl-18,19,20-trinor-;
2,2-Difluoro-16-methyl-16-phenyl-18,19,20-trinor-;
2,2-Difluoro-16-phenoxy-17,18,19,20-tetranor-;
2,2-Difluoro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-;
2,2-Difluoro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-;
2,2-Difluoro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-;
2,2-Difluoro-16-phenoxy-18,19,20-trinor-;
2,2-Difluoro-16-methyl-16-phenoxy-18,19,20-trinor-;
2,2-Difluoro-15-methyl-13,14-didehydro-;
2,2-Difluoro-16-methyl-13,14-didehydro-;
2,2-Difluoro-16,16-dimethyl-13,14-didehydro-;
2,2,16-Trifluoro-13,14-didehydro-;
2,2,16,16-Tetrafluoro-13,14-didehydro-;
2,2-Difluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-17-(m-chlorophenyl)-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-17-(p-fluorophenyl)-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16-methyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2,16-Trifluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2,16,16-Tetrafluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16-phenyl-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16-methyl-16-phenyl-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16-phenoxy-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
2,2-Difluoro-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-16-methyl-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
2,2-Difluoro-13,14-dihydro-;
2,2-Difluoro-15-methyl-13,14-dihydro-;
2,2-Difluoro-16-methyl-13,14-dihydro-;
2,2-Difluoro-16,16-dimethyl-13,14-dihydro-;
2,2,16-Trifluoro-13,14-dihydro-;
2,2,16,16-Tetrafluoro-13,14-dihydro-;
2,2-Difluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-dihydro-;
2,2-Dihydro-17-(m-chlorophenyl)-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-17-(p-fluorophenyl)-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16-methyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2,16-Trifluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2,16,16-Tetrafluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16-phenyl-17,18,19,20-tetranor-13,14,-dihydro-;
2,2-Difluoro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16-methyl-16-phenyl-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-16-phenoxy-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
2,2-Difluoro-16-methyl-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
2,2-Difluoro-15-epi-13-cis-;
2,2-Difluoro-15-methyl-15-epi-13-cis-;
2,2-Difluoro-16-methyl-15-epi-13-cis-;
2,2-Difluoro-16,16-dimethyl-15-epi-13-cis-;
2,2,16-Trifluoro-15-epi-13-cis-;
2,2,16,16-Tetrafluoro-15-epi-13-cis-;
2,2-Difluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-17-(m-chlorophenyl)-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-17-(p-fluorophenyl)-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-16-methyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-16,16-dimethyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2,2,16-Trifluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2,2,16,16-Tetrafluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-16-phenyl-17,18,19,20-tetranor-15-epi-13-cis-;
2,2-Difluoro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
2,2-Difluoro-16-(m-chlorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
2,2-Difluoro-16-(p-fluorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
2,2-Difluoro-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-16-methyl-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-16-phenoxy-17,18,19,20-tetranor-15-epi-13-cis-;
2,2-Difluoro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
2,2-Difluoro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
2,2-Difluoro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
2,2-Difluoro-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
2,2-Difluoro-16-methyl-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
5-Oxa-;
5-Oxa-15-methyl-;
5-Oxa-16-methyl-;
5-Oxa-16,16-dimethyl-;
5-Oxa-16-fluoro-;
5-Oxa-16,16-difluoro-;
5-Oxa-17-phenyl-18,19,20-trinor-;
5-Oxa-17-(m-trifluoromethylphenyl)-18,19,20-trinor-;
5-Oxa-17-(m-chlorophenyl)-18,19,20-trinor-;
5-Oxa-17-(p-fluorophenyl)-18,19,20-trinor-;
5-Oxa-16-methyl-17-phenyl-18,19,20-trinor-;
5-Oxa-16,16-dimethyl-17-phenyl-18,19,20-trinor-;
5-Oxa-16-fluoro-17-phenyl-18,19,20-trinor-;
5-Oxa-16,16-difluoro-17-phenyl-18,19,20-trinor-;
5-Oxa-16-phenyl-17,18,19,20-tetranor-;
5-Oxa-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-;
5-Oxa-16-(m-chlorophenyl)-17,18,19,20-tetranor-;
5-Oxa-16-(p-fluorophenyl)-17,18,19,20-tetranor-;
5-Oxa-16-phenyl-18,19,20-trinor-;
5-Oxa-16-methyl-16-phenyl-18,19,20-trinor-;
5-Oxa-16-phenoxy-17,18,19,20-tetranor-;
5-Oxa-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-;
5-Oxa-16-(m-chlorophenoxy)-17,18,19,20-tetranor-;
5-Oxa-16-(p-fluorophenoxy)-17,18,19,20-tetranor-;
5-Oxa-16-phenoxy-18,19,20-trinor-;
5-Oxa-16-methyl-16-phenoxy-18,19,20-trinor-;
5-Oxa-15-methyl-13,14-didehydro-;
5-Oxa-16-methyl-13,14-didehydro-;
5-Oxa-16,16-dimethyl-13,14-didehydro-;
5-Oxa-16-fluoro-13,14-didehydro-;
5-Oxa-16,16-difluoro-13,14-didehydro-;
5-Oxa-17-phenyl-18,19,20-trinor-13,14-didehydro-;
5-Oxa-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-didehydro-;
5-Oxa-17-(m-chlorophenyl)-18,19,20-trinor-13,14-didehydro-;
5-Oxa-17-(p-fluorophenyl)-18,19,20-trinor-13,14-didehydro-;
5-Oxa-16-methyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
5-Oxa-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
5-Oxa-16-fluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
5-Oxa-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
5-Oxa-16-phenyl-17,18,19,20-tetranor-13,14-didehydro-;
5-Oxa-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-didehydro-;
5-Oxa-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
5-Oxa-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
5-Oxa-16-phenyl-18,19,20-trinor-13,14-didehydro-;
5-Oxa-16-methyl-16-phenyl-18,19,20-trinor-13,14-didehydro-;
5-Oxa-16-phenoxy-17,18,19,20-tetranor-13,14-didehydro-;
5-Oxa-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
5-Oxa-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
5-Oxa-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
5-Oxa-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
5-Oxa-16-methyl-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
5-Oxa-13,14-dihydro-;
5-Oxa-15-methyl-13,14-dihydro-;
5-Oxa-16-methyl-13,14-dihydro-;
5-Oxa-16,16-dimethyl-13,14-dihydro-;
5-Oxa-16-fluoro-13,14-dihydro-;
5-Oxa-16,16-difluoro-13,14-dihydro-;
5-Oxa-17-phenyl-18,19,20-trinor-13,14-dihydro-;
5-Oxa-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-dihydro-;
5-Oxa-17-(m-chlorophenyl)-18,19,20-trinor-13,14-dihydro-;
5-Oxa-17-(p-fluorophenyl)-18,19,20-trinor-13,14-dihydro-;
5-Oxa-16-methyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
5-Oxa-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
5-Oxa-16-fluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
5-Oxa-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
5-Oxa-16-phenyl-17,18,19,20-tetranor-13,14-dihydro-;
5-Oxa-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-dihydro-;
5-Oxa-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
5-Oxa-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
5-Oxa-16-phenyl-18,19,20-trinor-13,14-dihydro-;
5-Oxa-16-methyl-16-phenyl-18,19,20-trinor-13,14-dihydro-;
5-Oxa-16-phenoxy-17,18,19,20-tetranor-13,14-dihydro-;
5-Oxa-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
5-Oxa-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
5-Oxa-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
5-Oxa-16-methyl-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
5-Oxa-15-epi-13-cis-;
5-Oxa-15-methyl-15-epi-13-cis-;
5-Oxa-16-methyl-15-epi-13-cis-;
5-Oxa-16,16-dimethyl-15-epi-13-cis-;
5-Oxa-16-fluoro-15-epi-13-cis-;
5-Oxa-16,16-difluoro-15-epi-13-cis-;
5-Oxa-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
5-Oxa-17-(m-trifluoromethylphenyl)-18,19,20-trinor-15-epi-13-cis-;
5-Oxa-17-(m-chlorophenyl)-18,19,20-trinor-15-epi-13-cis-;
5-Oxa-17-(p-fluorophenyl)-18,19,20-trinor-15-epi-13-cis-;
5-Oxa-16-methyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
5-Oxa-16,16-dimethyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
5-Oxa-16-fluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
5-Oxa-16,16-difluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
5-Oxa-16-phenyl-17,18,19,20-tetranor-15-epi-13-cis-;
5-Oxa-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
5-Oxa-16-(m-chlorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
5-Oxa-16-(p-fluorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
5-Oxa-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
5-Oxa-16-methyl-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
5-Oxa-16-phenoxy-17,18,19,20-tetranor-15-epi-13-cis-;
5-Oxa-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
5-Oxa-16-(m-chlorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
5-Oxa-16-(p-fluorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
5-Oxa-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
5-Oxa-16-methyl-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
4-Oxa-;
4-Oxa-15-methyl-;
4-Oxa-16-methyl-;
4-Oxa-16,16-dimethyl-;
4-Oxa-16-fluoro-;
4-Oxa-16,16-difluoro-;
4-Oxa-17-phenyl-18,19,20-trinor-;
4-Oxa-17-(m-trifluoromethylphenyl)-18,19,20-trinor-;
4-Oxa-17-(m-chlorophenyl)-18,19,20-trinor-;
4-Oxa-17-(p-fluorophenyl)-18,19,20-trinor-;
4-Oxa-16-methyl-17-phenyl-18,19,20-trinor-;
4-Oxa-16,16-dimethyl-17-phenyl-18,19,20-trinor-;
4-Oxa-16-fluoro-17-phenyl-18,19,20-trinor-;
4-Oxa-16,16-difluoro-17-phenyl-18,19,20-trinor-;
4-Oxa-16-phenyl-17,18,19,20-tetranor-;
4-Oxa-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-;
4-Oxa-16-(m-chlorophenyl)-17,18,19,20-tetranor-;
4-Oxa-16-(p-fluorophenyl)-17,18,19,20-tetranor-;
4-Oxa-16-phenyl-18,19,20-trinor-;
4-Oxa-16-methyl-16-phenyl-18,19,20-trinor-;
4-Oxa-16-phenoxy-17,18,19,20-tetranor-;
4-Oxa-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-;
4-Oxa-16-(m-chlorophenoxy)-17,18,19,20-tetranor-;
4-Oxa-16-(p-fluorophenoxy)-17,18,18,20-tetranor-;
4-Oxa-16-phenoxy-18,19,20-trinor-;
4-Oxa-16-methyl-16-phenoxy-18,19,20-trinor-;
4-Oxa-15-methyl-13,14-didehydro-;
4-Oxa-16-methyl-13,14-didehydro-;
4-Oxa-16,16-dimethyl-13,14-didehydro-;
4-Oxa-16-fluoro-13,14-didehydro-;
4-Oxa-16,16-difluoro-13,14-didehydro-;
4-Oxa-17-phenyl-18,19,20-trinor-13,14-didehydro-;
4-Oxa-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-didehydro-;
4-Oxa-17-(m-chlorophenyl)-18,19,20-trinor-13,14-didehydro-;
4-Oxa-17-(p-fluorophenyl)-18,19,20-trinor-13,14-didehydro-;
4-Oxa-16-methyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
4-Oxa-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
4-Oxa-16-fluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
4-Oxa-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
4-Oxa-16-phenyl-17,18,19,20-tetranor-13,14-didehydro-;
4-Oxa-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-didehydro-;
4-Oxa-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
4-Oxa-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
4-Oxa-16-phenyl-18,19,20-trinor-13,14-didehydro-;
4-Oxa-16-methyl-16-phenyl-18,19,20-trinor-13,14-didehydro-;
4-Oxa-16-phenoxy-17,18,19,20-tetranor-13,14-didehydro-;
4-Oxa-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
4-Oxa-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
4-Oxa-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
4-Oxa-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
4-Oxa-16-methyl-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
4-Oxa-13,14-dihydro-;
4-Oxa-15-methyl-13,14-dihydro-;
4-Oxa-16-methyl-13,14-dihydro-;
4-Oxa-16,16-dimethyl-13,14-dihydro-;
4-Oxa-16-fluoro-13,14-dihydro-;
4-Oxa-16,16-difluoro-13,14-dihydro-;
4-Oxa-17-phenyl-18,19,20-trinor-13,14-dihydro-;
4-Oxa-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-dihydro-;
4-Oxa-17-(m-chlorophenyl)-18,19,20-trinor-13,14-dihydro-;
4-Oxa-17-(p-fluorophenyl)-18,19,20-trinor-13,14-dihydro-;
4-Oxa-16-methyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
4-Oxa-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
4-Oxa-16-fluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
4-Oxa-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-didhydro-;
4-Oxa-16-phenyl-17,18,19,20-tetranor-13,14-dihydro-;
4-Oxa-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-dihydro-;
4-Oxa-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
4-Oxa-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
4-Oxa-16-phenyl-18,19,20-trinor-13,14-dihydro-;
4-Oxa-16-methyl-16-phenyl-18,19,20-trinor-13,14-dihydro-;
4-Oxa-16-phenoxy-17,18,19,20-tetranor-13,14dihydro-;
4-Oxa-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
4-Oxa-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
4-Oxa-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
4-Oxa-16-methyl-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
4-Oxa-15-epi-13-cis-;
4-Oxa-15-methyl-15-epi-13-cis-;
4-Oxa-16-methyl-15-epi-13-cis-;
4-Oxa-16,16-dimethyl-15-epi-13-cis-;
4-Oxa-16-fluoro-15-epi-13-cis-;
4-Oxa-16,16-difluoro-15-epi-13-cis-;
4-Oxa-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
4-Oxa-17-(m-trifluoromethylphenyl)-18,19,20-trinor-15-epi-13-cis-;
4-Oxa-17-(m-chlorophenyl)-18,19,20-trinor-15-epi-13-cis-;
4-Oxa-17-(p-fluorophenyl)-18,19,20-trinor-15-epi-13-cis-;
4-Oxa-16-methyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
4-Oxa-16,16-dimethyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
4-Oxa-16-fluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
4-Oxa-16,16-difluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
4-Oxa-16-phenyl-17,18,19,20-tetranor-15-epi-13-cis-;
4-Oxa-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
4-Oxa-16-(m-chlorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
4-Oxa-16-(p-fluorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
4-Oxa-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
4-Oxa-16-methyl-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
4-Oxa-16-phenoxy-17,18,19,20-tetranor-15-epi-13-cis-;
4-Oxa-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
4-Oxa-16-(m-chlorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
4-Oxa-16-(p-fluorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
4-Oxa-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
4-Oxa-16-methyl-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
3-Oxa-;
3-Oxa-15-methyl-;
3-Oxa-16-methyl-;
3-Oxa-16,16-dimethyl-;
3-Oxa-16-fluoro-;
3-Oxa-16,16-difluoro-;
3-Oxa-17-phenyl-18,19,20-trinor-;
3-Oxa-17-(m-trifluoromethylphenyl)-18,19,20-trinor-;
3-Oxa-17-(m-chlorophenyl)-18,19,20-trinor-;
3-Oxa-17-(p-fluorophenyl)-18,19,20-trinor-;
3-Oxa-16-methyl-17-phenyl-18,19,20-trinor-;
3-Oxa-16,16-dimethyl-17-phenyl-18,19,20-trinor-;
3-Oxa-16-fluoro-17-phenyl-18,19,20-trinor-;
3-Oxa-16,16-difluoro-17-phenyl-18,19,20-trinor-;
3-Oxa-16-phenyl-17,18,19,20-tetranor-;
3-Oxa-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-;
3-Oxa-16-(m-chlorophenyl)-17,18,19,20-tetranor-;
3-Oxa-16-(p-fluorophenyl)-17,18,19,20-tetranor-;
3-Oxa-16-phenyl-18,19,20-trinor-;
3-Oxa-16-methyl-16-phenyl-18,19,20-trinor-;
3-Oxa-16-phenoxy-17,18,19,20-tetranor-;
3-Oxa-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-;
3-Oxa-16-(m-chlorophenoxy)-17,18,19,20-tetranor-;
3-Oxa-16-(p-fluorophenoxy)-17,18,19,20-tetranor-;
3-Oxa-16-phenoxy-18,19,20-trinor-;
3-Oxa-16-methyl-16-phenoxy-18,19,20-trinor-;
3-Oxa-15-methyl-13,14-didehydro-;
3-Oxa-16-methyl-13,14-didehydro-;
3-Oxa-16,16-dimethyl-13,14-didehydro-;
3-Oxa-16-fluoro-13,14-didehydro-;
3-Oxa-16,16-difluoro-13,14-didehydro-;
3-Oxa-17-phenyl-18,19,20-trinor-13,14-didehydro-;
3-Oxa-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-didehydro-;
3-Oxa-17-(m-chlorophenyl)-18,19,20-trinor-13,14-didehydro-;
3-Oxa-17-(p-fluorophenyl)-18,19,20-trinor-13,14-didehydro-;
3-Oxa-16-methyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
3-Oxa-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
3-Oxa-16-fluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
3-Oxa-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
3-Oxa-16-phenyl-17,18,19,20-tetranor-13,14-didehydro-;
3-Oxa-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-didehydro-;
3-Oxa-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
3-Oxa-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
3-Oxa-16-phenyl-18,19,20-trinor-13,14-didehydro-;
3-Oxa-16-methyl-16-phenyl-18,19,20-trinor-13,14-didehydro-;
3-Oxa-16-phenoxy-17,18,19,20-tetranor-13,14-didehydro-;
3-Oxa-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
3-Oxa-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
3-Oxa-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
3-Oxa-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
3-Oxa-16-methyl-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
3-Oxa-13,14-dihydro-;
3-Oxa-15-methyl-13,14-dihydro-;
3-Oxa-16-methyl-13,14-dihydro-;
3-Oxa-16,16-dimethyl-13,14-dihydro-;
3-Oxa-16-fluoro-13,14-dihydro-;
3-Oxa-16,16-difluoro-13,14-dihydro-;
3-Oxa-17-phenyl-18,19,20-trinor-13,14-dihydro-;
3-Oxa-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-dihydro-;
3-Oxa-17-(m-chlorophenyl)-18,19,20-trinor-13,14-dihydro-;
3-Oxa-17-(p-fluorophenyl)-18,19,20-trinor-13,14-dihydro-;
3-Oxa-16-methyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
3-Oxa-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
3-Oxa-16-fluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
3-Oxa-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
3-Oxa-16-phenyl-17,18,19,20-tetranor-13,14-dihydro-;
3-Oxa-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-dihydro-;
3-Oxa-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
3-Oxa-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
3-Oxa-16-phenyl-18,19,20-trinor-13,14-dihydro-;
3-Oxa-16-methyl-16-phenyl-18,19,20-trinor-13,14-dihydro-;
3-Oxa-16-phenoxy-17,18,19,20-tetranor-13,14-dihydro-;
3-Oxa-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
3-Oxa-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
3-Oxa-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
3-Oxa-16-methyl-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
3-Oxa-15-epi-13-cis-;
3-Oxa-15-methyl-15-epi-13-cis-;
3-Oxa-16-methyl-15-epi-13-cis-;
3-Oxa-16,16-dimethyl-15-epi-13-cis-;
3-Oxa-16-fluoro-15-epi-13-cis-;
3-Oxa-16,16-difluoro-15-epi-13-cis-;
3-Oxa-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
3-Oxa-17-(m-trifluoromethylphenyl)-18,19,20-trinor-15-epi-13-cis-;
3-Oxa-17-(m-chlorophenyl)-18,19,20-trinor-15-epi-13-cis-;
3-Oxa-17-(p-fluorophenyl)-18,19,20-trinor-15-epi-13-cis-;
3-Oxa-16-methyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
3-Oxa-16,16-dimethyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
3-Oxa-16-fluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
3-Oxa-16,16-difluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
3-Oxa-16-phenyl-17,18,19,20-tetranor-15-epi-13-cis-;
3-Oxa-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
3-Oxa-16-(m-chlorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
3-Oxa-16-(p-fluorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
3-Oxa-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
3-Oxa-16-methyl-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
3-Oxa-16-phenoxy-17,18,19,20-tetranor-15-epi-13-cis-;
3-Oxa-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
3-Oxa-16-(m-chlorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
3-Oxa-16-(p-fluorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
3-Oxa-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
3-Oxa-16-methyl-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
trans-2,3-Didehydro-;
trans-2,3-Didehydro-15-methyl-;
trans-2,3-Didehydro-16-methyl-;
trans-2,3-Didehydro-16,16-dimethyl-;
trans-2,3-Didehydro-16-fluoro-;
trans-2,3-Didehydro-16,16-difluoro-;
trans-2,3-Didehydro-17-phenyl-18,19,20-trinor-;
trans-2,3-Didehydro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-;
trans-2,3-Didehydro-17-(m-chlorophenyl)-18,19,20-trinor-;
trans-2,3-Didehydro-17-(p-fluorophenyl)-18,19,20-trinor-;
trans-2,3-Didehydro-16-methyl-17-phenyl-18,19,20-trinor-;
trans-2,3-Didehydro-16,16-dimethyl-17-phenyl-18,19,20-trinor-;
trans-2,3-Didehydro-16-fluoro-17-phenyl-18,19,20-trinor-;
trans-2,3-Didehydro-16,16-difluoro-17-phenyl-18,19,20-trinor-;
trans-2,3-Didehydro-16-phenyl-17,18,19,20-tetranor-;
trans-2,3-Didehydro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-;
trans-2,3-Didehydro-16-(m-chlorophenyl)-17,18,19,20-tetranor-;
trans-2,3-Didehydro-16-(p-fluorophenyl)-17,18,19,20-tetranor-;
trans-2,3-Didehydro-16-phenyl-18,19,20-trinor-;
trans-2,3-Didehydro-16-methyl-16-phenyl-18,19,20-trinor-;
trans-2,3-Didehydro-16-phenoxy-17,18,19,20-tetranor-;
trans-2,3-Didehydro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-;
trans-2,3-Didehydro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-;
trans-2,3-Didehydro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-;
trans-2,3-Didehydro-16-phenyl-18,19,20-trinor-;
trans-2,3-Didehydro-16-methyl-16-phenoxy-18,19,20-trinor-;
trans-2,3-Didehydro-15-methyl-13,14-didehydro-;
trans-2,3-Didehydro-16-methyl-13,14-didehydro-;
trans-2,3-Didehydro-16,16-dimethyl-13,14-didehydro-;
trans-2,3-Didehydro-16-fluoro-13,14-didehydro-;
trans-2,3-Didehydro-16,16-difluoro-13,14-didehydro-;
trans-2,3-Didehydro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-17-(m-chlorophenyl)-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-17-(p-fluorophenyl)-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-16-methyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-16-fluoro-17-phenyl-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-didehydro;
trans-2,3-Didehydro-16-phenyl-17,18,19,20-tetranor-13,14-didehydro-;
trans-2,3-Didehydro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-didehydro-;
trans-2,3-Didehydro-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
trans-2,3-Didehydro-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-didehydro-;
trans-2,3-Didehydro-16-phenyl-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-16-methyl-16-phenyl-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-16-phenoxy-17,18,19,20-tetranor-13,14-didehydro-;
trans-2,3-Didehydro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
trans-2,3-Didehydro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
trans-2,3-Didehydro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-didehydro-;
trans-2,3-Didehydro-16-phenoxy-18,19,20-trinor-13,14-didehydro-;
trans-2,3-Didehydro-16-methyl-16-phenoxy-18,19,20-trinor-13,14-didehydro;
trans-2,3-Didehydro-13,14-dihydro-;
trans-2,3-Didehydro-15-methyl-13,14-dihydro-;
trans-2,3-Didehydro-16-methyl-13,14-dihydro-;
trans-2,3-Didehydro-16,16-dimethyl-13,14-dihydro-;
trans-2,3-Didehydro-16-fluoro-13,14-dihydro-;
trans-2,3-Didehydro-16,16-fluoro-13,14-dihydro-;
trans-2,3-Didehydro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-17-(m-chlorophenyl)-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-17-(p-fluorophenyl)-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-16-methyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-16,16-dimethyl-17-phenyl-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-16-fluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-16,16-difluoro-17-phenyl-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-16-phenyl-17,18,19,20-tetranor-13,14-dihydro-;
trans-2,3-Didehydro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-13,14-dihydro-;
trans-2,3-Didehydro-16-(m-chlorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
trans-2,3-Didehydro-16-(p-fluorophenyl)-17,18,19,20-tetranor-13,14-dihydro-;
trans-2,3-Didehydro-16-phenyl-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-16-methyl-16-phenyl-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-16-phenoxy-17,18,19,20-tetranor-13,14-dihydro-;
trans-2,3-Didehydro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
trans-2,3-Didehydro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
trans-2,3-Didehydro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-13,14-dihydro-;
trans-2,3-Didehydro-16-methyl-16-phenoxy-18,19,20-trinor-13,14-dihydro-;
trans-2,3-Didehydro-15-epi-13-cis-;
trans-2,3-Didehydro-15-methyl-15-epi-13-cis-;
trans-2,3-Didehydro-16-methyl-15-epi-13-cis-;
trans-2,3-Didehydro-16,16-dimethyl-15-epi-13-cis-;
trans-2,3-Didehydro-16-fluoro-15-epi-13-cis-;
trans-2,3-Didehydro-16,16-difluoro-15-epi-13-cis-;
trans-2,3-Didehydro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
trans-2,3-Didehydro-17-(m-trifluoromethylphenyl)-18,19,20-trinor-15-epi-13-cis-;
trans-2,3-Didehydro-17-(m-chlorophenyl)-18,19,20-trinor-15-epi-13-cis-;
trans-2,3-Didehydro-17-(p-fluorophenyl)-18,19,20-trinor-15-epi-13-cis-;
trans-2,3-Didehydro-16-methyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
trans-2,3-Didehydro-16,16-dimethyl-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
trans-2,3-Didehydro-16-fluoro-17-phenol-18,19,20-trinor-15-epi-13-cis-;
trans-2,3-Didehydro-16,16-difluoro-17-phenyl-18,19,20-trinor-15-epi-13-cis-;
trans-2,3-Didehydro-16-phenyl-17,18,19,20-tetranor-15-epi-13-cis-;
trans-2,3-Didehydro-16-(m-trifluoromethylphenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
trans-2,3-Didehydro-16-(m-chlorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
trans-2,3-Didehydro-16-(p-fluorophenyl)-17,18,19,20-tetranor-15-epi-13-cis-;
trans-2,3-Didehydro-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
trans-2,3-Didehydro-16-methyl-16-phenyl-18,19,20-trinor-15-epi-13-cis-;
trans-2,3-Didehydro-16-phenoxy-17,18,19,20-tetranor-15-epi-13-cis-;
trans-2,3-Didehydro-16-(m-trifluoromethylphenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
trans-2,3-Didehydro-16-(m-chlorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
trans-2,3-Didehydro-16-(p-fluorophenoxy)-17,18,19,20-tetranor-15-epi-13-cis-;
trans-2,3-Didehydro-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
trans-2,3-Didehydro-16-methyl-16-phenoxy-18,19,20-trinor-15-epi-13-cis-;
3,7-Inter-m-phenylene-4,5,6-trinor-;
3,7-Inter-m-phenylene-4,5,6-trinor-15-methyl-;
3,7-Inter-m-phenylene-4,5,6-trinor-16-methyl-;
3,7-Inter-m-phenylene-4,5,6-trinor-16,16-dimethyl-;
3,7-Inter-m-phenylene-4,5,6-trinor-16-fluoro-;
3,7-Inter-m-phenylene-4,5,6-trinor-16,16-difluoro-;
3,7-Inter-m-phenylene-17-phenyl-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-17-(m-trifluoromethylphenyl)-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-17-(m-chlorophenyl)-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-17-(p-fluorophenyl)-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-16-methyl-17-phenyl-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-16,16-dimethyl-17-phenyl-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-16-fluoro-17-phenyl-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-16,16-difluoro-17-phenyl-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-16-phenyl-4,5,6,17,18,19,20-heptanor-;
3,7-Inter-m-phenylene-16-(m-trifluoromethylphenyl)-4,5,6,17,18,19,20-heptanor-;
3,7-Inter-m-phenylene-16-(m-chlorophenyl)-4,5,6,17,18,19,20-heptanor-;
3,7-Inter-m-phenylene-16-(p-fluorophenyl)-4,5,6,17,18,19,20-heptanor-;
3,7-Inter-m-phenylene-16-phenyl-4,5,6,18,19,20-hexanor;
3,7-Inter-m-phenylene-16-methyl-16-phenyl-4,5,6,18,19,20-hexanor-;
3,7-inter-m-phenylene-16-phenoxy-4,5,6,17,18,19,20-heptanor-;
3,7-Inter-m-phenylene-16-(m-trifluoromethylphenoxy)-4,5,6,17,18,19,20-heptanor-;
3,7-Inter-m-phenylene-16-(m-chlorophenoxy)-4,5,6,17,18,19,20-heptanor-;
3,7-Inter-m-phenylene-16-(p-fluorophenoxy)-4,5,6,17,18,19,20-heptanor-;
3,7-Inter-m-phenylene-16-phenoxy-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-16-methyl-16-phenoxy-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-15-methyl-13,14-didehydro-4,5,6-trinor-;
3,7-Inter-m-phenylene-16-methyl-13,14-didehydro-4,5,6-trinor-;
3,7-Inter-m-phenylene-16,16-dimethyl-13,14-didehydro-4,5,6-trinor-;
3,7-Inter-m-phenylene-16-fluoro-13,14-didehydro-4,5,6-trinor-;
3,7-Inter-m-phenylene-16,16-difluoro-13,14-didehydro-4,5,6-trinor-;
3,7-Inter-m-phenylene-17-phenyl-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-17-(m-trifluoromethylphenyl)-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-17-(m-chlorophenyl)-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-17-(p-fluorophenyl)-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-16-methyl-17-phenyl-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-16,16-dimethyl-17-phenyl-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-16-fluoro-17-phenyl-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-16,16-difluoro-17-phenyl-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-16-phenyl-4,5,6,17,18,19,20-heptanor-13,14-didehydro-;
3,7-Inter-m-phenylene-16-(m-trifluoromethylphenyl)-4,5,6,17,18,19,20-heptanor-13,14-didehydro-;
3,7-Inter-m-phenylene-16-(m-chlorophenyl)-4,5,6,17,18,19,20-heptanor-13,14-didehydro-;
3,7-Inter-m-phenylene-16-(p-fluorophenyl)-4,5,6,17,18,19,20-heptanor-13,14-didehydro-;
3,7-Inter-m-phenylene-16-phenyl-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-16-methyl-16-phenyl-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-16-phenoxy-4,5,6,17,18,19,20-heptanor-13,14-didehydro-;
3,7-Inter-m-phenylene-16-(m-trifluoromethylphenoxy)-4,5,6,17,18,19,20-heptanor-13,14-didehydro-;
3,7-Inter-m-phenylene-16-(m-chlorophenoxy)-4,5,6,17,18,19,20-heptanor-13,14-didehydro-;
3,7-Inter-m-phenylene-16-(p-fluorophenoxy)-4,5,6,17,18,19,20-heptanor-13,14-didehydro-;
3,7-Inter-m-phenylene-16-phenoxy-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-16-methyl-16-phenoxy-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-4,5,6-trinor-13,14-dihydro-;
3,7-Inter-m-phenylene-4,5,6-trinor-15-methyl-13,14-dihydro-;
3,7-Inter-m-phe-ylene-3-oxa-4,5,6-trinor-16-methyl-13,14-dihydro-;
3,7-Inter-m-phenylene-4,5,6-trinor-16,16-dimethyl-13,14-dihydro-;
3,7-Inter-m-phenylene-4,5,6-trinor-16-fluoro-13,14-dihydro-;
3,7-Inter-m-phenylene-4,5,6-trinor-16,16-difluoro-13,14-dihydro-;
3,7-Inter-m-phenylene-17-phenyl-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-17-(m-trifluoromethylphenyl)-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-17-(m-chlorophenyl)-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-17-(p-fluorophenyl)-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-16-methyl-17-phenyl-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-16,16-dimethyl-17-phenyl-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-16-fluoro-17-phenyl-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-16,16-difluoro-17-phenyl-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-16-phenyl-4,5,6,17,18,19,20-heptanor-13,14-dihydro-;
3,7-Inter-m-phenylene-16-(m-trifluoromethylphenyl)-4,5,6,17,18,19,20-heptanor-13,14-dihydro-;
3,7-Inter-m-phenylene-16-(m-chlorophenyl)-4,5,6,17,18,19,20-heptanor-13,14-dihydro-;
3,7-Inter-m-phenylene-16-(p-fluorophenyl)-4,5,6,17,18,19,20-heptanor-13,14-dihydro-;
3,7-Inter-m-phenylene-16-phenyl-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-16-methyl-16-phenyl-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-16-phenoxy-4,5,6,17,18,19,20-heptanor-13,14-dihydro-;
3,7-Inter-m-phenylene-16-(m-trifluoromethylphenoxy)-4,5,6,17,18,19,20-heptanor-13,14-dihydro-;
3,7-Inter-m-phenylene-16-(m-chlorophenoxy)-4,5,6,17,18,19,20-heptanor-13,14-dihydro-;
3,7-Inter-m-phenylene-16-(p-fluorophenoxy)-4,5,6,17,18,19,20-heptanor-13,14-dihydro-;
3,7-Inter-m-phenylene-16-methyl-16-phenoxy-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-4,5,6-trinor-15-epi-13-cis-;
3,7-Inter-m-phenylene-4,5,6-trinor-15-methyl-15-epi-13-cis-;
3,7-Inter-m-phenylene-4,5,6-trinor-16-methyl-15-epi-13-cis-;
3,7-Inter-m-phenylene-4,5,6-trinor-16,16-dimethyl-15-epi-13-cis-;
3,7-Inter-m-phenylene-4,5,6-trinor-16-fluoro-15-epi-13-cis-;
3,7-Inter-m-phenylene-4,5,6-trinor-16,16-difluoro-15-epi-13-cis-;
3,7-Inter-m-phenylene-17-phenyl-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-17-(m-trifluoromethylphenyl)-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-17-(m-chlorophenyl)-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-17-(p-fluorophenyl)-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-16-methyl-17-phenyl-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-16,16-dimethyl-17-phenyl-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-16-fluoro-17-phenyl-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-16,16-difluoro-17-phenyl-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-16-phenyl-4,5,6,17,18,19,20-heptanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-16-(m-trifluoromethylphenyl)-4,5,6,17,18,19,20-heptanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-16-(m-chlorophenyl)-4,5,6,17,18,19,20-heptanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-16-(p-fluorophenyl)-4,5,6,17,18,19,20-heptanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-16-phenyl-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-16-methyl-16-phenyl-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-16-phenoxy-4,5,6,17,18,19,20-heptanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-16-(m-trifluoromethylphenoxy)-4,5,6,17,18,19,20-heptanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-16-(m-chlorophenoxy)-4,5,6,17,18,19,20-heptanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-16-(p-fluorophenoxy)-4,5,6,17,18,19,20-heptanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-16-phenoxy-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-16-methyl-16-phenoxy-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-4,5,6-trinor-;
3,7-Inter-m-phenylene-3-oxa-4,5,6-trinor-15-methyl-;
3,7-Inter-m-phenylene-3-oxa-4,5,6-trinor-16-methyl-;
3,7-Inter-m-phenylene-3-oxa-4,5,6-trinor-16,16-dimethyl-;
3,7-Inter-m-phenylene-3-oxa-4,5,6-trinor-16-fluoro-;
3,7-Inter-m-phenylene-3-oxa-4,5,6-trinor-16,16-difluoro-;
3,7-Inter-m-phenylene-3-oxa-17-phenyl-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-3-oxa-17-(m-trifluoromethylphenyl)-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-3-oxa-17-(m-chlorophenyl)-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-3-oxa-17-(p-fluorophenyl)-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-3-oxa-16-methyl-17-phenyl-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-3-oxa-16,16-dimethyl-17-phenyl-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-3-oxa-16-fluoro-17-phenyl-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-3-oxa-16,16-difluoro-17-phenyl-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-3-oxa-16-phenyl-4,5,6,17,18,19,20-heptanor-;
3,7-Inter-m-phenylene-3-oxa-16-(m-trifluoromethylphenyl)-4,5,6,17,18,19,20-heptanor-;
3,7-Inter-m-phenylene-3-oxa-16-(m-chlorophenyl)-4,5,6,17,18,19,20-heptanor-;
3,7-Inter-m-phenylene-3-oxa-16-(p-fluorophenyl)-4,5,6,17,18,19,20-heptanor-;
3,7-Inter-m-phenylene-3-oxa-16-phenyl-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-3-oxa-16-methyl-16-phenyl-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-3-oxa-16-phenoxy-4,5,6,17,18,19,20-heptanor-;
3,7-Inter-m-phenylene-3-oxa-16-(m-trifluoromethylphenoxy)-4,5,6,17,18,19,20-heptanor-;
3,7-Inter-m-phenylene-3-oxa-16-(m-chlorophenoxy)-4,5,6,17,18,19,20-heptanor-;
3,7-Inter-m-phenylene-3-oxa-16-(p-fluorophenoxy)-4,5,6,17,18,19,20-heptanor-;
3,7-Inter-m-phenylene-3-oxa-16-phenoxy-4,5,6,18,19,20-hexanor-;
3,7-Inter-m-phenylene-3-oxa-16-methyl-16-phenoxy-4,5,6,18,19,20-hexanor-;
3,7-INter-m-phenylene-3-oxa-15-methyl-13,14-didehydro-4,5,6-trinor-;
3,7-Inter-m-phenylene-3-oxa-16-methyl-13,14-didehydro-4,5,6-trinor-;
3,7-Inter-m-phenylene-3-oxa-16,16-dimethyl-13,14-didehydro-4,5,6-trinor-;
3,7-Inter-m-phenylene-3-oxa-16-fluoro-13,14-didehydro-4,5,6-trinor-;
3,7-Inter-m-phenylene-3-oxa-16,16-difluoro-13,14-didehydro-4,5,6-trinor-;
3,7-Inter-m-phenylene-3-oxa-17-phenyl-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-17-(m-trifluoromethylphenyl)-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-17-(m-chlorophenyl)-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-17-(p-fluorophenyl)-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-16-methyl-17-phenyl-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-16,16-dimethyl-17-phenyl-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-16-fluoro-17-phenyl-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-16,16-difluoro-17-phenyl-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-16-phenyl-4,5,6,17,18,19,20-heptanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-16-(m-trifluoromethylphenyl)-4,5,6,17,18,19,20-heptanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-16-(m-chlorophenyl)-4,5,6,17,18,19,20-heptanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-16-(p-fluorophenyl)-4,5,6,17,18,19,20-heptanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-16-phenyl-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-16-methyl-16-phenyl-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-16-phenoxy-4,5,6,17,18,19,20-heptanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-16-(m-trifluoromethylphenoxy)-4,5,6,17,18,19,20-heptanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-16-(m-chlorophenoxy)-4,5,6,17,18,19,20-heptanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-16-(p-fluorophenoxy)-4,5,6,17,18,19,20-heptanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-16-phenoxy-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-16-methyl-16-phenoxy-4,5,6,18,19,20-hexanor-13,14-didehydro-;
3,7-Inter-m-phenylene-3-oxa-4,5,6-trinor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-4,5,6-trinor-15-methyl-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-4,5,6-trinor-16-methyl-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-4,5,6-trinor-16,16-dimethyl-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-4,5,6-trinor-16-fluoro-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-4,5,6-trinor-16,16-difluoro-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-17-phenyl-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-17-(m-trifluoromethylphenyl)-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-17-(m-chlorophenyl)-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-17-(p-fluorophenyl)-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-16-methyl-17-phenyl-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-16,16-dimethyl-17-phenyl-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-16-fluoro-17-phenyl-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-16,16-difluoro-17-phenyl-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-16-phenyl-4,5,6,17,18,19,20-heptanor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-16-(m-trifluoromethylphenyl)-4,5,6,17,18,19,20-heptanor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-16-(m-chlorophenyl)-4,5,6,17,18,19,20-heptanor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-16-(p-fluorophenyl)-4,5,6,17,18,19,20-heptanor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-16-phenyl-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-16-methyl-16-phenyl-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-16-phenoxy-4,5,6,17,18,19,20-heptanor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-16-(m-trifluoromethylphenoxy)-4,5,6,17,18,19,20-heptanor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-16-(m-chlorophenoxy)-4,5,6,17,18,19,20-heptanor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-16-(p-fluorophenoxy)-4,5,6,17,18,19,20-heptanor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-16-methyl-16-phenoxy-4,5,6,18,19,20-hexanor-13,14-dihydro-;
3,7-Inter-m-phenylene-3-oxa-4,5,6-trinor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-4,5,6-trinor-15-methyl-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-4,5,6-trinor-16-methyl-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-4,5,6-trinor-16,16-dimethyl-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-4,5,6-trinor-16-fluoro-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-4,5,6-trinor-16,16-difluoro-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-17-phenyl-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-17-(m-trifluoromethylphenyl)-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-17-(m-chlorophenyl)-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-17-(p-fluorophenyl)-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-16-phenoxy-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-16-methyl-17-phenyl-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-16,16-dimethyl-17-phenyl-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-16-fluoro-17-phenyl-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-16,16-difluoro-17-phenyl-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-16-phenyl-4,5,6,17,18,19,20-heptanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-16-(m-trifluoromethylphenyl)-4,5,6,17,18,19,20-heptanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-16-(m-chlorophenyl)-4,5,6,17,18,19,20-heptanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-16-(p-fluorophenyl)-4,5,6,17,18,19,20-heptanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-16-phenyl-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-16-methyl-16-phenyl-4,5,6,18,19,20-hexanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-16-phenoxy-4,5,6,17,18,19,20-heptanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-16-(m-trifluoromethylphenoxy)-4,5,6,17,18,19,20-heptanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-16-(m-chlorophenyl)-4,5,6,17,18,19,20-heptanor-15-epi-13-cis-;
3,7-Inter-m-phenylene-3-oxa-16-(p-fluorophenyl)-4,5,6,17,18,19,20-heptanor-15-epi-13cis-;
3,7-Inter-m-phenylene-3-oxa-16-phenoxy-4,5,6,18,19,20-hexanor-15-epi-13-cis-; and
3,7-Inter-m-phenylene-3-oxa-16-methyl-16-phenoxy-4,5,6,18,19,20-hexanor-15-epi-13-cis-.
EXAMPLE 5 -- 2-Decarboxy-2-methylcarbonyl-PGF 2 α (Formula XXVI: R 1 is methyl, Z 1 is cis-CH CH-(CH 2 ) 3 -, R 8 is hydroxy, R 1 is trans-CH CH-, R 3 and R 4 of the L 1 moiety and R 5 of the M 1 moiety are all hydrogen, and R 7 is n-butyl).
Refer to Chart A.
A. To a solution of 30 g of PGF 2 α, 11,15-bis(tetrahydropyranyl ether), methyl ester, 190 ml of tetrahydrofuran, and 100 ml of hexamethyldisilizane at ambient temperature is added with stirring 25 ml of trimethylsilyl chloride. The mixture is then allowed to stand at ambient temperature for about one day. When silica gel TLC Rf indicates the C-9 monosilylation is complete, the crude (Formula XXII) product is then concentrated under reduced pressure and the residue taken up in benzene and filtered. Chromatography of the filtrate yields pure Formula XXII compound.
B. Following the procedure of Example 1, Parts A-C, the reaction product of Part A above is transformed to 2-decarboxy-2-alkylcarbonyl-PGF 2 α, 11,15-bis(tetrahydropyranyl ether).
C. The reaction product of Part B above in a mixture of acetic acid, water, and tetrahydrofuran (20:10:3) is maintained at ambient temperature for about 4 hr. Thereafter the resulting solution is concentrated under reduced pressure, the residue dissolved in methylene chloride, and chromatographed on silica gel. Accordingly there is obtained pure title product.
Following the procedure of Example 5, but employing the appropriate PGF 2 α-type, 8β,12α-PGF 2 α-type, PGF 1 α, 8β,12α-PGF 1 α-type, PGF 2 β-type, 8β,12α-PGF 2 β-type, PGF 1 β-type, or 8β, 12α-PGF 1 β-type starting material, there are prepared the corresponding
2-decarboxy-2-methylcarbonyl-PGF 2 α-type;
2-decarboxy-2-methylcarbonyl-8β,12α-PGF 2 α-type;
2-decarboxy-2-methylcarbonyl-PGF 1 α-type;
2-decarboxy-2-methylcarbonyl-8β,12α-PGF 1 α-type;
2-decarboxy-2-methylcarbonyl-PGF 2 β-type;
2-decarboxy-2-methylcarbonyl-8β,12α-PGF 2 β-type;
2-decarboxy-2-methylcarbonyl-PGF 1 β-type; and
2-decarboxy-2-methylcarbonyl-8β,12α-PGF 1 β-type
compounds, either as the respective parent compounds thereof or an analogs thereof exhibiting those specific side chain characteristics described above for the 2-decarboxy-2-methylcarbonyl-9-deoxy-9-methylene-PGF 2 -type, 2-decarboxy-2-methylcarbonyl-9-deoxy-9-methylene-8β,12α-PGF.sub.2 -type, 2-decarboxy-2-methylcarbonyl-9-deoxy-9-methylene-PGF 1 -type, or 2-decarboxy-2-methylcarbonyl-9-deoxy-9-methyl-8β,12α-PGF 1 -type compounds.
Further, following the procedure of Example 5, but employing the appropriate 11-deoxy-PGF 2 α-type, 11-deoxy-8β,12α-PGF 2 α-type, 11-deoxy-PGF 1 α-type, 11-deoxy-8β,12α-PGF 1 α-type, 11-deoxy-PGF 2 β-type, 11-deoxy-8β,12α-PGF 2 β-type, 11-deoxy-PGF 1 β-type, or 11-deoxy-8β,12A-PGF 1 β-type starting material, there are prepared the corresponding
2-decarboxy-2-methylcarbonyl-11-deoxy-PGF 2 α-type;
2-decarboxy-2-methylcarbonyl-11-deoxy-8β,12α-PGF 2 α-type;
2-decarboxy-2-methylcarbonyl-11-deoxy-PGF 1 α-type;
2-decarboxy-2-methylcarbonyl-11-deoxy-8β,12α-PGF 1 α-type;
2-decarboxy-2-methylcarbonyl-11-deoxy-PGF 2 β-type;
2-decarboxy-2-methylcarbonyl-11-deoxy-8β,12α-PGF 2 β-type;
2-decarboxy-2-methylcarbonyl-11-deoxy-PGF 1 β-type; and
2-decarboxy-2-methylcarbonyl-11-deoxy-8β,12α-PGF 1 β-type
compounds, either as the respective parent compounds thereof or as analogs thereof exhibiting those specific side chain characteristics described above for the 2-decarboxy-2-methylcarbonyl-9-deoxy-9-methylene-PGF 2 -type, 2-decarboxy-2-methylcarbonyl-9-deoxy-9-methylene-8β-12α-PGF.sub.2 -type, 2-decarboxy-2-methylcarbonyl-9-deoxy-9-methylene-PGF 1 -type, 2-decarboxy-2-methylcarbonyl-9-deoxy-9-methylene-8β,12α-PGF.sub.1 -type compounds.
EXAMPLE 6 -- 2-Decarboxy-2-methylcarbonyl-PGE 2 (Formula LXXXV: R 1 , Z 1 , R 8 , Y 1 , M 1 , L 1 , and R 7 are as defined in Example 5).
Refer to Chart G.
A. A mixture of 30 mg of PGE 2 , 11,15-bis(tetrahydropyranyl ether), methyl ester, 1 ml of methanol, 25 mg of hydroxylamine hydrochloride, 30 mg of sodium acetate, and 0.5 ml of water was allowed to stand about 18 hr at 25° C. The resulting mixture was then concentrated under a stream of nitrogen at 25° C. The residue was then extracted with dichloromethane, washed, and evaporated to yield a residue. Chromatographing the residue on silica gel yields pure Formula LXXXIII compound: PGE 2 , 11,15-bis(tetrahydropyranyl ether), methyl ester, oxime.
B. Following the procedure of Example 1, Parts A, B, and C, the reaction product of Part A above is transformed to 2-decarboxy-2-methylcarbonyl-PGE 2 , 11,15-bis(tetrahydropyranyl ether), oxime.
C. The reaction product of Part B (150 mg) in 10 ml of 90% aqueous acetic acid is cooled to 10° C. and 5 ml of 10% aqueous sodium nitrite is added. The resulting mixture is allowed to stand for 1 hr at 10° C. and thereafter warmed to ambient temperature and treated with 5 ml of 10% aqueous sodium nitrate. The mixture is then allowed to stand an additional 1 hr at ambient temperature and thereafter excess water is added and the resulting mixture extracted with ethyl acetate. These organic extracts are then washed, dried, and concentrated to yield a residue containing pure title product.
Following the procedure of Example 6, but employing the appropriate Formula LXXXII PGE-type, 8β,12α-PGE-type, 11-deoxy-PGE-type, or 8β,12α-11-deoxy-PGE-type starting material, there are prepared.
2-decarboxy-2-methylcarbonyl-PGE-type;
2-decarboxy-2-methylcarbonyl-8β,12α-PGE-type;
2-decarboxy-2-methylcarbonyl-11-deoxy-PGE-type; or
2-decarboxy-2-methylcarbonyl-11-deoxy-8β,12α-PGE-type
compounds either as the parent compounds thereof or exhibiting the side chain characteristics of those compounds described following Example 4.
EXAMPLE 7 -- 2-Decarboxy-2-methylcarbonyl-PGA 2 (Formula II: D is ##STR71## Z 1 , Y 1 , M 1 , L 1 , and R 7 are as defined in Example 5).
A solution of 2-decarboxy-2-methylcarbonyl-PGE 2 (300 mg), 4 ml of tetrahydrofuran and 4 ml of 0.5 N. hydrochloric acid is left standing at 25° C. for 5 days. Brine and dichloromethane (1:3) are added and the resulting mixture is stirred. The organic phase is then separated, dried, and concentrated to a residue. The residue is then chromatographed on silica gel yielding pure title products.
Following the procedure of Example 7, but employing the appropriate 2-decarboxy-2-methylcarbonyl-PGE-type or 2-decarboxy-2-methylcarbonyl-8β,12α-PGE-type starting material, there are prepared
2-decarboxy-2-methylcarbonyl-PGA-type; or
2-decarboxy-2-methylcarbonyl-8β,12α-PGA-type
compounds, which exhibit the side chain characteristics described following Example 6 for the various starting material.
EXAMPLE 8 -- 2-Decarboxy-2-methylcarbonyl-PGB 2 (Formula II: D is ##STR72## and Z 1 , Y 1 , M 1 , L 1 , and R 7 are as defined in Example 5).
A solution of 2-decarboxy-2-methylcarbonyl-PGE 2 in 100 ml of 50% aqueous ethanol containing about 1 g of potassium hydroxide is kept at 25° C. for 10 hr under a nitrogen atmosphere. The resulting solution is then cooled to 10° C. and extracted repeatedly with diethyl ether. The organic extracts are then washed, dried, and concentrated to yield a residue containing the title product. Chromatographing on silica gel yields pure product.
Following the procedure of Example 8, but employing the appropriate 2-decarboxy-2-methylcarbonyl-PGE-type starting material, there are prepared 2-decarboxy-2-methylcarbonyl-PGB-type compounds, which exhibit the side chain characteristics described following Example 6 for the starting material.
EXAMPLE 9 -- 2-Decarboxy-2-methylcarbonyl-PGD 2 (Formula II: D is ##STR73## Z 1 , Y 1 , M 1 , L 1 , and R 7 are as defined in Example 5).
Following the procedure of Example 6, PGD 2 , methyl ester, 15-tetrahydropyranyl ether (the methyl ester of the compound of Example 22, Part B, of U.S. Patent 4,016,814) is transformed to the title product.
Following the procedure of Example 9, but employing the appropriate PGD-type, 8β,12α-type, 9β-PGD-type, or 8β,9β,12α-PGD-type starting material, there are prepared
2-decarboxy-2-methylcarbonyl-PGD-type;
2-decarboxy-2-methylcarbonyl-8β,12α-PGD-type;
2-decarboxy-2-methylcarbonyl-9β-PGD-type; or
2-decarboxy-2-methylcarbonyl-8β,9β,12α-PGD-type
compounds which exhibit the side chain characteristics as the 2-decarboxy-2-methylcarbonyl-PGE-type compounds described following Example 6.
EXAMPLE 10 -- 2-Decarboxy-2-methylcarbonyl-9-deoxy-9,10-didehydro-PGD 2 (Formula II: D is ##STR74## Z 1 , Y 1 , M 1 , L 1 , and R 7 are as defined in Example 5).
Following the procedure of Example 7, 2-decarboxy-2-methylcarbonyl-PGD 2 is dehydrated to yield the title product.
Following the procedure of the above examples, but employing the appropriate PGD-type or 8β,12α-PGD-type starting material there are prepared
2-decarboxy-2-methylcarbonyl-9-deoxy-9,10-didehydro-PGD-type; or
2-decarboxy-2-methylcarbonyl-9-deoxy-9,10-didehydro-PGD-type
compounds which exhibit the side chain characteristics described following Example 8 for the corresponding starting material.
Further following the procedures of Examples 5-10, but employing in the ketonization step in place of S-phenyl N-methyl -S-methylsulfoximine the corresponding S-ethylsulfoximine, S-propylsulfoximine, S-isopropylsulfoximine, S-butylsulfoximine, S-isobutylsulfoximine, or S-sec-butylsulfoximine, there are prepared the corresponding 2-decarboxy-2-ethylcarbonyl-, 2-decarboxy-2-propylcarbonyl-, 2-decarboxy-2-isopropylcarbonyl-, 2-decarboxy-2-butylcarbonyl-, 2-decarboxy-2-isobutylcarbonyl-, or 2-decarboxy-2-sec-butylcarbonyl-PG-type products corresponding to the 2-decarboxy-2-methylcarbonyl-PG-type products described in and following Examples 5-10.
Further, in following the procedure of Example 5, but employing the various sulfoximine reagents described in the preceding paragraph and employing in place of the PGFα-type starting material, the corresponding 9-deoxy-9-methylene-PGF compound (i.e., 9-deoxy-9-methylene-PGF 2 , methyl ester, 11,15-bis(tetrahydropyranyl ether)), there are prepared the corresponding 2-decarboxy-2-ethylcarbonyl-, 2-decarboxy-2-propylcarbonyl-, 2-decarboxy-2-isopropylcarbonyl-, 2-decarboxy-2-butylcarbonyl-, 2-decarboxy-2-isobutylcarbonyl-, or 2-decarboxy-2-sec-butylcarbonyl-9-deoxy-9-methylene-PGF 2 products. Further, employing such sulfoximine reagents and the various 9-deoxy-9-methylene-PGF-type or 9-deoxy-9-methylene-8β,12α-PGF-type compounds exhibiting side chain substituents as are described following Example 5 for the corresponding 2-decarboxy-2-methylcarbonyl-PGF 2 α-type products, the corresponding 2-decarboxy-9-deoxy-9-methylene-PGF-type or 8β,12α-PGF-type products are prepared.
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The present invention provides novel prostaglandin analogs wherein the C-2 carboxyl is replaced by alkylcarbonyl, i.e., a C-2 ketone. These novel 2-decarboxy-2-alkylcarbonyl-PG-type compounds are disclosed as improved gastrointestinal cytoprotective agents, being devoid or substantially devoid of other prostaglandin-type effects (e.g., smooth muscle or cardiovascular).
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This invention concerns a support provided with a pellet of rigid plastic material. This pellet is provided with two faces, one of which bears a coupling means and the other of which is covered with a layer of adhesive material.
BACKGROUND OF THE INVENTION
Supports of this type are known. They may be readily fastened by simple pressure onto a planar surface. Unfortunately as soon as the surface is curved or warped, adhesion is no longer possible.
The purpose of this invention is to enable the fastening of such a support as readily onto a curved or warped surface as to a planar surface.
SUMMARY OF THE INVENTION
This purpose is attained by the provision of a support including a pellet of rigid plastic material having two opposed faces one of which bears a coupling means and the other of which is covered with a layer of adhesive material, said pellet exhibiting a groove defining a flexure zone.
The invention will be readily understood following reading of the description to follow having reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows in perspective a support according to a first embodiment of the invention;
FIG. 2 is a cross-section of the support of FIG. 1 fixed onto a tube;
FIGS. 3 and 4 are perspective views of supports according to the second and third embodiments of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The support shown in FIGS. 1 and 2 includes a pellet 10 of plastic material having an upper face 12 and lower face 14, a coupling means 16 integral with the upper face 12 as well as a layer of adhesive material 18 which covers the lower face 14 with the interposition of a layer of flexible material 20.
The upper face 12 of the pellet 10 exhibits furthermore two parallel grooves 22 situated on either side of the coupling means 16. These grooves are such as to leave remaining only a thin and flexible bridge of material 24 between the central portion 10a of the pellet 10 and the lateral portions 10b forming flexure zones.
The layers of flexible material 20 and adhesive material 18 are advantageously interrupted facing the grooves 22, thus defining slots 26 parallel to the grooves 22.
In view of this special configuration, the support may be fixed onto a cylindrical surface such as the tube 28 shown on FIG. 2. In view of the presence of bridges 24, the outer portions 10b of the pellet 10 may be folded back thus to surround the tube 28. The layer of flexible material 20 enables the adhesive layer 18 to conform to the form of the cylindrical surface. Furthermore, the slots 26 prevent the layers 18 and 20 from forming wrinkles when the fold back is substantial, which could spoil the adhesion of the support.
The radius of curvature of the holding surface may be small, smaller even than the radius of the pellet 10. It is thus possible to fasten such a support to the handle bar of a bicycle in particular, in order to mount thereon various accessories such as a watch 30 for instance as may be seen in FIG. 2.
To this effect, the coupling means 16 is formed of a split stud capable of radial deformation and formed of material from the pellet 10. The watch is fastened by means of a coupling member 32 provided with a hole 34 in which the coupling means 16 is snap engaged and from clamps 36 retaining the watch 30 by its case.
The support shown in FIG. 3 likewise comprises a pellet 10 with an upper face 12 and a lower face 14, a coupling means 16 and a layer of adhesive material 18 which covers the lower face 14 with interposition of a layer of flexible material 20. The pellet 10 in the same manner exhibits grooves 22. The latter are no longer parallel but form a triangle at the center of which may be found the coupling means 16. The arrangement of three grooves in a triangle enables the adaptation of the support to a warped surface, for instance a headlight, a fuel tank of a motorcycle or a vase.
The support shown on FIG. 4 differs from the two previous embodiments insofar as it includes a central portion 10a of cylindrical form and two outer portions 10b in the form of a sector of a crown surrounding the central portion 10a. The outer portions 10b are coupled to one another by two bridges 38 thus defining two grooves 40. Bridges 42 furthermore couple the bridges 38 to the central portion 10a of the pellet. They are to be seen in the elongation of bridges 38.
A support of this type may be fixed to a body having a ridge or into a corner.
Although not shown on FIGS. 3 and 4, it is self-evident that the supports may likewise be provided with slots facing the grooves.
Supports according to the invention could furthermore be formed in accordance with numerous further variants. Thus the outer portions 10b of pellet 10 could have a thickness less than that of the portion 10a without weakening the support.
The support could also include a greater number of grooves. It would thus be possible to add to the support of FIG. 3 an additional groove parallel to one of grooves 22.
In the various embodiments which have been described, the pellet 10 may advantageously be formed of an acetal resin such as Delrin 100ST of the Dupont de Nemours Company (USA). The layer of flexible material may be of polyethylene, or polyvinyl or polyurethane, the two surfaces of which are coated with an acrylic glue.
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The support of this invention includes a pellet of rigid plastic material. The pellet has two opposed faces one of which bears a coupling means, the other being covered by a layer of adhesive material with an interposed layer of flexible material. The pellet exhibits grooves defining flexure zones. The support may thus be fastened to non-planar surfaces.
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CROSS REFERENCES
This application is a continuation in part of and incorporates by reference in its entirety U.S. Utility application Ser. No. 10/159,489 filed May 31, 2002, which claims the benefit of U.S. Provisional Application Ser. No. 60/349,883. This application also claims the benefit of U.S. Provisional Application Ser. No. 60/408,689 filed Sep. 5, 2002.
FIELD OF THE INVENTION
The invention relates generally to the field of computer security, and in particular to providing security for information stored on a computer server.
BACKGROUND OF THE INVENTION
The pervasiveness of the Internet has allowed information to become available to a user anywhere and at anytime. A user can store his/her personal information, for example, an address book and family photos on a Web server and be able to access the personal information from, e.g., a home personal computer (PC) or from a cell phone while on vacation in a foreign country. However, unauthorized users, e.g., hackers, also have an increased opportunity to access the user's personal information to, for example, copy, delete, or modify, the user's information.
Despite the growing number of hackers ranging from mischievous teenagers to hardened criminals, the typical Web site has minimal security. A typical Web site has the user's information stored on an on-line database connected to the Web server. A user accesses his/her data via a user ID and a password. The password file is also stored on the Web server. Both the password file and all the information in the database are vulnerable to a hacker. As users begin to store sensitive information such as credit card numbers or personal medical information, on a Web site, this minimal security is inadequate.
In the case of a person's medical records, there are significant advantages to having a person's medical records available on-line, i.e., accessible on a Web server via the Internet. For example, when a person visits a specialist or a physician that is not adequately familiar with the person's medical history and/or current conditions, treatments and medications, a commercially available service is available that will allow the specialist or physician to receive and review information, including the clinical records that have been prepared by the person's previous or other current health care providers, that could indicate the cause of the current problem, help avoid redundant or unnecessary tests and conflicting or ineffective treatments, and help reduce the possibility of adverse drug reactions. However, a person's medical records are particularly sensitive and patients need to be sure of security measures before their records are available for on-line access. Conventional web servers with their on-line databases and password files provide little assurance that a person's medical records will remain secure.
Therefore what is needed is a computer security system which significantly reduces the risk of unauthorized access via the Internet to sensitive information, for example, a user's personal information and more specifically, to a person's medical records stored in a database.
SUMMARY OF THE INVENTION
The present invention provides a system and method for protecting sensitive information, for example, a user's personal information, stored on a database where the information is accessible via a communications network such as the Internet. An exemplary embodiment stores the sensitive information on an off-line server. The off-line server is connected to an on-line server. The on-line server is connected to the user via the Internet. The user interfaces with the on-line server, and at a scheduled time window, the sensitive information is made available to the on-line server by the off-line server. Outside of the time window, none of the sensitive information is kept in the on-line server nor can the information be accessible from the on-line server. Thus by placing the sensitive information on-line for only limited periods of time the risk of compromise to the sensitive information is greatly reduced.
One embodiment of the present invention provides a method for securing information stored on a computer system. First, a user ID and a personal password are created for a user to access the computer system. Next, an access code is generated in response to the authenticated and authorized user scheduling a start time and duration at which to access the information on the computer system. At least at the scheduled start time, the computer system receives the access code and personal password from the user, and responsive to the access code and personal password, the computer system allows the user to access the information for the duration.
Another embodiment of the present invention provides a security system for protecting information stored on a database. The security system includes: a first server computer having the database; a second server computer connected to the first server computer by a first communications path; a user computer connected to the second server computer by a second communications path, where the user computer's only connection to the database is via the second server computer; and an access code generated by the first server computer in response to an authenticated and authorized user scheduling a start time and a duration to access the information on the database. In response to receiving the access code at or after the scheduled start time from the user computer, the first server computer copies a portion of the information to the second server computer, and the copied portion is made accessible to the user via the user computer.
A further embodiment of the present invention includes a security system for protecting information stored on a database. The security system includes: a first server computer having the database; a second server computer connected to the first server computer by a first communications path; a user computer for a user to access the information, where the user computer is connected to the second server computer by a second communications path, and wherein the user computer's only connection to the database is via the second server computer; a phone system, including a telephone connection to the user and a third communications path to the first server computer; and an access code generated by the first server computer after a request by the user via the phone system, where the user enters the access code into the user computer to access the information.
An aspect of the present invention includes a method for providing security for information stored on a first server system, where the first server system is connected to a second server system, and where the second server system is connected to a user computer. First, the first server system generates a code in response to a user scheduling a time period to access information on the first server system and sends the code to the user. At the scheduled time period the second server system receives the code from the user computer system. Responsive to the code, the second server system loads at least part of the information that is stored on the first server system and that has been made available for use by the user computer during the scheduled time period.
Another aspect of the present invention includes a method for accessing information stored on a system having a computer, where the system is connected to a user computer via a communications network. First, a user schedules a time and duration when the user computer is allowed to access information on the system. The scheduling is done via a first communications path of the communications network. Next, an access code is received from the system, where the access code is based on the scheduled time and duration. During the scheduled time period the user computer connects to the system using the access code and a predetermined password. The connecting occurs via a second communications path of the communications network, where the second communications path is different from the first communications path. The user computer has access to the information for the time duration.
These and other embodiments, features, aspects and advantages of the invention will become better understood with regard to the following description, appended claims and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of a client-server security system of one embodiment of the present invention;
FIG. 2 is a schematic of a client-server security system of another embodiment of the present invention;
FIG. 3 is a diagram of the process of a user scheduling an access period of an embodiment of the present invention;
FIG. 4 is a diagram of the process of a user accessing information during the pre-scheduled time period of one embodiment of the present invention;
FIG. 5 is an example of a document log sorted by medical sub-category of an embodiment of the present invention; and
FIG. 6 is a display of an example document from a patient's medical records.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, numerous specific details are set forth to provide a more thorough description of the specific embodiments of the invention. It is apparent, however, to one skilled in the art, that the invention may be practiced without all the specific details given below. In other instances, well known features have not been described in detail so as not to obscure the invention.
One of the major problems with sensitive information located on a Web server is that the sensitive information is continuously on-line, i.e., directly accessible via the Internet, and highly vulnerable to attack by unauthorized users such as hackers. A preferred embodiment of the present invention reduces the risk of comprise by putting the sensitive information on-line only for fixed periods of time called “access periods.” The remainder of the time the sensitive information is stored off-line.
One type of sensitive information is a patient's medical records. In one embodiment Internet access to the patient's medical records is restricted to authorized users only during access periods scheduled in advance by the patient or certain other designated users. Scheduling of access periods is performed by a voice telephone request and is therefore independent of the Internet Web Server. The caller making the voice telephone request can be authenticated as an authorized user of the sensitive information by a voice-print recognition process, by a process making use of a telephone-based token, or by traditional combinations of user ID and password. This greatly reduces the possibility of unauthorized access to a patient's medical records by the typical Internet hacking techniques. Further the medical records are not available on the Internet web server until an authorized user logs onto the web server with the appropriate authentication. The information is removed from the Internet web server when the authorized user logs off from the Internet web server (either explicitly logging out or implicitly by not accessing the Internet web server for a specified period of time) or the scheduled time period ends.
In the preferred embodiment of the present invention the security system supports multiple levels of user access. The owner of the medical records, identified as the patient, has the most complete set of rights. The patient can create users with surrogate rights. With the exception of access to certain information designated as private by the patient, surrogate users have the same access rights as the patient. In addition to read access to the medical records, the patient and surrogate user have write access to selected portions of the patient's medical and configuration records. Both the patient and surrogate users have the right to create additional users. The other three types of users are the provider that has write access to selected portions of the patient's medical and configuration records, the provider that does not have such write access, and the limited user. The surrogate, provider, and limited users have read access rights to all medical records except the records that the patient has designated as private records or as records not available to certain levels of user access. Table 1 below summarizes the access rights of each type of user to the patient's medical records. The users for each access level in Table 1, i.e., patient, surrogate, provider with write access, provider without write access, and limited, are all considered authorized users.
TABLE 1
Access Rights
Assign
Edit patient's
(create) new
Schedule a
records and
View
users to
specific time for
distribute
View
patient's
access
viewing patient's
records to
patient's
non
Access
patient's
medical records
another
“Private”
“Private”
Levels
account?
online?
party?
pages?
pages?
Patient
YES
YES
YES
YES
YES
Surrogate
YES
YES
YES
NO
YES
Provider-
NO
YES
YES
NO
YES
Level 1
Provider-
NO
YES
NO
NO
YES
Level 2
Limited
NO
NO (*)
NO
NO
YES
(*) The patient or surrogate user must schedule a session for the limited rights user.
The time during which a patient's medical records are accessible on-line, i.e., the access period, is scheduled by voice and menu-based telephone instructions to a service provider's fully automated voice recognition unit (VRU) or service provider agent. The patient and the surrogate user can schedule access periods for all users in Table 1. The provider can schedule his/her own access period. Access periods for limited-rights users are available only when scheduled by a patient or a surrogate user. Note that a patient's medical records are not on-line during the entire access period, but only need to be on-line when an authorized scheduled user is logged into the Internet Web Server.
FIG. 1 is a schematic of a client-server security system of one embodiment of the present invention. An authorized user 110 , having a telephone 112 and a personal computer (PC) 114 , is connected to a service provider operations center 130 . The service provider operations center 130 , includes a customer service center 132 having telephone 134 and PC 136 , a backend server 140 with associated user information database (DB) 142 , and a security router 138 connected to backend server 140 . The backend server 140 is connected to PC 136 in customer service center 132 . The authorized user 110 uses telephone 112 to contact the service provider via telephone 134 in customer service center 132 using a public telephone connection 128 . A customer service representative of the service provider first authenticates that the caller is an authorized user and then receives the authorized user's scheduling request on telephone 134 . Next, using PC 136 , the customer service representative schedules a time period on backend server 140 during which the authorized user will be able to access the user information, e.g., a patient's medical records that are stored on user information DB 142 . In an alternative embodiment the customer service center is fully automated, using for example a voice recognition unit (VRU), with a voice-print matching process to authenticate the identity of the caller, and menu-based processes for authentication of callers, scheduling of on-line access times, and delivery of session access codes to authorized users. At the scheduled time, the authorized user 110 logs on to Web server 120 using PC 114 , where PC 114 is connected to Web server 120 via Internet 118 . In the preferred embodiment the Web server DB 120 has only a subset of the user information available, where the subset includes links back to the user information DB 142 for the rest of the user information. In an alternative embodiment a full set of the requested user information, e.g., medical records, is copied from the user information DB 142 to the Web server DB 122 . In this embodiment, the backend server 140 initiates the copy process as a result of scheduling instructions received from the customer service center and without any prompts or communications from the authorized user 110 via Internet 118 and security router 138 . In yet another embodiment only a subset of user information is on Web server DB 122 and only as a user request more information is the requested information and only the requested information copied to the Web server DB 122 from the user information DB 142 . Another authorized user 144 may also schedule an access period with customer service center 132 via telephone 134 and access information at a time scheduled by user 144 on Web server database 122 via Internet 118 . Web server 120 and Web server DB 122 are typically operated by the service provider.
In order to increase secure communications, several IP security checks have been implemented. First, only communications between the web server 120 and the backend server 140 are allowed to pass through the security router 138 . Second, the backend server 140 only accepts external database requests that originate from the web server 120 IP Address. And third, the web server 120 only accepts schedule requests and user database information from the backend server 140 IP Address.
A significant security feature of an embodiment of the present invention is the use of two separate databases, e.g., web server DB 122 and user information DB 142 . The web server database 122 only contains user information required by an authorized user currently logged into the system. The complete database is stored on the user information DB 142 . The fact that only a small fraction of the database is stored on the web server 122 for only limited periods of time, significantly reduces the user information that is at risk, if there is a successful unauthorized penetration of the Web Server 120 .
Another significant security feature of an embodiment of the present invention is the use of two or more separate communication paths, e.g., a first primary communication path via telephone connection 128 and a separate primary communication path via connection on Internet 118 . The first primary communication path is used for authentication of authorized users of specific information that is stored on user information DB 142 , and for scheduling time periods to access such information. The first primary communications path, or a secondary communication path, can be used to communicate an access code to the authenticated caller. The access code enables the authorized user to initiate use of a second primary communications path that can access information that has been copied from user information DB 142 . A third primary communication path, controlled by the service provider, can be used to schedule the movement information stored on user information DB 142 , via the backend server 140 , to web server 120 and web server DB 122 . The use of multiple communications paths allows for the combination of authentication based on voice communication with Internet-based user access to protected personal or sensitive information. The use of such multiple communication paths, and the associated authentication and information-access processes, make it much more difficult for hackers to obtain unauthorized access to information that can be readily available on the Internet to authorized users. This result is attributable to the fact that many of the methods that could be used by hackers to obtain such unauthorized access to Internet-accessible information become much more complex and difficult to implement successfully in the context of such a multiple-communication-pathway security feature.
The two significant security features described in above paragraphs [0027] and [0028] can each, independently, reduce the risk of unauthorized access to information that, in authorized situations, is readily accessible via Internet 118 . In combination the two security features increase the effort required to obtain unauthorized access while at the same time reducing the amount of sensitive information that could be obtained if there were a successful unauthorized penetration of the Web Server 120 . By increasing the effort required and also reducing reward obtained, i.e., the amount of information accessed, if there were a successful penetration of Web Server 120 , the two security features, working in combination, also reduce the risk that user information will be compromised because they significantly reduce the incentives for hackers that are hoping to benefit economically from their hacking efforts.
FIG. 2 is a schematic of a client-server security system of another embodiment of the present invention. Authorized user 210 , having telephone 212 and PC 214 , is connected to service provider operations center 230 by a public telephone connection 228 and a separate Internet connection 226 , where telephone 212 is connected to telephone 234 equipped with a VRU and PC 214 is connected to security router 238 via Internet 218 . The service provider operations center 230 , includes a customer service center 232 , having telephone 234 and PC 236 , a backend server 240 with an associated user information database (DB) 242 connected to customer service center 232 , a user-only Web server 243 , including associated Web server database 222 , connected to backend server 240 , and security router 238 connected to the user only Web server 243 . Security router 238 is connected via Internet 218 to public Web server 220 . Authorized user 210 views publicly available information on public Web server 220 . At the scheduled time, when authorized user 210 logs on to public Web server 220 via PC 214 , authorized user 210 is re-directed to the user-only Web server 243 which is inside the security router 238 . Once logged on, the authorized user 210 communicates directly with user-only Web server 243 and accesses Web server DB 222 . Web server DB 222 has available a subset of the user information with the rest of the user information indirectly available on user information DB 242 for the scheduled time period.
FIG. 3 is a diagram of the process of a user 310 scheduling an access period of an embodiment of the present invention. When an authorized user desires access to information stored on backend server user information DB 142 or 242 , e.g., a patient's medical records, at step 320 , the user 310 calls the customer service center 132 or 232 to request on-line access to the information. In the case of medical records, the user must be a patient, surrogate user, or provider to schedule an access period for on-line access of a patient's medical records. At step 322 the service provider's customer service center 132 or 232 answers the call and requests information to authenticate the caller's authority to access information stored on user information DB 142 or 242 and their authority to schedule information access periods (step 324 ). The information provided for authentication is used by the service provider 312 to determine the caller's identity, and their authority to access user information and schedule information access periods. The authentication access information can include a user ID (e.g., a patient's service provider member number or a login name) and a previously assigned personal password, or a voice print recorded from the caller that is verified as matching a voice print from user 310 that is already on record with service provider 312 . At step 326 , the user (e.g., patient, surrogate user, or provider) receives the authentication request and at step 328 , sends to the customer service center 132 or 232 , the user's ID and requested authentication information. At step 330 , the customer service center 132 or 232 authenticates the caller using the user's ID and requested authentication information which should match the user's ID and authentication information stored in the user information database 142 or 242 . In the preferred embodiment, a voice-print based authentication process is used, and the caller is prompted or asked to say a name or other word or phrase that will allow the service provider 312 to compare the recorded voice print from the caller to the voice print of the specified user that is already on record with the service provider and stored in the user information DB 142 or 242 . In another embodiment, a password-based authentication process is used, and the password match is done by first doing a one way encryption, e.g., using a hash function, of the password and then comparing the encrypted password to a table of encrypted passwords stored in the user information database 142 or 242 . The unencrypted passwords are not stored on any of the databases. Hence even if the encrypted password file is stolen, decrypting the file to get the original unencrypted passwords would be extremely difficult. When, at step 330 , there is a User ID and voice print match or a User ID and encrypted password match, at step 332 the customer service center 132 or 232 requests a time window for on-line access from the user, which is received at step 334 by the user 310 . If the person who is going to view the patient's medical records has limited access, then the patient or surrogate user tells the customer service center the name, i.e., User ID, of the limited user who will access the records at the scheduled time. At step 336 the user sends the access period, i.e., the date/time and duration (and if necessary, limited user name) for on-line access to the customer service center. The customer service center schedules via PC 136 or 236 , the date/time and duration (and if necessary, limited user name) for on-line access to user information on Web Server 120 or User-only Web Server 243 (step 338 ). Backend server 140 or 240 generates a Session ID, i.e., a session access code, and the customer service center sends to the user this Session ID for future use (steps 340 and 342 ). At step 344 the scheduled date/time, time duration, and session ID are stored in user information DB 142 or 242 .
FIG. 4 is a diagram of the process of a user accessing information during the pre-scheduled time period of one embodiment of the present invention. At step 420 at the scheduled time the backend server 140 or 240 loads the user ID and session ID from the user information database 142 or 242 onto the Web server 120 or the User-only Web server 243 . At or after the scheduled time (but before the end of the access period), the authorized user 310 logs on to web server 120 with a user ID, password, and session ID (step 422 ). At step 424 , the Web server 120 or User-only Web server 243 authenticates the user ID and session ID. Upon this preliminary authentication, the password is sent from Web server 120 or User-only Web server 243 to backend server 140 or 240 , one-way encrypted, and compared to an encrypted password file by the backend server 140 or 240 . Unencrypted passwords are not stored on the servers, e.g., Web server 120 and backend server 140 , nor any of the Databases, e.g., DB 122 and 142 . In an alternative embodiment the password is encrypted on Web server 120 or User-only Web server 243 before being sent to backend server 140 for comparison. Upon authentication of the password, backend server 140 or 240 loads a subset of the user information from user information DB 142 or 242 onto Web server DB 122 or 222 . For example user information DB 142 may have a patient's complete set of medical records which are indexed by a document log. The document log includes hyperlinks to pages in the patient's medical records. In this case, the subset of user information which is loaded on to Web server DB 122 includes the document log. Other subset information may include the patient's name, patient input forms, patient health information summary reports, and clinical summaries of the patient's health collected from the patient's health care providers. At step 432 the authorized user uses the subset, for example, selects a hyperlink in the document log, to access the rest of the set of user information stored in the user information database 142 or 242 , for example the scanned medical record page associated with the hyperlink. The backend server 140 or 240 provides the rest of the set of user information when requested by the user, e.g., the user selects a hyperlink (step 434 ). This indirect access to a user's information on DB 142 or 242 reduces the exposure to hackers compared to the conventional Web server which has the user's information available directly on Web server DB 122 . The user may explicitly log off or implicitly log off, i.e., the PC 114 or 214 remains idle for predetermined amount of time (step 436 ). The backend server 140 or 240 will terminate the connection 126 or 226 when the user explicitly or implicitly logs off or the scheduled time period expires (step 438 ). At step 440 , the subset of user information, the user's ID (including patient's service provider member ID and login name) and session ID are removed from the Web server database 122 or 222 .
A significant security feature of the above embodiment of the present invention is that there are two separate codes needed to access the user information: a voice print or a personal password that is user specific and a Session ID which is specific to the particular access period. In addition the communication path, e.g., public telephone path 128 , to obtain the Session ID is different than the communication path, e.g., Internet path 116 and 124 , to logon to the Web server 120 at the scheduled time. Both of these security measures either alone or in combination significantly reduce the risk of an unauthorized access to user information.
As an example of the subset and set of information stored in the Web server DB 122 and User Information DB 142 during the scheduled access period by a user is illustrated in FIGS. 5 and 6 below. FIG. 5 shows a document log that is loaded as part of the subset of information stored on the Web server DB 122 . FIG. 6 shows one of the medical records stored on the user information DB 142 that is displayed on user PC 114 , when a hyperlink is selected by the user from the document log.
FIG. 5 is an example of a document log sorted by medical sub-category of an embodiment of the present invention. The pane 552 in window 550 includes the document log sorted by the medical sub-categories, e.g., “Medications & Allergies,” “Patient Intake Applications,” and “Physical Exams.” Column 554 gives the document ID for each document of a patient's medical records stored in user information DB 142 . Cell 570 has document ID 457 , which is a hyperlink to the document image. When link “ 457 ” is selected a separate window ( FIG. 6 ) opens with the document's image. The pane 552 further includes, column 556 , which has the date the document was created, e.g., Jun. 15, 1999, column 558 , which has the healthcare provider that provided the document, e.g., Dr. Jane Doe, column 560 , which has the “Page Category,” e.g., medical sub-category and the primary “Sort Key,” and in this example, “Physical Exams,” column 562 , which has the name of the doctor who created the document, e.g., Jane Doe, M.D., and column 564 , which has the specialization of the doctor in column 562 , e.g., Internal Medicine.
FIG. 6 is a display 610 of an example document from a patient's medical records. The document ID is 457 as shown by label 620 . The document includes two parts, the scanned and indexed image of a Physical Exam record 612 and a comment section 614 for patient or doctor comments. The document is displayed when hyperlink “ 457 ” 570 is selected in FIG. 5 .
Although specific embodiments of the invention have been described, various modifications, alterations, alternative constructions, and equivalents are also encompassed within the scope of the invention. The described invention is not restricted to operation within certain specific data processing environments, but is free to operate within a plurality of data processing environments. Additionally, although the invention has been described using a particular series of transactions and steps, it should be apparent to those skilled in the art that the scope of the invention is not limited to the described series of transactions and steps.
Further, while the invention has been described using a particular combination of hardware and software, it should be recognized that other combinations of hardware and software are also within the scope of the invention. The invention may be implemented only in hardware or only in software or using combinations thereof.
The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. It will, however, be evident that additions, subtractions, deletions, and other modifications and changes may be made thereunto without departing from the broader spirit and scope of the invention as set forth in the claims.
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A system and method for protecting sensitive information, for example, a user's personal information, stored on a database where the information is accessible via a communications network such as the Internet. An exemplary embodiment stores the sensitive information on an off-line server. The off-line server is connected to an on-line server. The on-line server is connected to the user via the Internet. The user interfaces with the on-line server, and at a scheduled time window, the sensitive information is made available to the on-line server by the off-line server. Outside of the time window, none of the sensitive information is kept on the on-line server. Thus by placing the sensitive information on-line for only limited periods of time the risk of compromise to the sensitive information is greatly reduced.
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RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 09/738,180 filed Dec. 15, 2000 now U.S. Pat. No. 6,522,977 which claims the benefit of U.S. Provisional Application Ser. No. 60/172,473 entitled “Computer-Implemented Method and Apparatus for Matching Paint” filed Dec. 17, 1999.
BACKGROUND OF THE INVENTION
The present invention is directed to a computerized method for matching paint on vehicles and a networked computer system for implementing the method.
Matching the original paint color on vehicles being repaired is an inexact process in which a person attempting to match the paint often must rely on trial and error processes by which the paint is matched. In spite of the availability of computerized color matching aids, the painter at a body shop often must ultimately resort to “eyeballing” the paint in order to achieve an acceptable match. This results in an inefficient process that can significantly affect labor cost in a typical body shop.
A number of methods have been devised to automate the process of paint matching. A typical automated method uses a device (e.g., a spectrophotometer) that measures certain qualities of the painted surface, such as reflectance at one or more wavelengths and at different angles, and automatically matches the measurements to those archived in a computer database in connection with paint formulas. In this method, the computer database is located at the repair facility. The paint formulas are then used to prepare a paint and the paint is compared to the original paint on the vehicle. If the paint matches, the area is painted. If not, the paint formula is adjusted manually by trial and error until a match is made. These processes are described in U.S. Pat. Nos. 5,668,633 and 5,841,421. The difficulty in these processes is that there is no assurance that the new formulation is entered into the local body shop's database, and no assurance that each computer database at each body shop will be updated. It is common in the automotive body repair industry to find most computer paint databases are not kept up-to-date They are updated sporadically, and with limited feedback from the body shop to the manufacturer of the paint matching system.
Automobile paint color variability within the same nominal color is typically due to slight variations in color in the paint formulations used by the original equipment manufacturers (OEM). These variations may occur from one manufacturing location to another manufacturing location, or from one production run to another of a given color on the same vehicle model, or even during the course of a particular production run. Although these differences may be unnoticeable on separate vehicles, when they are present on adjacent body panels of the same vehicle, the differences can be visibly perceptible. These color variations make it difficult to attain excellent color matching in repair shops.
SUMMARY OF THE INVENTION
The present invention provides a system for matching paint color on a vehicle being repaired in which remote terminals located at a large number of repair shops transmit color readings and associated individual vehicle identification information to a central computer system. The central computer system includes a processor and a data storage device that contains a database of color data associated with particular vehicles and corresponding paint tinting information. After determining a recommended tinting formulation calculated to be a best known match to the measured color, the tinting formulation is transmitted to the remote terminal, and the repair shop formulates the paint and sprays the area to be repaired. Subsequently, the shop takes a color reading of the repaired area and transmits this second reading to the central computer system. The second reading is then processed to determine the accuracy of the recommended tinting formula, and correction data stored to be implemented in future tinting formula recommendations. In this manner the accuracy of the database is continually upgraded by means of large numbers of readings transmitted from the field.
The individual vehicle identification information may also be employed in the calculation of recommended tinting formulations, thereby improving the accuracy of the color match by taking into account variations in a manufacturing run of nominally the same color. By tracking trends in these variations in association with individual vehicle identification information, subsequent color matches can be made substantially more accurately for vehicles identified as having been part of the same manufacturing run.
The system of the present invention may optionally include an automated merit system for inducing repair shops to transmit color readings of completed jobs. This may entail a register for storing merit points for each repair shop and automatically adding merit points to the register for the shop each time it transmits a second color reading transmitted to the central computer for a particular vehicle. Accumulated merit points at certain levels may then be utilized as a basis to provide financial or other rewards to repair shops attaining target levels. Alternatively, the system could operate to register demerits for failure to transmit a second color reading with avoidance of predetermined demerit levels being a condition for continuing as an authorized member of the color matching system.
Thus it can be seen that an object of at least some aspects of the present invention involves providing a method and system for color matching vehicle paint colors that account for trends in colors over a production sequence. It is an object of other aspects of the present invention to provide a color matching method and system that updates automatically based on a large amount of feedback from a large number of sources, thereby yielding a highly accurate system.
The central computer system comprises a processor; one or more input ports for receiving scanned paint data and individual vehicle identifying information; an output port or device for communicating information to one of an output device, a remote terminal and/or a second computer; a storage means in which a database is stored in which paint formulations are stored in connection with vehicle identifying information for specific vehicles; software for implementing a process that compares vehicle identifying information received through said one or more input ports to vehicle identifying information stored in the database and determines a best match paint formulation based upon the comparison.
The system also includes a plurality of remote terminals for communicating to the central computer vehicle identification data and color data, such as reflectance data obtained from the surface of the vehicle being repaired. Each remote terminal may include a processor, one or more input ports for receiving color data and vehicle identifying data, an output port or device such as a modem for communicating information to the central computer system. Although inclusion of data storage means in association with the remote terminal is not precluded, it is an advantage of the present invention that the remote terminals need not be provided with substantial data storage or data processing capacity as is required for prior art systems that maintain a color matching database at each repair shop. Appropriate software may be included with the remote terminal for reading the data and transmitting it digitally to the central computer.
The system can also include software for implementing additional processes. For instance a process can be provided for collecting and analyzing physical measurements taken from a repaired surface of the vehicle and determining whether a given paint match was accurate. The system can include statistical processes for analyzing the accuracy of the paint match and for identifying paint measurements that indicate errors or malfunctions in obtaining the paint measurements at the remote location and/or errors in the formulation of the paint by the computer.
A computer-implemented method for matching paint is also provided that includes the steps of obtaining vehicle identifying information and paint measurements from a vehicle to be repaired and determining a best match paint formulation based at least partially on the vehicle identifying number of the vehicle to be repaired. The determination of a best match paint formulation can be made by comparison with, and in reference to, data stored in a central database that contains vehicle identifying information stored in connection with paint formulas and/or physical measurements taken from other repairs. Once the vehicle is repaired, paint measurements from the repair can be obtained and compared to the initial paint measurements. The information obtained from the scans can then be stored in the database to aid in prediction of paint formulations based upon the vehicle identifying information of the vehicle to be matched by increasing the number of data points in the central database.
The regular updating of the database provides each user at each remote location the benefit of the data obtained by matches determined for other users. A further advantage is that centralized management of color matching data is made possible, thereby eliminating the need to periodically update data on personal computers at a large number of repair shops. This also results in better control of the integrity and security of the data stored in the database.
It is another unique feature of this invention that it can be configured to provide for a color matching database that is continually being improved by feedback from a very large number of field locations. For example, for a given product line or brand of paint, virtually every use of the paint can be monitored for color accuracy and the color predicting algorithms improved in response thereto to yield continually improving accuracy. For a major product line of auto refinish paint with nation-wide or world-wide distribution, feedback can be expected from hundreds or thousands of repair shops, each typically handling several paint jobs daily. Data that is highly relevant statistically can be derived from such a system.
THE DRAWING
FIG. 1 is a flow diagram of the typical operation of an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The individual vehicle identification information used in the present invention may be any unique identifying number (such as a serial number) or other indicia associated with a particular automobile, usually affixed to the vehicle by the manufacturer. For example, many automobiles include a “Vehicle Identification Number” (VIN) that is visible from the exterior of the automobile through the lower edge of the windshield. Because use of the VIN system is extensive on automobiles, it is currently the preferred identification information for use in the present invention. The VIN will be frequently referred to herein as the exemplary individual vehicle identification information, but it should be understood that any alternative identification system used regionally or which may supplant the VIN system in the future can be used in place of or in addition to the VIN system. It should also be apparent that the present invention may be practiced with any product being painted for which an accurate color match is desired. In addition to automobiles, other vehicles such as trucks, motorcycles, boats, airplanes and recreation vehicles sometimes require accurate color matching. But the objects being painted need not be limited to vehicles, nor are repairs the only occasion in which the invention may find utility.
The automobile VIN is typically (but not exclusively) a seventeen character alphanumeric identifier that provides the following information about the vehicle:
Positions 1-3
World Manufacturer Identifier
Position 4
Restraint System Type
Positions 5-7
Line, Series, Body type
Position 8
Engine Type
Position 9
Check Digit
Position 10
Model Year
Position 11
Assembly Plant
Positions 12-17
Production Sequence Number
This information is employed in the present invention to track and to permit modeling of trends in coloration in coating. Consequently, the identified trends and models can be used to predict color formulations for use in repair of a vehicle with increased accuracy. Although the present invention is described in connection with a VIN, any vehicle-specific designation that can be used to identify the location of the vehicle in a production sequence may be used to determine a best match color formulation according to the present invention.
One embodiment of a system for implementing the method of the preset invention includes a central computer and a number of remote terminals. The remote terminals include a scanning device for obtaining coloration data, such as without limitation reflectance data, from a painted surface of a vehicle and a VIN input device for obtaining a VIN number from a vehicle. The remote terminals also include a remote storage means for temporarily storing the obtained data and a communication device, such as a modem, for transmitting the obtained data to the central computer
In this embodiment, the central computer includes one or more input and one or more output ports, which can be the same port(s), a processor and software for implementing the paint match according to the method of the present invention. In connection with the central computer is a central storage device by which a database is stored. The database includes data that is used to determine a requested color match. The data transmitted to the central computer can be stored, at least temporarily, on the central storage device or on a secondary central storage device.
Referring to FIG. 1 , the present invention in its most basic form utilizes a network of remote terminals into which vehicle-specific information is supplied corresponding to the particular vehicle being repaired. FIG. 1 shows a flow diagram of the method of the present invention as used by one such terminal. This vehicle-specific information, particularly in the case of an automobile, may include the VIN number for that automobile, which may be manually input or scanned into the remote terminal in step 10 . Additionally, paint color data is input into the remote terminal by scanning a sample of the paint to be matched with an appropriate color-measuring device (e.g., a spectrophotometer) in step 12 . The remote terminals may store the information temporarily. In step 14 , the information on the VIN and paint color is transmitted to the central computer. A best match paint formulation is determined by a paint matching process that may be performed in the remote terminal but preferably is performed in a central computer in step 16 . When the paint matching process is performed at the central computer, the vehicle-specific information is also transmitted to the central computer. The central computer determines the best match and then forwards the best match paint formulation to the remote terminal.
The vehicle-specific information is matched by comparing information parsed from the VIN number with paint formulation information and physical data stored in connection with VIN information for other vehicles in a storage device, such as a hard drive. The storage device is connected to or integral with the remote terminal or the central computer. A paint formulation is recalled by this process and communicated to the user of the reading device. If no close VIN number is identified, the paint formulation can be interpolated or extrapolated based upon scanned physical data for known paint formulations that are stored in the database. In making a decision on the propriety of a match, the central computer weighs differentially the data provided in the VIN number and the scanned data to provide an accurate match. Greater weight is given to the VIN information when there is one or more close VIN numbers stored in the database.
Once the best match paint formulation is communicated to a remote user by an output device in step 20 , such as a display or a printer, the user prepares the specified paint formulation and the vehicle is repaired. The amount of paint used by a paint shop in repairing a vehicle can be monitored in step 22 with a smart scale which confirms the weight of the components used to prepare the paint, the accuracy of the formula and monitors the inventory of paint components at the repair shop. When the paint has cured or dried, the repaired area of the vehicle is scanned by the color measuring device in step 24 , color data regarding the newly painted area is transmitted to the central computer in step 26 , and the accuracy of the match is determined by comparing the first set of color data (from the original paint) with the color data scanned from the repaired paint area in step 28 . If the match is accurate (within a pre-determined range of accuracy), the vehicle identifying information and the corresponding paint formulation are recorded in the database for use in future matches. If the match is not accurate, the data is applied to a correction algorithm to improve future matches involving the same family of vehicles. More weight can be given to paint formulations stored in the database in connection with VINs having a close Production Sequence Number to the Production Sequence Number parsed from the VIN of the vehicle to be repaired.
The steps, components and operation of the present invention are described in further detail hereinafter.
Remote Terminal
The remote terminal used in steps 10 and 20 comprises a paint scanning device, for example, without limitation, a spectrophotometer or calorimeter, a vehicle identifying input device, one or more input and output ports (I/O ports) and a remote storage means. The remote terminals can be located at a large variety of vehicle repair shops that are geographically remote from each other, world-wide, with no theoretical limit to their number. This number can be substantial considering the large number of body shops, world-wide. All reading devices are in communication with a central computer. The means by which each reading device communicates with the central computer may vary and is limited only by the number of available means by which one computer can communicate with another. The communication can be, without limitation, direct through a local area network (LAN) or other direct hard-wired communication systems, over a wide area network (WAN), through a modem over standard telephone lines or by wireless communication through cellular telephone networks, or otherwise or through a variety of combinations of these or other known computer communication methods, including the global computer communications network referred to as the Internet. Encryption may be employed to preserve the confidentiality of proprietary information.
Paint Scanning Device
A typical paint scanning device used in step 10 is a handheld device that includes a device that measures the reflectance of a paint sample over the visible spectrum (about 300-700 nm). The measurement can be made at a number of angles (i.e., 3-5 different angles). Optionally, other physical data regarding the original finish of the vehicle can be measured by separate devices, such as gloss (i.e., at 60 degrees), depth of image and orange peel. These separate devices may be integrated into a single unit. The paint scanning device, the vehicle identifying input device, the I/O ports and the remote storage device may be provided as separate units in communication with, or capable of communication with each other, or they may be partially or completely integrated into one or more units, such as a handheld unit.
This data obtained by the paint scanner and the vehicle identifying input device is stored in memory (i.e., random access memory, RAM) or in a storage device, collectively termed a “remote storage means,” in the remote terminal. The remote storage means can be integral with the reader or provided as a separate device in direct local communication with the reader, such as a personal computer or another stand-alone storage device. Paint scanners (i.e., calorimeters) and vehicle identifying input devices (i.e., alphanumeric keyboards or keypads) are available commercially and can be custom designed to fit into a single handheld device. Non-limiting examples of paint scanners are described in U.S. Pat. Nos. 4,771,580 and 4,853,879. Storage devices include any device that can store computer information either temporarily or permanently. Such devices include, without limitation, hard drives, diskettes, CD-ROMs, DVD ROMs, magnetic tapes, high capacity removable disks and other magnetic or optical storage devices onto which computer data may be temporarily or permanently recorded and read at a later time.
Vehicle Identifying Input Device
The vehicle identifying information is provided in step 20 by a vehicle identifying input device. The vehicle identifying input device can be either a scanner for scanning the vehicle identifying information as an image, an alphanumeric keypad or keyboard, other input device compatible with the particular vehicle identifying system The keypad or the vehicle identifying scanner can be integral with or separate from the reader. If the vehicle identifying information is to be scanned as an image, a simple scanner can be provided, either integral with the reader, or as a separate device. Optical character recognition (OCR) software or firmware (collectively, an “OCR converter”) can be provided at each remote location to convert the scanned image of the vehicle identifying information to computer recognizable text, such as ASCII text or rich text. The OCR converters can be any computer process that converts a scanned image of a number or a letter into a text character that is recognizable by a computer, such as ASCII Text.
Alternatively, the conversion of the vehicle identifying image to text can be performed by the central computer Rather than providing the OCR converter at each remote location, the central computer houses the OCR converter.
In this embodiment, the vehicle identifying image is forwarded intact to the central computer, which converts the vehicle identifying image to text. Although in this embodiment more data would be transferred from the remote storage to the central computer, this option may be more cost-effective than providing each reader with an OCR converter.
Central Computer
After the vehicle identifying information and physical color data are scanned into the remote terminal and the vehicle-specific information is transferred into the remote storage means, it is compared to data retrievable by the central computer and a first best match paint formulation is provided to the user at the remote location. The first best match paint formulation can be determined either locally at the remote terminal or (preferably) in a central computer. When the determination of a best match paint formulation is to be made at the central computer, the vehicle-specific information is communicated to the central computer, where the match is determined and the formulation is communicated to the remote terminal for use by the user.
Alternatively, the best match paint formulation is determined at the remote terminal and match information is transmitted to the central computer once the accuracy of the match is determined. In this embodiment, each remote terminal would be connected to the database of paint formulations stored in connection with vehicle identifying information and the database at the remote terminal is updated at fixed intervals. The update could be automatic and could be performed after working hours so as to not interfere with operation of the remote terminal during work hours.
The central computer comprises one or more input ports by which data is uploaded from the remote reading devices and/or from other sources, a processor, one or more data storage devices and one or more output ports by which data can be downloaded to the remote reading devices and/or to other locations. The central computer can be a personal computer, a mainframe-type computer, or any type of computer or computer network, so long as it can process data and communicate at a satisfactory rate. The processing and storage capacity of the central computer will therefore depend upon the number of remote reading devices and the level of their activity.
The input and output port(s) can be the same or different device(s) and communicate with the remote reading devices or other devices or locations by the variety of methods described above. The data storage device(s) of the central computer includes a database that comprises the paint matching data. The paint matching data comprises paint formulations, vehicle identifying data, physical paint data, which can include one or more of reflectance data, gloss data, depth of image data and orange peel data and data received from remote reading devices. Other data may be present, such as data or constants that would enable the processes used to generate paint matches and statistical data that can be used by the administrator of the paint matching system to evaluate the accuracy of the paint matching processes.
Databases
It must be recognized that database structures differ as well as the manner in which each given database searches and stores data. The data described herein need not be stored in separate tables or records, or in any particular form so long as the processes of the computer can achieve the described processes. The processes described herein are non-limiting examples with respect to a standard database structure. The manner of establishing the relationship between data is not as critical as the fact that the relationships are established. The following non-limiting description is described in reference to a typical relational database structure in which data is stored in tables and relationships are established between the data in the tables.
In one embodiment of the present invention, paint formulation tables include a list of ingredients that are combined to create a specifically colored paint. The ingredients comprise base paints and tinting compositions that impart a desired color to the paint. Other ingredients may be added, depending upon the nature of the paint. Such other ingredients include, without limitation, reflective pigments (i.e., metallic flakes) other special effect pigments (i.e., pearlescent) and gloss enhancers. Thus, the paint formulation table may include the formulation for a given matching color.
The vehicle identifying data table(s) comprise at least one table which includes unique, vehicle-specific identification data (e.g., VIN numbers). Because certain characters in a VIN number have greater relation than others to the color of the vehicle and to color trending; such as, without limitation, the Assembly Plant and the Production Sequence Number, these data may be parsed automatically and stored in separate tables of fields. However, these data need not be broken out into separate fields to achieve the purpose of the present invention because a process can be applied that can parse the total VIN number for pertinent data.
The paint formulation tables are related to physical data tables based upon actual physical readings from surfaces coated (finished) with the paint product of the paint formulation. The vehicle identifying table(s) are related to the physical data tables and the paint formulation tables. These relationships are based upon readings taken from actual vehicles.
In this embodiment, the central computer is configured with software to implement a process that enables the computer to match paint. When information is received from a remote terminal, it is stored in the central computer in one or more tables. All information received regarding one vehicle is stored in relationship to the vehicle identifying information.
Paint Data Matching Process
Once data is received from the remote reading device, the vehicle identifying information that describes some or all of the vehicle's make, model, year, line, series, body type and assembly plant is matched with vehicle identifying information stored on the central computer to retrieve a first set of matches. The physical data received from the remote reading device, especially the reflectance data, is used to narrow the first set of matches to a second set of matches which optimally contains only those vehicles with the same general paint color (the manufacturer's designated colors, such as those designated by OEM code numbers, hereinafter “OEM colors”). Alternately, the data indicating which vehicles in a production sequence are colored each manufacturer's designated color may be obtained from a manufacturer, since manufacturers typically paint vehicles in batches. Manufacturers'data preferably is transmitted to the central computer in step 30 from vehicle manufacturers and paint manufacturers world-wide.
At this point, the computer process determines a paint match from the second set of data that is limited by vehicle identifying information and OEM color. An example of such a matching operation is as follows. First, if a VIN Production Sequence Number in the second set of matching paint formulations is sufficiently “close” to the Production Sequence Number downloaded from the remote reader, the paint formulation corresponding to the stored close Production Sequence Number is recommended, provided that the physical data stored in connection with the paint formulation matches the physical data obtained from the remote location. If a “close”Production Sequence Number is not available, the formulation is interpolated or extrapolated from paint formulations for other Production Sequence Number in the same production sequence. Lastly, if the paint formulation cannot be interpolated or extrapolated with a predetermined degree of statistical confidence, the paint physical data is used to match the paint by matching or by extrapolation or interpolation.
In the first step, if the production sequence number of the received VIN is close to that of a VIN stored on the central computer, the paint formulation which is related to the stored VIN number is considered to be a best match. A “close” production sequence number may be within a designated production sequence number unit or can be expressed as a percentage of the total vehicles in a given production sequence. The total number of automobiles in any given production sequence is broadly available from manufacturers and/or from VIN searching agencies. It should be recognized that the degree of color trending for a given production series at a given manufacturing facility can vary little or greatly. A close production sequence number for one production series may not be considered close for another.
Literally, a close match is a match that would be considered acceptable to a vehicle owner, and relates to the inability to discern by eye the differences between the vehicle's original paint and the matching paint. Thus, the measurable physical parameters between matching paints for two vehicles with “close” VINs should not differ significantly. Consequently, one sub-process that can be integrated with the matching process would vary the value for “closeness” for any production sequence to account for the degree of trending of color in a production series. For instance, the default setting for a production series may consider a close VIN as one having a Production Sequence Number within a certain number of vehicles. If, over time, there is no color trending seen in the entire production sequence, as determined by either the received color data or the formulation data, the limit for “close” vehicles could be expanded to a larger number of units. If, on the other hand, color trending is seen which is discernable in vehicles with Production Sequence Numbers differing by fewer units than the default, the limit for “close” vehicles can be narrowed.
The software for determining a “match” can be any software program that is capable of matching two data sets and determining whether certain records in one data falls within predetermined ranges, for example and without limitation, lookup functions. The ranges can be set manually by an operator or can be determined statistically. Each parameter can be weighted differently and/or matched in different sequences. For instance, when matching VIN information, the World Manufacturer Identifier might be matched exactly, as might the Line, Series, Body type, Model Year and Assembly Plant data. The Production Sequence Numbers could be matched within a predetermined range, within a percentage of the total number of vehicles manufactured in the same production series of vehicles or manufactured within the same fixed time period. In either case, a sub-process may be made available to calculate the “closeness” of the match of the Production Sequence Numbers. If the matching criterion for the Production Sequence Numbers is based upon a fixed time period, a sub-process must be available which identifies which Production Sequence Numbers were manufactured within the given fixed time period. The production information necessary to run such a sub-process can be obtained from a manufacturer.
The second step of the matching process could optionally be reserved for instances in which the database contains insufficiently “close” individual vehicle information for that particular model, or it may be performed in each color matching cycle, or performed only for selected vehicle groups. This process involves interpolation or extrapolation of paint formulations from known matching formulations. Typically, in such a case most of the VIN information would match exactly, but the Production Sequence Number would not fall within an acceptable “close” range. In such a case, the paint formulations corresponding to other Production Sequence Numbers in the same production sequence can be used to generate a new formulation by interpolation and/or extrapolation of values for each ingredient in the formulation based on the amount of ingredients in the other formulations in the same production sequence. Optionally, chromaticity values for each tinting composition can be drawn upon to determine the best match color formulation. The interpolated or extrapolated formulation can be obtained by implementing interpolation or extrapolation functions that are commercially available in common spreadsheet or database programs. The interpolations are typically obtained by generating a series of curves (i.e., best fit lines) which relate Production Sequence Number to the amount of each Toner (pigment) or other ingredient, such as metallic flakes, used in a given formulation and determining the amount of each ingredient for the Production Sequence Number of the vehicle to be matched. Chromaticity values for tinting compositions can be considered in this process. More than one flanking formulation can be considered in generating the best fit curve for each ingredient of the formulations.
Paint formulations can also be extrapolated. Extrapolation is necessary in two instances. First, if the Production Sequence Number of the vehicle to be matched is greater than or less than that of all formulations represented in the database for a production series, the formulation values must be extrapolated. Second, in the case where the Production Sequence Number of the vehicle to be matched falls between two related Production Sequence Numbers in the database, one or more different ingredients may have been used in the formulations. By generating best fit curves both for those Production Sequence Numbers lower than and/or higher than the Production Sequence Number of the vehicle to be matched, the amount of each ingredient can be extrapolated with reasonable accuracy.
For the purposes of the present invention, a best fit curve for each ingredient can be a line or a more complex relationship. The limits to the complexity of the curve can be preset by the operator to optimize the speed of the system and the accuracy of the prediction.
In certain cases, a production sequence might not be represented by a paint formulation, or a formulation might not be determinable to a predetermined degree of statistical significance by interpolation or extrapolation. In such a case, the process would use the physical data obtained from the vehicle to be matched and would provide a formulation to best match the physical data according to known approaches. The matching sub-process might be similar to that process for matching formulations based upon the Production Sequence Number, but would consider the physical data as well as the VIN information in determining a match. The logic of this process would be the same as the process for matching the formulations based upon physical data, but would use reflectance data, and/or other physical parameters to determine flanking formulations. Other processes and apparatuses are available to calculate matches based upon physical data alone, such as that described in U.S. Pat. No. 4,997,522.
Matching by physical parameters might only be relied upon in determining a match when there is insufficient data to determine the match based upon the VIN information. When the match determination is made based upon the VIN information, the physical parameters can be used only to limit the formulations under consideration to the manufacturer's designated color. However, in one embodiment, the paint formulations provided by the paint matching process may be compared to paint formulations based upon measured physical parameters and weighted variably in calculating a match. The greater the number of VIN data points and the closer the proximity of the Production Sequence Numbers of the VIN data points to the Production Sequence Number of the vehicle under repair, the greater the weight given to the paint formulation calculated by the VIN information. However, when there are less VIN data points, the physical data may be relied upon more heavily to determine the paint formulation. Statistical sub-processes may be employed to determine the potential accuracy of the paint formulation based upon the VIN information and, depending upon predetermined criteria, the respective weighting of the VIN information and physical parameters, paint formulations can be determined automatically.
Once a matching formulation is determined by the central computer, it is communicated back to the remote terminal. The formulation can be displayed on a visual display connected to, or integral with, the reading device or it can be printed by a printing device connected to, or integral with, the reading device. By the phrase “connected to” it is understood that the “connected” devices are in communication with each other by one of many means known in the art, whether “wired” or “wireless”. For instance and without limitation, if the display and/or the printing device are provided separately from the reading device, they can be connected to the reading device by parallel or serial communication, EtherNet, FireWire, USB, SCSI, infrared or other communication means or interfaces.
At this point, the remote user can prepare a paint sample according to the provided formulation and the paint sample can be applied to the vehicle. Once the matching paint is applied to the vehicle, irrespective of whether or not a visual match is made, the user again reads the VIN and the physical parameters of the repaired surface. The remote terminal might be configured to require input of a VIN every time a scan is made of the paint. This data is then communicated to the central computer where it is compared to the original physical parameters measured from the same vehicle in step 12 . If the physical data sets match with a preset degree of correlation, then the formulation, VIN information and physical data can be entered into the database for use in future matches. If the correlation between the physical data is imperfect, or if upon visual inspection of the repair the remote user indicates that a match is not perfect, then the match formulation, VIN information excluding the Production Sequence Number and physical data for that formulation are stored in the database. This results in a data set that is useful when matching, interpolating or extrapolating a paint formulation based upon physical parameters, but not in matching based upon Production Sequence Number. The software in the central computer may be refined to provide a match based on the most popular variant of OE color (a shift from an original color).
In cases where the match cannot be made with any statistical confidence, the paint can be applied to an appropriate test surface or only a small portion of the test vehicle prior to painting the entire surface of the vehicle that must be painted. The application of the paint to a test surface may be recommended automatically by the central computer in situations where the paint formulation is determined by interpolation and/or extrapolation, and especially where a predetermined level of statistical confidence in the match cannot be met.
The remeasurement of the physical parameters of the painted surface after application of the recommended paint formulation is not an automatic process. The remote user must physically measure the painted surface with the reading device. As such, the central computer can record instances of when a remote user measures the repaired surface and tallies these instances. The provider of the paint matching services can then track these instances and can reward the remote user with rebates and/or product credits for taking the time to measure the painted surface, rather than simply accepting that the paints match visually.
An additional process can be integrated with the paint matching and verification processes that identifies data points and data contributed by each individual remote user. Every time a remote user communicates with the central computer, a user identification code can be communicated to the central computer and every data point or record contributed by that user can be tagged with that user's identification code. By this process, the central computer can identify data points that correlate with other data points or data curves to a certain degree of confidence. If a particular user's (either a particular person or repair facility) data points vary too greatly and/or too regularly, the provider of the paint matching services can be notified and field representatives can be sent to the remote user's facility to determine whether the statistical deviation is due to user error or to equipment malfunction. The equipment can then be repaired or the user trained. The tracking by user can be used as a method for implementing a certification program for technicians and/or facilities.
An additional process in optional step 32 can be integrated with the paint matching processes to identify manufacturer's designated colors that are difficult to match over time. This additional process would identify such colors by measuring the correlation between the original paint physical data and the physical data for the matching paint If the correlation between the original and the matching paint falls below a predetermined threshold, a predetermined percentage of time (e.g., correlation coefficient of less than 0.8), the provider of the paint matching service can be notified and appropriate research can be conducted in step 34 to determine how to measure that paint accurately or whether to reformulate a color formula and/or recall that color formula in step 36 .
The accumulation of data points in any given production sequence benefits future users of the system because the greater the number of data points, the greater the confidence of the matches based primarily upon VIN information. Therefore, when the system is first set up, based upon known data points either gathered in the field or determined in the laboratory, more extrapolation and/or interpolation will be conducted than later when the database “matures”. When many data points are available for a given production sequence, certain statistically disparate data points can be ignored and, thus, the accuracy of matching will increase with the system's maturity. As such, for many product lines a “perfect” match can be ensured.
It may be noted that paint application techniques can affect the appearance of the color of a repainted surface. Therefore, “matching” as used herein, is not intended to mean that an absolutely perfect match can be guaranteed, since there are variable factors beyond the control of the color matching system.
It will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed in the foregoing description. Such modifications are to be considered as included within the following claims unless the claims, by their language, expressly state otherwise. Accordingly, the particular embodiments described in detail herein are illustrative only and are not limiting to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof.
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A computer implemented method for matching paint on a vehicle, having the steps of receiving in a central computer, from a remote terminal, vehicle identifying information relating to a specific vehicle and a first set of paint color data from a portion of the body of the vehicle. The central computer includes a processor, an electronic storage means in which a database is stored. The database includes vehicle identifying information for a plurality of vehicles, paint color data associated with respective vehicle identifying information, and paint formulations associated with paint color data. A first process by software in the computer determines a first best match paint formulation which relates submitted vehicle identifying information and submitted paint data to a paint formulation. The software in the computer determines a first best match paint formulation which is transmitted to the remote terminal. The central computer receives a second set of paint color data from the remote terminal representing a surface of the specific vehicle painted with the first best paint formulation and compares by a second process the second paint color data to the first paint color data so as to establish accuracy data. The accuracy data is applied to the first process so as to be implemented in subsequent paint formulation identifications.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. application Ser. No. 13/061,745, filed on Mar. 2, 2011 which is a U.S. National Stage of PCT International Application No. PCT/IL09/00842, filed on Sep. 1, 2009, which claims priority to and benefit of domestic filing of U.S. Provisional Application No. 61/190,712, filed on Sep. 2, 2008, the disclosure of which is also incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to the formation of metal nanowire thin-films.
BACKGROUND OF THE INVENTION
[0003] Applications of thin, transparent and electrically conducting films are numerous. The most attractive application is as a transparent electrode for low-cost photovoltaics and other opto-electronic applications. Light emitting devices often require such electrodes, in particular, large area displays. Currently, the existing technology uses conducting metal oxide films, primarily indium-tin oxide (ITO) and doped zinc oxide for these applications. These films have a limited transparency/conductivity trade-off and are produced by expensive vacuum deposition techniques. Such films are also hard and brittle and may therefore be unsuitable for flexible coatings such as plastic electronics. A flexible alternative that has been considered is a film of a conducting polymer, but such films are much less conductive and more sensitive to radiation and chemical attack and would thus not be good candidates for ITO replacement.
[0004] In recent years, there is a growing interest in finding alternatives for these transparent oxide electrodes. The primary candidates have been carbon nanotube-based electrodes. However, such films could not exceed the performance of ITO films in terms of conductivity vs. visible light transmittance. There are several problems in producing highly conductive, transparent carbon nanotube mesh films. The limited solubility of the tubes makes it difficult to disperse them in various solvents for efficient coating applications. To produce such dispersions, high molecular weight polymer surfactants are required, which produce an insulating or semiconducting layer [1] around the nanotubes and thus significantly increase the inter-tube contact resistance.
[0005] Another alternative is to use pure carbon nanotube meshes or fabrics for this purpose, but here the nanotube density is too high and optical transmission is degraded, and it is thus difficult to integrate such meshes into thin-film devices. The same difficulties hold for other types of prefabricated nanowires made of various oxides and semiconductors.
[0006] Recently, thin conducting films consisting of high aspect ratio nanostructures have been suggested as a substitute for metal oxide based transparent electrodes, particularly in combination with conducting polymer based devices [2, 3, 4]. Such films, made of metallic nanowires have high conductivity while maintaining a metal volume fraction as low as ˜1% and thus are highly transparent.
[0007] Many schemes of synthesizing conducting and semi-conducting nanowires were developed in the last 15 years. A very high control level of the nanowires geometry and composition, including modulation of compositions along or across the nanowires, has been achieved. A control over the position and orientation of the nanowire growth has been achieved in catalytic growth of carbon nanotubes and semiconductor nanowires by positioning of the catalyst particles at selected places. However, the task of forming uniform thin films of such elongated nano-objects to obtain highly conductive meshes over large areas has been more difficult to achieve. High molecular weight polymeric surfactants are required for dispersing the nanowires/nanotubes in various solvents. These polymers usually form insulating barriers over the nanowires, which would then require annealing to reduce inter-wire electrical resistance [2], unless the polymer itself is (semi-)conducting [1, 4].
[0008] Peumans et al., have recently published a first calculation and demonstration of a random silver nanorods mesh electrode as a replacement for a metal oxide film in a polymer based solar cell [2]. Peumans et al used prefabricated silver nanorods with an average aspect ratio of ˜84, coated by a high molecular weight polymer and dispersed in a solvent to prepare the thin conductive film. The film required substantial annealing to reduce the contact resistance between the nanorods, which probably was the primary factor limiting the performance of this film. The film, with comparable transmittance and conductivity to an ITO film, exhibited 19% higher photocurrent when used for the polymer solar cell compared to the ITO analog.
[0009] Gold nanowires have also been prepared in oleylamine, employing a variety of methods.
REFERENCES
[0010] [1] US patent application No. 20080088219, Transparent carbon nanotube electrode using conductive dispersant, Yoon, S. M. et al., 13 Apr. 2007.
[0011] [2] Lee, J-Y., Connor, S., T. Cui, Y., Peumans, P., Solution - Processed Metal Nanowire Mesh Transparent Electrodes, Nano Lett. 8, 689-692 (2008).
[0012] [3] Kang, M. G., Kim, M. S., Kim, J., Guo, L. J., Organic Solar Cells Using Nanoimprinted Transparent Metal Electrodes, Adv. Mater. 20, 4408-4413 (2008).
[0013] [4] Hellstrom, S. L., Lee, H. W., Bao, Z., Polymer - Assisted Direct Deposition of Uniform carbon nanotube bundle networks for high performance transparent Electrodes, ACS Nano, 3, 1423-1430 (2009).
[0014] [5] Lu, X., Yavuz, M. S., Tuan, H-Y., Korgel, B. A., Xia, Y., Ultrathin Gold Nanowires Can Be Obtained by Reducing Polymeric Strands of Oleylamin - AuCl Complexes Formed via Aurophilic Interaction, J. Am. Chem. Soc. 130, 8900-8901 (2008).
[0015] [6] Wang, C., Hu, Y., Lieber, C. M., Sun, S., Ultrathin Au Nanowires and Their Transport Properties, J. Am. Chem. Soc., 130, 8902-8903 (2008).
[0016] [7] Huo, Z., Tsung, C-K., Huang, W., Zhang, X., Sub - Two Nanometer Single Crystal Au Nanowires, Nano Lett., 8, 2041-2044 (2008).
[0017] [8] Pazos-Perez, N., Baranov, D., Irsen, S., Hilgendorff, M., Liz-Marazan, L. M., Giersing, M., Synthesis of Flexible, Ultrathin Gold Nanowires in Organic Media, Langmuir, 24, 9855-9860 (2008).
[0018] [9] Krichevski, O., Tirosh, E., Markovich, G., Formation of Gold - Silver Nanowires in Thin Surfactant Solution Films, Langmuir 22, 867-870 (2006).
[0019] [10] Krichevski, O., Levi-Kalisman, Y., Szwarcman, D., Lereah, Y., Markovich, G., Growth of Au/Ag nanowires in thin surfactant solution films: an electron microscopy study, J. Colloid Interface Sci. 314, 304 (2007).
[0020] [11] Krichevski, O., Markovich, G., Growth of Colloidal Gold Nanostars and Nanowires Induced by Palladium Doping, Langmuir 23, 1496-1499 (2007).
[0021] [12] Jana, N. R., Gearheart, L., Murphy, C. J., Wet Chemical Synthesis of High Aspect Ratio Cylindrical Gold Nanorods, J. Phys. Chem. B 105, 4065 (2001).
[0022] [13] Jana, N. R., Gearheart, L. A., Obare, S. O., Johnson, C. J., Edler, K. J., Mann, S., Murphy, C. J., Liquid crystalline assemblies of ordered gold nanorods, J. Mater. Chem. 12, 2909-2912 (2002).
SUMMARY OF THE INVENTION
[0023] The inventors of the present application, in their pursuit to improve on the deficiencies of the art have developed a finer, higher aspect-ratio (above 1000) homogeneous highly conductive mesh of metal nanowires. The manufacture of these nanowires employed a solution-process whereby the metal nanowires are formed from a solution of metal precursors, which slowly dries into a mesh of nanowires with controllable surface coverage. These metal nanowires made of a metal such as gold, silver, copper, nickel, palladium, and combinations thereof, significantly out-perform many of the nanowires known in the literature, including the silver nanorod and ITO films of the art, by having at least one order of magnitude better conductivity, for visible light transmission levels of 80-90% regularly achieved in such films, e.g., ITO films.
[0024] This invention is, thus, generally concerned with a process for the preparation of a conductive nanowire film (herein referred to as a nanowire film) based on a high aspect-ratio metal, e.g., gold nanowires. The nanowire film is produced by inducing metal reduction in a concentrated surfactant solution containing metal precursor ions, at least one surfactant and at least one reducing agent, forming a thin-film thereof on a surface of a substrate and allowing the film to dry. The metal nanostructures begin forming in the concentrated surfactant solution that progressively becomes more concentrated as the film dries.
[0025] The nanowire film, thus obtained, has metallic conductivity and high transparency to light due to the low volume filling of the metal in the film. These nanowire films find use as transparent electrodes for photovoltaic and other opto-electronic devices (e.g., photovoltaic and light emitting diode devices), as will be further disclosed hereinbelow. The processes of the invention for manufacturing nanowire films are suitable for printing conducting patterns on various surfaces using a great variety of techniques such as ink jet printing.
[0026] Thus, in one aspect of the present invention there is provided a process for the preparation of a nanowire film on a surface of a substrate, said process comprising:
[0027] (a) obtaining an aqueous precursor solution comprising at least one metal precursor, at least one surfactant and at least one metal reducing agent wherein the concentration of the at least one surfactant in said solution is at least 5% (w/w);
[0028] (b) forming a thin-film of the precursor solution, i.e., of step (a), on at least a portion of a surface of a substrate; and
[0029] (c) allowing nanowires to form in said thin-film, on a portion of said surface, e.g., by allowing the thin film to dry;
[0000] thereby obtaining a nanowire film on at least a portion of said surface.
[0030] In some embodiments, the nanowire is conductive.
[0031] In certain embodiments, the process of the invention comprises a step of pre-treating the surface of the substrate to prepare it to better receive the deposition of the solution.
[0032] The pre-treatment may include, in a non-limiting fashion, solvent or chemical washing (e.g., by a non-liquid medium such as a gas), etching, heating, deposition of an optionally patterned intermediate layer to present an appropriate chemical or ionic state to the nanowire formation, as well as further surface treatments such as plasma treatment, UV-ozone treatment, or corona discharge.
[0033] In certain embodiments, the process further comprises the step of post-treating the resulting conductive nanowire film. In some embodiments, the post-treatment involves at least one of washing the conductive nanowire film with an aqueous or organic liquid or solution to e.g., remove excess surfactant, and thermally treating the film, e.g., at a temperature not exceeding 100° C.
[0034] The aqueous solution comprising the at least one metal precursor, at least one surfactant and at least one metal reducing agent, herein referred to as the precursor solution, may be prepared by forming a solution or a mixture (by mixing, admixing) of the components together at a temperature which permits complete dissolution of the components in each other or in an inert medium (such as water), permitting formation of a substantially homogenous solution. It should be noted, that the term “solution” should be given its broadest definition to encompass a liquid state in which one component is fully dissolved in another or in a liquid medium, a liquid state of emulsion (nano- or microemulsion) of one or more components of the precursor solution in another or in a medium, and a state of dispersion (nano- or microdispersion) of one or more components of the precursor solution in another or in a medium. In some embodiments, the precursor solution is a homogenous nano- or micro-emulsion.
[0035] The precursor solution is prepared, in some embodiments, by combining (mixing, admixing) the components at room temperature. In some other embodiments the mixing is carried out at a temperature above room temperature, e.g., in different embodiments the temperature is between 25-100° C., between 25-75° C., between 30-50° C., between 30-40° C., between 40-75° C., or between 50-75° C.
[0036] In some embodiments, the precursor solution is prepared by first forming a solution of at least two of the components, e.g., the at least one first metal precursor and at least one surfactant at a temperature allowing dissolution of one component in the other, or both components in an inert medium such as water (or another medium which permits their dissolution or emulsification), followed by the addition (e.g., by way of admixing) of the at least one other component, e.g., reducing agent and/or at least one second metal precursor, while maintaining the temperature so as to sustain a substantially homogenous solution.
[0037] In some embodiments, the aqueous precursor solution is prepared by first forming a solution of at least one first metal precursor, at least one surfactant and at least one second metal precursor at a temperature allowing dissolution, followed by the addition of at least one reducing agent.
[0038] In some embodiments, the aqueous precursor solution is prepared by first forming a solution of at least one first metal precursor, at least one surfactant, at least one reducing agent and at least one second metal precursor at a temperature allowing dissolution, followed by the addition of at least one second reducing agent.
[0039] The process of the invention is suitable for the preparation of a great variety of conductive metal nanowires. The metal nanowires may be of gold, silver, copper, nickel, palladium, platinum or combinations thereof. The at least one metal precursor is thus a metal precursor containing the element (in any form, e.g., ionic or non-ionic) making up the nanowire. Typically, the metal precursor is in the form of metal ions or in a form which under the reaction conditions dissociates into metal ions. Non-limiting examples of metal precursors are chloroauric acid, HAuCl 4 , as a source of gold; AgNO 3 as a source of silver; (NH 4 ) 2 PdCl 6 as a source of palladium; Cu(NO 3 ) 2 as a source of copper; NiCl 2 as a source of nickel; and H 2 PtCl 6 as a source of platinum.
[0040] In some embodiments, the at least one metal precursor is a single metal precursor. In other embodiments, the at least one metal precursor is a combination of two or more metal precursors or the same metal or of different metals.
[0041] In some embodiments, the metal precursor is a gold precursor, such as chloroauric acid. In other embodiments, the metal precursor is a combination of gold and silver metal precursors. In still further embodiments, the metal precursor is a combination of palladium, silver and/or gold metal precursors.
[0042] The metal precursor concentration is about at least 1 mM. In some embodiments, the concentration is between 1 and 15 mM. In other embodiments, the concentration is between 1 and 10 mM.
[0043] The at least one surfactant may be a single surfactant or a mixture of two or more surfactants. The at least one surfactant is typically selected amongst cationic-type surfactants, typically quaternary ammonium based molecules, such as those having at least one alkyl chain of 10 or more carbon atoms; in some embodiments of at least 14 carbon atoms, e.g., 14, 16 or 18 carbon atoms. In some embodiments, the at least one surfactant has one alkyl chain of between 14 and 16 carbon atoms. In other embodiments, the at least one surfactant is a multi-chain surfactant having two or more alkyl chains, each of between 10 and 16 carbon atoms.
[0044] Non-limiting examples of said surfactant are cetyltrimethylammonium bromide (CTAB), didodecyldimethylammonium bromide, tetradecyltrimethylammonium bromide, didecyldimethylammonium bromide, wherein the bromide counterion, alternatively, may be a chloride or an iodide.
[0045] In some embodiments, the concentration of the at least one surfactant is above 5%, in further embodiments above 10%, in still other embodiments above 15%, and in yet other embodiments, the concentration is above 20%. In some additional embodiments, the surfactant concentration is at most 30%. In additional embodiments, the surfactant concentration is between 7.5 and 21%.
[0046] It should be noted that where various embodiments are described by using a given range, the range is given as such merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible sub-ranges as well as individual numerical values within that range. For example, an alkyl chain having between 10 and 16 carbon atoms should be considered to have specifically disclosed sub-ranges such as from 10 to 13, from 10 to 14, from 10 to 15, from 11 to 13, from 11 to 14, from 11 to 15, from 11 to 16, from 12 to 14, from 12 to 15, etc., as well as individual numbers within that range, for example, 10, 11, 12, 13, 14, 15, and 16.
[0047] The at least one reducing agent employed in the precursor solution is an agent capable of reducing the at least one first and/or second metal precursors. In some embodiments, the metal reducing agent is inorganic and in other embodiments, the metal reducing agent is an organic agent. Non-limiting examples of such reducing agents are metal borohydride, e.g., such as sodium borohydride and other hydride derivatives, such as cyanoborohydride, sodium ascorbate, hydroquinone and hydroquinone derivatives, hydrazine and hydrazine derivatives, such as methylhydrazine and any combinations thereof.
[0048] In some embodiments, the at least one reducing agent is two or more agents introduced into the reaction mixture at the same time or at different times. In some embodiments, the two or more reducing agents are different in their reducing ability; the first may be a weak reducing agent such as sodium ascorbate and the second may be a strong reducing agent such as a metal borohydride.
[0049] As the process of the method recites, upon formation of the precursor solution, the solution or an aliquot thereof is placed on at least a portion of the surface to be coated (which had optionally been pre-treated) and a thin-film is allowed to form thereon. To enable the deposition of the precursor solution with a controlled thickness and uniformity over the surface, different techniques may be employed depending on the size of the surface, its structure, viscosity of the solution (as derived for example by the specific surfactant concentration), the temperature of the precursor solution, and other parameters as may be known to a person skilled in the art. Generally, for lower surfactant (low viscosity) solutions containing 1-15% surfactant (w/w) spray coating may be used, by employing, for example, a spray coating system having a high pressure nebulizer and a temperature controlled substrate holder. Such precursor solutions may also be applied onto the surface by employing the ink-jet printing technology and the roller printing technique known in the art. For higher surfactant concentrations of above 15% (w/w), drop casting, dip- and spin-coating techniques and roller printing techniques are also suitable for covering large surfaces.
[0050] The thickness of the thin-film depends on the viscosity, as determined by the surfactant concentration and temperature, of the precursor solution. Notwithstanding, the spread thickness typically employed is between 10 and 100 μm.
[0051] The surface of a substrate or an object on which the thin-film is formed according to the process of the present invention may be of any rigid or flexible substrate or object. The substrate can be clear (transparent; any degree of transparency) or opaque. The surface may be hydrophobic or hydrophilic in nature (or at any degree of hydrophobicity/hydrophilicity or a surface which may be switched between the two states). The surface may be an organic or inorganic surface such as a silicon surface (such as a standard, polished silicon wafer), a fused silica surface (such as a standard fused silica window polished to optical quality), a carbon surface (such as a highly oriented pyrolitic graphite), a surface of a relatively smooth polymer sheet (such as polycarbonate copying machine transparency film and a semiconducting polymer layer comprising the active layer of an organic light emitting diode made, for example from MEH-PPV or doped polyacetylene), and any other surface.
[0052] The surface may be whole surface or a portion thereof. The portion (region) of the substrate's surface to be coated may be of any size and structure, the portion may be continuous or comprise of several non-continuous sub-regions on the surface. In some embodiments, the surface of the substrate is substantially two-dimensional. In other embodiments, the surface is that of a three-dimensional object. In other embodiments, the at least one portion of the substrate's (or object's) surface is its whole surface.
[0053] Once the surface is covered, partially or wholly, with a thin-film of the precursor solution, it is allowed to dry. Unlike processes of the art, the drying of thin-film produced by the process of the present invention does not require high temperature. In some embodiments, the thin-film of the invention is allowed to dry at ambient temperature, i.e., between 25-27° C. In other embodiments, drying is achieved at a temperature not exceeding 40° C. In further embodiments, drying is achieved at a temperature between 27-40° C. In still other embodiments, drying is achieved at a temperature between 35-40° C.
[0054] The drying period does not typically exceed 60 minutes. In some embodiments, the thin-film is dried over a period of between 30-60 minutes, in other embodiments, between 30-45 minutes and in further embodiments over a period of up to 30 minutes (e.g., 1, 5, 7, 10, 15, 17, 20, 22, 25, 27 minutes or any period therebetween).
[0055] In some embodiments, nanowire formation may be induced (initiated), accelerated or generally controlled (controlling the morphology of the nanowires, their formation, their length, aspect ratio, bundle formation, accelerating their formation, arresting their formation, etc) by irradiating the film of the precursor solution (on at least a portion of the surface of a substrate) with ultraviolet light (UV). In some embodiments, the film is irradiated with a UV light at 254 nm (e.g., mercury lamp). The exposure duration may be from a few seconds to a few hours depending on the thickness of the film, the concentration of the surfactant, the temperature of the film, the size of the substrate and other factors.
[0056] In some embodiments, the film is exposed to a 100 W mercury lamp, in some embodiments, for 1-30 minutes.
[0057] The processes of the invention may be compatible with large scale deposition techniques, such as roll-to-roll printing. This process may allow better control of the nanowire dimensions and densities as well as reduction of the residual spherical nanoparticle population which is detrimental for the optical transmission properties of the films. Due to the directionality of the nanowire bundles of the invention, as will be further disclosed hereinbelow, they may be aligned using various alignment techniques used for liquid crystals, such as the use of external fields or shear forces. Such aligned nanowire arrays may be useful for future nanoelectronic circuits.
[0058] The present invention, in another of its aspects provides an aqueous solution (e.g., the homogeneous precursor aqueous solution, emulsion or dispersion) comprising at least one metal precursor (e.g., at least one salt of a metal selected from gold, silver, copper, palladium, platinum or a mixture thereof), at least one surfactant and at least one reducing agent, wherein the concentration of the at least one surfactant in said solution is at least 5% (w/w), and wherein each of the components is as defined hereinabove.
[0059] In some embodiments, the concentration of the at least one surfactant is above 5%, in further embodiments above 10%, in still other embodiments above 15%, and in yet other embodiments, the concentration is above 20%. In some additional embodiments, the surfactant concentration is at most 30%. In additional embodiments, the surfactant concentration is between 7.5 and 21%.
[0060] In some embodiments, the medium is water, preferably pure water, e.g., double distilled, triply distilled, or ultra-pure. In other embodiments, the at least one metal precursor is gold and/or silver.
[0061] In still other embodiments, the solution (e.g., precursor solution) of the invention is at a temperature at which the solution is substantially homogeneous. Such a temperature, as disclosed above, may be ambient or a higher temperature.
[0062] In some embodiments, where the at least one metal reducing agent is sodium ascorbate, the surfactant concentration is at least 1%.
[0063] In further embodiments, the solution of the invention is for use in a process for the preparation of a conductive thin-film as disclosed herein.
[0064] In another aspect of the present invention, there is provided a process for the preparation of a nanowire film on a surface of a substrate, said process being independent of a surfactant concentration, said method comprising:
[0065] (a) obtaining an aqueous precursor solution, said solution being prepared by:
(i) combining (forming a solution of) at least one surfactant, at least one (first) metal precursor and at least one metal reducing agent in an aqueous medium; (ii) inducing metal reduction of said at least one metal precursor;
[0068] (b) forming a thin-film of the solution of step (a) on at least a portion of a surface of a substrate; and
[0069] (c) allowing nanowires in said thin-film to form, e.g., by drying the thin film;
[0070] thereby obtaining a nanowire film (e.g., a conductive film) on at least a portion of said surface.
[0071] In some embodiments, the reduction of the at least one first metal precursor (a first metal precursor) is induced by the addition of at least one second metal precursor. In some embodiments, said at least one second metal precursor is a silver metal precursor.
[0072] In further embodiments, the at least one first metal precursor is a gold metal precursor and the aqueous precursor solution is obtained by:
(i) forming a solution of at least one surfactant, at least one gold metal precursor and at least one metal reducing agent in an aqueous medium; (ii) adding into the aqueous solution at least one silver metal precursor to thereby induce reduction of said at least one gold metal precursor.
[0075] In other embodiments, the metal reducing agent is sodium ascorbate.
[0076] In yet additional embodiments of this process of the invention, the concentration of said at least one surfactant is between 1% and 10% (w/w) of the total weight of the precursor solution. In some embodiments, the concentration is between 1% and 5%. In other embodiments, the concentration is between 1% and 3%. In other embodiments the concentration is between 1% and 2%. In still further embodiments, the surfactant concentration is 1.6% (w/w).
[0077] There is thus provided a process for the preparation of a conductive nanowire film on a surface of a substrate, said process comprising:
[0078] (a) obtaining an aqueous precursor solution, said solution being prepared by:
(i) forming a solution of at least one surfactant at a concentration of between 1-10% (w/w), at least one gold metal precursor and sodium ascorbate in an aqueous medium; (ii) adding at least one silver metal precursor
[0081] (b) forming a thin-film of the solution of step (a) on at least a portion of a surface of a substrate; and
[0082] (c) allowing said thin-film to dry;
[0083] thereby obtaining a gold/silver nanowire film on at least a portion of said surface.
[0084] As stated hereinabove, in some embodiments, the precursor solution is prepared by first forming a solution of at least one first metal precursor, at least one surfactant and at least one second metal precursor at a temperature allowing dissolution, followed by the addition of at least one reducing agent. In such embodiments, the process of the invention, being independent of a surfactant concentration, comprises:
[0085] (a) obtaining an aqueous precursor solution, said solution being prepared by:
(i) combining (forming a solution of) at least one surfactant, at least one first metal precursor, at least one reducing agent, and at least one second metal precursor in an aqueous medium; (ii) introducing at least one second reducing agent, to induce reduction of said at least one first metal precursor;
[0088] (b) forming a thin-film of the solution of step (a) on at least a portion of a surface of a substrate; and
[0089] (c) allowing said thin-film to dry;
[0090] thereby obtaining a nanowire film on at least a portion of said surface.
[0091] In these embodiments, the reduction of the at least one first metal precursor is induced by the addition of the at least one second reducing agent after a solution has been formed of the first and second metal precursors and first reducing agent and the at least one surfactant.
[0092] The reducing agents employed are typically a hydride or metal borohydride and sodium ascorbate.
[0093] In further embodiments, the at least one first metal precursor is a gold metal precursor and the at least one second metal precursor is silver.
[0094] As above, the concentration of said at least one surfactant is between 1% and 10% (w/w) of the total weight of the precursor solution. In some embodiments, the concentration is between 1% and 5%. In other embodiments, the concentration is between 1% and 3%. In other embodiments the concentration is between 1% and 2%. In still further embodiments, the surfactant concentration is 1.6% (w/w).
[0095] There is thus provided a process for the preparation of a conductive nanowire film on a surface of a substrate, said process comprising:
[0096] (a) obtaining an aqueous precursor solution, said solution being prepared by:
(i) forming a solution of at least one surfactant at a concentration of between 1-10% (w/w), at least one gold metal precursor and at least one silver metal precursor and at least one ascorbate reducing agent in an aqueous medium; (ii) adding a metal borohydride;
[0099] (b) forming a thin-film of the solution of step (a) on at least a portion of a surface of a substrate; and
[0100] (c) allowing said thin-film to dry;
[0101] thereby obtaining a gold/silver nanowire film on at least a portion of said surface.
[0102] The at least one surfactant employed with this process of the invention, is as defined hereinabove.
[0103] In some embodiments of all processes of the invention, the at least one surfactant is one comprising at least one quaternary ammonium group.
[0104] The invention also provides a kit comprising, in the same container or in different containers, at least one metal precursor, at least one surfactant and at least one reducing agent, optionally a liquid medium (such as water), means to permit dissolution of each of the components of the kit in each other or in the medium, and instructions to prepare a precursor solution. Where two or more metal precursors are to be used, the kit may comprise each in a separate container.
[0105] As used herein, the process, the precursor solution or the kit of the invention may include additional steps or ingredients or parts, only if the additional steps, ingredients, or parts do not alter the basic and novel characteristics of the claimed process, solution and kit.
[0106] As used herein, the singular form “a”, “an” and “the” include plural references unless the context clearly dictates otherwise. For example, the term “a metal precursor” or “at least one metal precursor” may independently include a plurality of metal precursors, including mixtures thereof.
[0107] As used herein, the term “metal nanowire” refers to a continuous metallic wire comprising one or more elemental metal, a metal alloy thereof and, in some embodiments, a metallic compound, e.g., a metal oxide thereof. The cross sectional diameter of the metal nanowire is less than 100 nm. In some embodiments, the cross-sectional diameter is less than 50 nm, in other embodiments less than 10 nm and in further embodiments the diameter is between 2-10 nm, or 2-9 nm, or 2-8 nm, or 2-7 nm, or 2-6 nm, or 2-5 nm, or 2-4 nm, or 3-5 nm.
[0108] The metal nanowire has an aspect-ratio (the ratio of length of the nanowire to its width) greater than 100, in some embodiments greater than 500, and further embodiments greater than 1000. As used herein, “high aspect ratio” refers to an aspect ratio above 100.
[0109] In some embodiments, the metal nanowires are of a metal selected from gold, silver, copper, nickel, palladium or combinations thereof. In some other embodiments, the metal nanowires are of gold and silver.
[0110] As stated above, the process of the invention provides for the preparation of a nanowire film which comprises a plurality of such metal nanowires. In some embodiments, the nanowire film comprises a plurality, i.e., at least two, metal nanowires arranged in the film as separate nanowires randomly distributed and having a random spatial arrangement, and/or in groups or bundles of two or more nanowires, with each nanowire in the bundle substantially having the same spatial arrangement and direction. The independent nanowires or bundles thereof may also take on the form of a mesh, namely a formation of closely spaced and randomly crossing metal nanowires, said mesh being conductive throughout, namely at any two arbitrary points thereof.
[0111] Since the nanowire film comprises of a sufficient number of metal nanowires, electrical conductivity is observed with electrical charge percolation from one metal nanowire to another. The nanowire film has thus electrical conductivity.
[0112] As one versed in the art would recognize, the conductivity referred to is a metallic electrical conductivity or ohmic electrical conductivity, i.e., exhibiting linear current/voltage curves. In some embodiments, the film conductivity does not exceed 1000 Ohm square.
[0113] The nanowire film additionally has high transparency to light due to the low volume filling of the metal in the film, namely the occupation of overall only a small surface area by the nanowires. The nanowire film is transparent between 400-800 nm. In some embodiments, the light transmission of the nanowire film is at least 75% and can be as high as 98%. In some further embodiments, the transmission is between 75-85%.
[0114] The metal nanowires and the conductive nanowire films of the invention may be fabricated into substantially any device that can utilize such nanostructures or articles associated therewith. Such nanostructures and articles of the invention can be used in a variety of applications, such as sensors (such as electrochemical sensors, mechanical sensors, electromechanical sensors), tags or probes, electrodes (such as transparent electrodes), switches, transistors, displays, photovoltaic cells and other opto-electronic devices.
[0115] The structural, chemical and electronic properties of the specific metal nanowire or film may be used in the design and manufacture of a variety of such devices. For some applications, the metal nanowires or films are integrated into a functional component of a device for use, in some non-limiting examples, in surface-enhanced Raman scattering, subwavelength optical waveguiding, biolabeling, and biosensing, particularly where the nanowires of composed or gold and/or silver metals.
[0116] For other applications, the metal nanowires of the invention and the film comprising same, may be further functionalized to impart to the film certain surface properties. Functionalization of the conductive nanowire film of the invention may be through functionalization of the metal nanowires or through functionalization of the exterior surfaces of the film.
[0117] The invention thus provides an electrode structure comprising an electrically conductive film comprising a plurality of electrically conductive nanowires on a substrate, which may or may not be optically transparent. In some embodiments, the electrode structure is configured as a photocathode. In other embodiments, the substrate is optically transparent. The film comprising said plurality of electrically conductive nanowires according to the invention may be a portion of a substrate.
[0118] The invention further provides a photocathode structure comprising an optically transparent substrate carrying a layer formed by an arrangement (e.g., a mesh) of the conductive nanowires.
[0119] An optically transparent electrode is also provided, said electrode comprising a conductive layer, according to the invention, formed by an arrangement of the conductive nanowires on an optically transparent substrate.
[0120] The invention also provides an electronic device comprising an electrodes' assembly wherein at least one of the electrodes comprises a conductive layer comprised of an arrangement of conductive nanowires according to the invention on a substrate. In some embodiments, the electronic device is configured and operable as a marker (e.g., unique random pattern of wires having unique distribution/profile of electric and/or magnetic field along the substrate); a sensor (photodetector); a switch (transistor) and other related devices. The electrodes' assembly may be selected from a diode, triode, transistor, etc.
[0121] There is thus provided a transistor device wherein at least one of source, drain and gate electrodes comprises the electrically conductive layer of the conductive nanowires of the invention, on a substrate.
[0122] A transistor device is also provided, wherein the device comprises a gate on insulator structure having an electrically insulating substrate carrying a conductive layer of electrically conductive nanowires according to the invention.
[0123] The present invention also provides an electroluminescent screen device comprising a luminescent substrate structure carrying a layer of conductive nanowires according to the invention.
[0124] For some applications it may be necessary to embed the nanowire film in a solid matrix, with portions of the nanowires extending from the matrix to enable access to a conductive network. Such a matrix may provide protection to the nanowires from adverse factors such as corrosion and abrasion. The matrix may also offer mechanical properties to the conductive nanowire layer.
[0125] Additionally, performance-enhancing layers may be used to further enhance the characteristics of the nanowire film. This, for example, may be achieved by introducing additional layers in the transparent conductor structure of the invention. Thus, in other embodiments, the invention also provides a multi-layer transparent conductor which comprises the conductive nanowire film of the invention and at least one additional layer selected from an anti-reflective layer, an anti-glare layer, an adhesive layer, a barrier layer, and a protective coat.
[0126] The invention thus provides a transparent conductor comprising a substrate and a conductive film on at least a portion of a surface of said substrate, the conductive film comprising a plurality of metal nanowires as disclosed herein, and optionally at least one performance enhancing layer, as disclosed.
[0127] In some embodiments, the nanowire conductive film is used for multiple conductors in an integrated circuit chip.
[0128] For certain applications, the nanowire film may be treated, during manufacture or after it has been formed with a polymeric surfactant such as a cationic polymeric surfactant, so as to endow the nanowires or the film as a whole with increased physical stability. In some embodiments, the polymeric surfactant is poly-diallyldimethylammonium chloride. Alternatively, polymerizable monomers, such as styrene, that can be polymerized after film drying and nanowire formation using a polymerization initiator solution may be employed.
[0129] It should be appreciated that certain embodiments of the invention, which are, for clarity, described as distinct embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable combination or as suitable in any other described embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0130] In order to understand the invention and to see how it may be carried out in practice, embodiments will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:
[0131] FIGS. 1A-1B are transmission electron microscope (TEM) images of a dried growth solution containing 7.5% CTAB deposited on a carbon coated copper grid after washing most of the CTAB with water and ethanol.
[0132] FIGS. 2A-2B are scanning electron microscope (SEM) images of thin-films prepared from the 7.5% growth solution deposited on ( FIG. 2A ) fused silica and ( FIG. 2B ) Si with native oxide 10×10 mm substrates.
[0133] FIG. 3 presents a visible light transmission curve of a film deposited from a 7.5% CTAB solution on a fused silica substrate. This film had a ˜500 Ωsq resistance.
[0134] FIG. 4 depicts a film prepared according to a process of the art.
[0135] FIG. 5A-5D are TEM images of nanowire films deposited on carbon coated grids:
FIGS. 5A-5B show TEM obtained from 0.25 M CTAB solution. The inset in FIG. 5A shows the uniformity of the nanowire film over a macroscopic area (>100 μm 2 area). FIGS. 5C-5D show TEM obtained from 0.6 M CTAB solution. The inset in FIG. 5C shows a case where silver ion concentration was too low relative to the CTAB 0.6 M concentration and the small nucleated segments could not connect.
[0138] FIG. 6 shows a SEM image of a part of a nanowire film prepared on a silicon substrate and washed with 70% ethanol.
[0139] FIGS. 7A-7D show SEM image of nanowire bundle, a typical measurement configuration and current-voltage curves:
FIG. 7A shows the current-voltage measurement for the SEM image shown in FIG. 7B of nanowire bundle conductance measurement using clean tungsten nanoprobes in the Zyvex S100 system. FIG. 7C shows a typical measurement configuration with the nanowire film deposited on a pre-patterned silicon substrate with gold electrodes. FIG. 7D shows current-voltage curves measured with various inter-electrode spacings as indicated in the legend.
[0143] FIGS. 8A-8C show visible light transmission curve of a nanowire film, bending of PET substrate coated with a nanowire film and the periodic table as observed through the PET film.
FIG. 8A shows a visible light transmission curve of a nanowire film deposited on a fused silica substrate with a sheet resistance of 200 Ω/sq. FIG. 8B demonstrates bending of a PET substrate coated with a nanowire film to a curvature radius of ˜1.5 cm maintains a ˜100 Ω/sq sheet resistance. FIG. 8C displays the periodic table as observed through the same PET film which had ˜80-85% optical transmission in the visible range. The bright stripes are silver paint lines used to estimate the sheet resistance. The upper right corner is film-free.
DETAILED DESCRIPTION OF EMBODIMENTS
General Experimental Procedures
[0147] The preparation of a high aspect-ratio metal nanowire mesh films with high conductivity, flexibility and transparency was based on an in-situ formation of the nanowires which occurred after the deposition of a thin film of precursor solution on top of a substrate of choice.
[0148] Gold-silver nanowires were grown in a drying thin film containing a high cationic surfactant concentration which formed a liquid-crystalline template phase for the formation of a nanowire network. The nanowire network films were uniform over macroscopic (cm 2 scale) areas and on a variety of substrates. These films, measuring only few nanometers in thickness were characterized by low sheet resistivities, in the range of 60-300 Ω/sq, as formed, and a high transparency, comparable to indium tin oxide (ITO) films.
[0149] One process for the preparation of the metal nanowire mesh films begins with the preparation of a relatively concentrated surfactant solution having at least 5%, or at least 7.5%, or from 5% to 30%, or from 5% to 21%, or from 7.5% to 21% (w/w) of a surfactant such as cetyltrimethylammonium bromide (CTAB) in ultrapure water. The formerly published process [9, 10] had only 1.6% CTAB. Such high concentrations require heating of the solution so as to produce a uniform micro-emulsion phase of the surfactant/water mixture.
[0150] A solution of chloroauric acid was added to this emulsion to yield a final Au precursor concentration of between 1 and 4 mM and a higher concentration of sodium ascorbate was added at a concentration of 40 to 60 times higher than the gold concentration. The initiation of the metal deposition process occurred by adding a concentrated AgNO 3 solution to the prepared solution at 30-40° C., while stirring, to a final silver concentration 2 times higher than that of the gold. The silver ions added were being reduced by the ascorbate ions and when small silver metal seeds formed, the reduction of gold ions by the ascorbate was catalyzed and the metal nanostructures began growing. Immediately after silver addition a thin-film of the solution was spread on the substrate of choice either by drop casting, dip-coating or spin-coating. The thickness of such a film depended on the viscosity (determined by surfactant concentration and temperature) and the spread conditions and was measured to be between 10 and 100 μm. Next, the film was dried, in some cases by placing the substrate under mild heating by a lamp at 35-40° C. until the film fully dried, after about 10 minutes.
[0151] For microscopy studies of the dried films, most of the surfactant was washed out with various solvents. For conductance measurements, a quick ethanol wash was sufficient to allow for good electrical contact, either to pre-fabricated electrodes patterned on the substrate or to electrodes patterned post-film-deposition, either by metal evaporation or by spreading silver paint on the film.
[0152] In another process according to the invention, the aqueous solution was first formed by preparing a relatively concentrated surfactant solution having at least 5%, or at least 7.5%, or from 5% to 30%, or from 5% to 21%, or from 7.5% to 21% (w/w) of a surfactant such as cetyltrimethylammonium bromide (CTAB) in ultrapure water. A solution of chloroauric acid was added to this emulsion together with a concentrated AgNO 3 solution, while stirring, to a final silver concentration 2 times higher than that of the gold. After a few minutes, a solution of sodium borohydride was added followed by a solution of sodium ascorbate. The silver and gold ions in the presence of the strongly reducing agent began undergoing reduction, forming silver/gold metal seeds, the reduction of gold and silver ions by the ascorbate was catalyzed and the metal nanostructures began growing.
EXAMPLE 1
[0153] A 8.3% (w/w) cetyltrimethylammonium bromide (CTAB) solution was prepared by heating and stirring the CTAB/water mixture at 50° C. for 5 minutes. To this solution, at 40° C., 500 μL of 25 mM HAuCl 4 solution and 425 μL of 1.8 M freshly prepared sodium ascorbate solution were added and stirred together. Then, 250 μL of 100 mM AgNO 3 solution were added while stirring. The final CTAB concentration in the nanowire growth solution was ˜7.5%. 30 seconds after the addition of the Ag solution, the stirring was discontinued and the solution was deposited on a substrate and let dry for 15-45 minutes at 35-40° C.
[0154] Transmission electron microscopy (TEM) and scanning electron microscopy (SEM) imaging revealed metal nanowire networks of varying wire densities and entanglement, depending on the exact solution and deposition conditions, uniformly spread over the substrates (See, FIGS. 1A to 1B showing transmission electron microscope images, and FIGS. 2A to 2B showing scanning electron microscope images). The nanowires were typically 3-5 nm wide and many micrometers long and in this case composed of 85-90% gold and 15-10% silver. A varying amount of non-elongated metal nanostructures was also observed. The minimization of the concentration of such structures in the films was a key to improving their optical transmission.
[0155] Nanowire films were obtained from solutions that had up to 21% CTAB concentrations, 5 mM HAuCl 4 , 0.2M sodium ascorbate and 10 mM AgNO 3 . These concentrated CTAB solutions were highly viscous and required longer mixing and heating times to prepare homogeneous solution thereof. With such growth solutions it was easy to coat the substrates by simple dip-coating.
[0156] The composition of the substrate did not influence the final results since the high surfactant concentration ensured proper wetting of either hydrophobic or hydrophilic surfaces. So far, the process produced similar results on silicon, fused silica, polycarbonate and carbon substrates. Differences between various substrates were mostly due to edge effects of the drying film which were more substantial in cases of small substrates such as TEM grids. The high level of uniformity and thus nanowire percolation, as seen in FIGS. 1A to 1B and 2A to 2B could not be obtained using the procedure described in the art [e.g., in refs. 9 and 10].
[0157] Electrical measurements, done on several length scales at various arbitrary positions on the substrates using various types of contacts have shown ohmic conductance of the order of 100-500 Ω/sq and 75-85% transmittance in the visible range ( FIG. 3 ), which is comparable to indium tin oxide (ITO) films. The estimated conductivity per Au/Ag wire was of the order of bulk gold conductivity. It should be noted that a significant part of the ˜20% extinction observed in these experiments came from light scattering that the simple spectrophotometer used for these measurements could not collect, while in a thin-film photovoltaic device most of the scattered light would be collected. Thus, the total transmitted light was probably significantly higher than the observed average ˜80%.
[0158] Contrary to the metal nanowire films prepared by the processes of the invention, films prepared by the methods of the art, particularly those described in references [9 and 10] do not result in the formation of mesh film arrangements of the type observed in FIGS. 1A to 1B and disclosed herein. In fact, and as FIG. 4 demonstrates, the previously published procedure typically yield a film of spherical nanoparticles rather than a film of nanowires on scaling up surfactant and reagent concentrations. The process of the invention reproducibly yields metal nanowire films.
EXAMPLE 2
[0159] A solution comprising surfactant cetyltrimethylammonium bromide (CTAB), chloroauric acid, as a gold precursor at a molar ratio of 1:200 relative to the CTAB concentration, and sodium ascorbate, at a molar ratio of 60:1 relative to the gold concentration, was prepared. The nanowire growth solutions had CTAB concentrations of 0.25 M and 0.6 M, significantly higher than the 0.1 M used by Murphy [12]. In addition, the growth solution contained a relatively high concentration of silver nitrate, twice the concentration of the Au(III) ions. When the four components were mixed together at 35° C. the gold ions were reduced to the colorless Au(I) state, forming a [AuX 2 ] − -CTA + complex (X═Cl, Br) but further reduction to the metallic state required the addition of catalytic metal seed particles. Similarly, the silver ions formed an AgBr-CTAB complex.
[0160] As an alternative, a small amount of sodium borohydride dissolved in water (e.g., 0.001-0.0001%) was added to the precursor solution in order to initiate metal reduction in this solution. The borohydride amount was enough to reduce up to 0.02% of the metal ions to form small metallic seed particles which catalyzed the reduction of the rest of the metal ions by the ascorbate. Immediately after the borohydride addition, the solution was deposited as a thin film, ˜100 μm thick, on the substrate of choice that was kept at ˜35° C. and a relative humidity of ˜50% for drying. The viscosity of the deposited solution at 35° C. was ˜2 cP for the 0.25 M CTAB solution and ˜100 cP for the 0.6 M CTAB solution.
[0161] FIGS. 5A to 5D display the results of drying the thin growth solution films on transmission electron microscopy (TEM) carbon coated grids for samples prepared with two CTAB concentrations: 0.25M and 0.6M. FIGS. 5A to 5B show TEM obtained from 0.25M CTAB solution. It may be noted that a highly uniform nanowire coating appeared across the 3 mm diameter grid for the 0.25 M CTAB sample. Most of the nanowires appeared in wavy bundles with characteristic bundle size of ˜20 wires, in the case of the 0.25 M CTAB sample and thicker nanowire domains for the 0.6 M CTAB sample ( FIG. 5C ). The high magnification image ( FIG. 5D ) provides more quantitative information about the structure of the nanowire bundles; Average nanowire diameters are in the range 2-2.5 nm, and inter-wire spacing is ˜2.5 nm, which is significantly smaller than the 3.9 nm estimated for a CTAB bilayer covering thicker gold nanorods [13]. This difference may be due to a larger radius of curvature around the ultra-thin nanowires of the invention, which would lead to a different bilayer packing. Thus, it appears that the metal was deposited at locally ordered surfactant mesostructure domains that were previously found to have liquid-crystalline characteristics, probably close to a reverse hexagonal phase. The nanowire bundle density and morphology varied with deposited solution thickness, drying temperature and drying rate (by control of relative humidity). One of the important parameters was the initial surfactant concentration; when it was increased to about 0.6 M the liquid crystalline domains were thicker than those formed at lower concentrations ( FIG. 5C ), but also with a larger number of spherical particles that were apparently formed out of the tubular mesostructures. In the case of the higher CTAB concentration the formed metal mesostructures bear a closer resemblance to the oxide based mesoporous materials.
[0162] A closer inspection of a sample with high surfactant concentration (0.6 M) and relatively low silver concentration (4 mM, relative to the usual 6 mM) revealed regions with discontinuous, segmented nanowires (inset of FIG. 5C ) with typical segment size and separations of the order of few nm up to ˜30 nm. Accordingly and without wishing to be bound by theory the nanowire formation process began in a large number of small metal clusters triggered by the borohydride addition. These small metal particles were apparently caught within the surfactant template structure as the film became progressively more concentrated on drying. While drying, additional metal atoms deposited on the seeds through catalytic reduction of the metal ions by ascorbate ions. It has been previously shown for mesostructured silica that regions of the mesophase ordered parallel to the interface were induced by proximity to the interface, as also appears to be the case in the present invention.
[0163] The processes of the invention may be performed using various different substrates such as silicon, quartz and polyethylene terphtalate (PET). FIG. 6 displays a scanning electron microscope (SEM) image of the film as disclosed herein above deposited a silicon substrate after gentle washing with 70%/30% ethanol/water solution. In this case it was not possible to resolve individual nanowires and only whole bundles of the CTAB coated nanowires were observable.
[0164] Conductance measurements of the nanowire films were performed on various length scales. For example, FIGS. 7A-7D show SEM images of nanowire bundle, a typical measurement configuration and current-voltage curves. FIG. 7A shows the current-voltage measurement for the SEM image shown in FIG. 7B of nanowire bundle conductance measurement using clean tungsten nanoprobes in the Zyvex S 100 system. FIG. 7C shows a typical measurement configuration with the nanowire film deposited on a pre-patterned silicon substrate with gold electrodes. FIG. 7D shows current-voltage curves measured with various inter-electrode spacings as indicated in the legend. On the smallest scale, sharp tungsten probes (500 nm in diameter) were used in a Zyvex 8100 nanomanipulator system to probe individual nanowire bundles in situ, while imaging with the SEM, as shown in FIG. 7 A. In order to avoid large contact resistance the tungsten probes were chemically cleaned in KOH solution followed by in-situ oxidation removal process in the SEM, which resulted in a probe-to-probe resistance of the order of 10Ω. In addition, the substrate with the deposited nanowires was thoroughly washed with 70%/30% ethanol/water and shortly exposed to low-power oxygen plasma, which removed part of the nanowire film in addition to the surfactant coating. The current-voltage curves of the nanowire bundles were ohmic with typical resistance values of the order of 1 kΩ/μm. Several measurements on isolated nanowire bundles as the one shown in the inset of FIG. 7A were performed. Assuming an average bundle of 20 nanowires and a diameter of 2.5 nm, an estimated nanowire resistivity of the order of 10 −7 Ωm was obtained, which is about 4 times the resistivity of bulk gold. Considering the roughness of the estimate and possible probe-wire contact resistance, this result is roughly consistent with bulk gold like nanowire resistivity.
[0165] In addition, the films were deposited over Si wafers with a 100 nm thick oxide layer and gold electrodes patterned on top with inter-electrode 2-20 μm gaps ( FIG. 7B ). The bundle resistances measured over these gaps, together with the bundle densities apparent in the SEM images, were used to estimate effective sheet resistances that were in the range of 100-300 Ω/sq. They also exhibited an ohmic behavior down to 4 K. Rough estimates of nanowires' width and length, connecting the micro-electrodes provided wire resistivities which are of the same order as bulk gold (˜10 −8 Ωm). This indicates that at least part of the nanowires grown within the CTAB meso-structures were formed at the bottom of the dried CTAB film, forming good electrical contact with the pre-formed gold electrodes. Optical dark field microscopy confirmed that the nanowire bundles were located at the bottom of the ˜5-10 μm thick dried CTAB films.
[0166] Furthermore, the nanowire films were deposited on a 1 cm 2 fused silica substrates (also from 0.6 M CTAB), silver paint was applied in two parallel lines at the edges of the substrate and sheet resistances of the order of 100 Ω/sq were measured after mild ethanol washing. In particular, the high flexibility of the film was demonstrated ( FIG. 8B ) where only up to 10% increase in the ˜100 Ω/sq sheet resistance occurred for a film deposited on a PET substrate which was bended with a curvature radius of ˜1.5 cm. Upon relaxing the bend in the film the sheet resistance returned to its exact original value, demonstrating the high flexibility of the nanowire film. The films deposited on PET have shown the lowest resistivity results, down to ˜60 Ω/sq.
[0167] FIGS. 8A-8C show visible light transmission curve of a nanowire film, bending of PET substrate coated with a nano wire film and the periodic table as observed through the PET film. FIG. 8A shows a visible light transmission curve of a nanowire film deposited on a fused silica substrate with a sheet resistance of 200 Ω/sq. FIG. 8B demonstrates bending of a 2×2 cm2 PET substrate coated with a nanowire film to a curvature radius of ˜1.5 cm maintains a ˜100 Ω/sq sheet resistance. FIG. 8C displays the periodic table as observed through the same PET film which had ˜80-85% optical transmission in the visible range. The bright stripes are silver paint lines used to estimate the sheet resistance. The upper right comer is film-free.
[0168] The optical extinction of the films was measured using a standard spectrophotometer. A transmission curve for a film with relatively high transparency and sheet resistance of 200 Ω/sq is presented in FIG. 8A . Typical far-field transmission of all samples was in the range of 80-90%. This extinction contained a large scattering component which, in the case of photovoltaic devices, may be collected within the device. Without wishing to be bound by theory, the varying amounts of residual spherical particles, which had relatively large diameters relative to the nanowires, may be responsible for a substantial part of the extinction.
EXAMPLE 3
[0169] As recited above, in some experiments, prior to the addition of the reducing agent (e.g., sodium ascorbate) to the Au precursor solution, the silver solution was added to the Au precursor solution and only then the mild reducing agent e.g., sodium ascorbate was added. Under such conditions no metal reduction was induced. Subsequently, low concentration (e.g., 1/100 of that of the sodium ascorbate or lower) of a stronger reducing agent with respect to ascorbate was added to the solution. Such stronger reducing agent should have a reduction potential (E 0 ) of −0.5 V or more negative. Non-limiting examples are sodium borohydride, sodium cyanoborohydride and hydrazine. The addition of the strong reducing agent initiated metal reduction in this solution and subsequent metal deposition on the substrate.
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A conductive nanowire film having a high aspect-ratio metal is described. The nanowire film is produced by inducing metal reduction in a concentrated surfactant solution containing metal precursor ions, a surfactant and a reducing agent. The metal nanostructures demonstrate utility in a great variety of applications.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of garments, and headgear in particular, and more directly to a novel cap having an internal storage compartment within the crown of the cap and having a visor constructed to serve as a handle for carrying purposes and alternatively provided with a transparent or translucent section through which visual observation can be taken.
2. Brief Description of the Invention
In the past, it has been the conventional practice to provide headgear, such as caps, with a visor and a crown. When worn by the user, the crown fits over the top of the user's head with the visor outwardly projecting so as to shade or protect the wearer's eyes. The visor is composed of a solid material and the crown includes a sweatband or liner which follows around the opening into the crown so as to support the cap on the head of the user. Conventionally, the cap is only employed to cover the user's head while the visor is used solely to shade or protect the user's eyes. Some attempts have been made to augment the cap by employing pivotal colored panels on the underside of the visor so that the user may readily "flip" the panel downwardly so that the panel will shield the eyes from undesired glare.
Although such "flip" panels or glasses may service the purpose of an anti-glare device, such means are merely add-ons to the visor and do not affect the construction or usage of the visor or the cap itself. In other words, there is no structural adaptation or modification required to mount the panel onto the visor itself. The panel is not used for any other purpose or accommodation.
Furthermore, the inside of the conventional crown serves no additional purpose than to accommodate the head of the user and the headband or liner forms a fit to the head of the user so that the wearing of the cap is comfortable. However, when not worn by the user, the cap is not easily carried and serves no other purpose. In fact, when the user is attending a sports event, for example, the user must carry storage bags, binocular cases or the like as separate items. The cap is one of the additional items and, as such, becomes awkward and cumbersome to carry.
Therefore, a long-standing need has existed to provide a cap which not only may serve the conventional purposes as a head covering and eye shade but can also accommodate the storage of small items, and which provides a variety of options for providing glare reduction to the user when worn as a cap.
SUMMARY OF THE INVENTION
Accordingly, the above problems and difficulties are avoided by the present invention which provides a novel combination visored cap, storage compartment and carrying handle which comprises a domed crown having an outwardly projecting visor and which includes a continuous sweatband mounted about an opening into the interior of the crown. The invention includes the provision of a cover which is detachably carried on the crown at the sweatband whereby means are provided for detachably connecting the cover thereto. Preferably, a portion of the cover is permanently attached at the back of the crown while the remaining portion of the cover is detachably connected about the sweatband or rim of the crown by means of a zipper or a hook and pile fastening means. When not worn by the user, the crown becomes a storage compartment enclosed by the detachable cover. However, when worn by the user, the crown fits the head of the user void of any stored contents. The invention further includes a visor having an elongated cutout opening which serves as a handle in order to carry the cap including items stored within the internal storage compartment. The visor includes a translucent or transparent panel which selectively covers the cutout opening in order to shield or protect the eyes of the user when the cap is worn. The panel may be mounted on the visor so as to slide through a slit opening for retention on the visor or the panel may be pivotally carried on the top of the visor for adjustment by the user.
It is among the primary objects of the present invention to provide a novel combined cap and carrying bag which has alternate conditions of use. In one condition, the cap maybe worn on the head of the user with the visor shielding the eyes of the user, and in another condition, the cap may be used as a carrying bag housing a variety of small articles within the crown of the cap by means of a closable cover.
Another object of the present invention is to provide a novel combined cap and carrying bag which has a novel visor, including a cutout opening that is covered by a translucent or transparent panel of colored pigmentation wherein the panel may be arranged in a sliding relationship on the visor with respect to the opening or may be pivotally carried on the visor for selectively covering the opening. Another version envisions a snap-on arrangement for the panel with respect to the visor for covering the opening.
Another object of the present invention is to provide a novel piece of headgear which may also serve as a carrying bag when not worn by the user, and which includes a detachably mounted cover with respect to the crown so that a storage compartment is defined within the crown when the cover is closed.
Another object of the present invention is to provide a novel alternative use for a cap which takes the form of a carrying bag wherein the crown of the cap serves as a storage compartment in combination with a detachable cover and the visor of the cap serves as a handle for carrying the cap as a storage bag.
The features of the present invention which are believed to be novel are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages thereof, may best be understood with reference to the following description, taken in conection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view showing the inventive cap and carrying bag of the present invention;
FIG. 2 is a perspective view illustrating the inventive cap and carrying bag in its condition for storing articles within the crown of the cap;
FIG. 3 is an enlarged longitudinal cross-sectional view, partly in broken away elevation, of the combined cap and carrying bag with a zipper closure for the cover;
FIG. 4 is a fragmentary elevational view of the zipper closure of FIG. 3 for detachably connecting the cover to the crown of the cap;
FIG. 5 is a transverse cross-sectional view of the crown of a cap illustrating a hook and pile attachment for the cover to the crown of the cap;
FIG. 6 is a front perspective view of the combined cap and carrying bag illustrating a pivotable panel for selectively covering the handle opening in the visor;
FIG. 7 is a side elevational view greatly enlarged, illustrating the pivotal action of the panel of FIG. 6 between its open position in broken lines and closed position in solid lines;
FIG. 8 is an exploded fragmentary perspective view of another embodiment of the combined cap and carrying bag, illustrating a snap-on panel for covering the handle opening in the visor;
FIG. 9 is a fragmentary perspective view of still another version of a panel for closing the handle opening taking the form of a sliding mount for the panel; and
FIG. 10 is a cross-sectional view of the visor shown in FIG. 9 taken in the direction of arrows 10--10.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the novel combined cap and carrying bag incorporating the present invention is illustrated in the general direction of arrow 10 and includes a crown 11 having a forward facing visor 12 which outwardly projects from the front of the cap. The crown may be of a solid material or may be segmented, as illustrated, and the visor or peak 12 is preferably composed of a stiffened material so as to be rigid or semi-rigid in order to shield the eyes of the wearer. As is practiced with conventional caps, the crown 11 is intended to fit over the top of the head while the forward facing visor projects beyond the front of the user's face. The visor 12 is provided with an elongated cutout opening 13 which is defined between side edge marginal regions 14 and 15 as well as a forward edge marginal region 16 and a rearward edge region 17. When the cap is worn by the user, the user may glance upwardly through the opening 13 for observation purposes and light is also permitted to pass through the opening so that the user's face is not completely shielded. Shielding means will be described with respect to other versions later in this specification. However, when the combined cap and carrying bag 10 is used for a carrying bag purpose, the forward edge marginal region 16 and the opening 13 constitute a handle which may be readily grasped by one hand of the user.
In connection with the usage of the invention as a carrying bag, reference is made to FIG. 2 wherein it can be seen that the rigid or semi-rigid visor 12 extends upwardly so that the crown 11 downwardly extends therefrom. The crown includes an interior storage compartment which is sealed by a detachable cover 20. The edge marginal region of the cover is fixedly secured to an edge of the crown, as indicated by numeral 21, and the stitch lines shown. Such attachment occurs at the sweatband region of the crown which is continuous about the opening into the storage area of the crown which is covered by cover 20. The cover is detachably connected to the remaining portion of the sweatband by a closure means such as a zipper closure 22. In broken lines, the cover 20 is illustrated as being detached from the sweatband of the crown 11. Regarding the zippered closure 22, it can be seen that the zipper is of a double type so that either a left or right side of the cover may be detached or separated from the sweatband. However, for gaining greater access for storage purposes, the zipper closure may be opened on both sides so that the cover 20 is solely attached to the cap by the stitching 21. In FIG. 4, for example, the zipper 22 is illustrated as being detachably coupled between the crown or peak 11 and the peripheral edge of the cover 20. The zipper follows tracks 23 and 23' in accordance with conventional zipper practice.
Referring now in detail to FIG. 3, the cap and carrying bag combination 10 is illustrated wherein it can be seen that the interior of the crown 11 includes an inner storage compartment generally indicated by numeral 24 and that the open entrance leading into the compartment is defined by the circular sweatband 25. In solid lines, the cover 20 is attached to the edge marginal region of the sweatband 25 by the zipper closure 22; however, as shown in one set of broken lines, the cover 20 is in a downwardly depending position from its stitching 21 so that the cover in such a position may represent a neck flap when the cap is worn by the user; as shown in another set of broken lines, the cover 20 is in an upwardly extending position from its stitching 21 so that the cover 20 lays inside the crown 11 and remains there when the cap is worn by the user. Preferably, the forward projecting visor 12 is arranged at a downwardly sloping angle for the convenience of the wearer.
Referring now in detail to FIG. 5, another embodiment of the invention is illustrated wherein the closure for the cover comprises a hook and pile fastening means, such as "VELCRO" or the like. In this embodiment, the sweatband 25 includes one-half of the closure, such as a layer of pile material 26, while the hook material 27 is carried on the edge marginal region of a cover 28. Therefore, it can be seen that the sweatband 25 need only be folded outwardly so that the other half of the fastener carried on the cover 28 can be attached thereto followed-by folding of the sweatband back into its position so that the cover closes the opening into the inner storage compartment 24. Such a provision also permits the user to store the cover 28 within the storage area 24 so that the cap may be worn on his head when the cap is not being used as a carrying bag.
Referring to FIGS. 6 and 7, another embodiment of the present invention is illustrated wherein the combined cap and carrying bag 10 includes a transparent, translucent or opaque panel 30 which is mounted by hinge 31 to the upper surface of the visor 12. The hinge 31 is secured to the rearward edge marginal region 17 of the visor so that the panel 30 may be raised or lowered with respect to the opening 13. The panel 30 is longer than the opening 13 so that the edge marginal regions of the panel will bear against or rest against the upper surface of the visor which surrounds or defines the opening 13. Therefore, the overlapping of the edge marginal regions of the panel, when engaged with the visor, constitutes a stop whereby the opening is completely closed. As shown more clearly in FIG. 7, the broken line showing of panel 30 is in its fully open position so that the panel is not a barrier or sight limitation, and the forward edge marginal region 16 and the opening 13 then are available as a handle.
Referring to FIG. 8, another barrier for opening 13 is disclosed, which takes the form of panel 32 which includes openings 33 and 34 for receiving snap studs 35 and 36 respectively. As shown in broken lines, the panel 32 is positioned over the opening 13 and the receptacles 33 and 34 are fully snaplocked with the studs 35 and 36. In this manner, the panel is detachably connected with respect to the visor 12.
Referring now in detail to FIGS. 9 and 10, another version of the invention is illustrated wherein the means for covering the opening 13 takes the form of a panel 40 that may be insertably received through a slot opening 41 in the extreme front portion of the visor 12. The slot opening or entrance 41 leads the edge marginal regions of the panel along guides or tracks on the side marginal regions 14 and 15 of the visor, as shown more clearly in FIG. 10. FIG. 10 also illustrates the slot opening 41 for receiving the edge of panel 40 when it is inserted through the slot 41 and along the edge marginal slots of the visor. The edge of the panel introduced through the slot 41 will bear against the inner marginal region 17 of the visor, which forms a stop so that the panel cannot be slid any further into position.
In view of the foregoing, it can be seen that the combined cap and carrying bag of the present invention provides a novel cap with protective visor and carrying bag with convenient handle. When employed as a cap, the opening which normally would be used as a handle in the visor for carrying the bag may be closed in a variety of ways, such as employment of the panels shown in FIGS. 6, 8 and 9. The panel may be translucent, transparent or opaque and a variety of attachment and securing means is disclosed. When employed as a carrying bag, the embodiment of the invention is shown in FIGS. 1, 2 and 3 whereby the cover may be fully closed to secure articles intended to be carried which are within the internal storage compartament in the crown. Also, the cover may be partially more fully secured to the crown of the cap by a variety of closures such as zippers or hook and pile fastening means. The cover may be used as a neck flap when partially detached from the crown of the cap and the cover may be readily stored on the inside of the crown so that the cap may be worn on the head of the user and will not interfere with the fit or appearance of the cap. The user has the option of either leaving the opening 13 free or a barrier, such as the panels disclosed in FIGS. 6-10, may be employed.
While particular embodiments of the present invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from this invention in its broader aspects and, therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of this invention.
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A visored cap is disclosed herein with a crown having an internal storage compartment when not being worn by the user and is provided with an elongated or cutout opening in the visor for grasping as a carrying handle by the user. A detachable cover is carried about the sweatband of the cap crown for enclosing the internal storage compartment when used for storage. The visor includes a sliding panel, a pivotal panel or a snap-on panel for selectively closing the cutout opening when the cap is worn by the user wherein the panel is translucent or transparent for accommodating visual observation. The closure for the cover with the cap crown may be of zippered or hook and pile construction.
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RELATED APPLICATION
This application is a continuation of International Application PCT/IL02/00560, filed Jul. 11, 2002, the contents of which are here incorporated by reference in their entirety; priority is claimed under 35 USC 120.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an improved ultrasonic generating and radiating device for use in a sonochemical reactor. More particularly, the invention relates to a device comprising transducers, preferably of the magnetostrictive type, and horns (sonotrodes) that emit ultrasound to the entire volume of a reactor containing liquid, wherein the distribution of ultrasonic energy and acoustic cavitation is homogeneous throughout the reactor volume, leading to an increase in the efficiency of sonochemical processes.
2. Prior Art
Ultrasonic energy has many applications in present-day technology in physical and chemical processes. Some general references are:
1) K. S. Suslick, Sonochemistry, Science 247, pp. 1439–1445 (23 Mar. 1990); 2) W. E. Buhro et al., Material Science Eng., A204, pp. 193–196 (1995); 3) K. S. Suslick et al., J. Am. Chem. Soc., 105, pp. 5781–5785 (1983); 4) Telesonic Co., Products Bulletin.
This invention relates to a type of reactor in which the reaction occurs in a localized space filled with a material, generally a liquid phase, which may contain solid particles. By the term “reaction” is meant herein whatever phenomenon is caused or facilitated by the ultrasonic radiation, viz. not necessarily a chemical phenomenon, but a physical one or a combination of the two, as well. A reactor of this type is coupled to a transducer, wherein an oscillating, generally alternating, electromagnetic field is generated and an ultrasound emitting means, generally and hereinafter called “horn” or “sonotrode”, receives the ultrasonic vibrations from the transducer and radiates them outwardly into the space occluded by the reactor, hereinafter called “the reaction volume”. The combination of transducer and horn will be called hereinafter, for brevity's sake, “ultrasonic device”. The reactor contains a material to be treated by ultrasound, which will be called hereinafter “reaction material”. The reaction material generally comprises a liquid phase and fills the reaction chamber.
There are several types of ultrasonic reactors. One of them is the loop reactor, described e.g. in D. Martin and A. D. Ward, Reactor Design for Sonochemical Engineering, Trans IChemE, Vol. 17, Part A, May 1992, 29, 3. Inside this reactor, a liquid, which is to be subjected to ultrasonic treatment, is caused to flow in a closed loop formed by a vessel provided with a stirrer and by a conduit in which the ultrasonic generator is housed.
The propagation of ultrasound from a source in an unbounded liquid medium is illustrated in FIG. 2 of the same publication. In this case, the sonochemical active zone is limited to a frusto-conical space diverging from the radiating face of the transducer.
Also, several transducers may be placed around an elongated enclosure, as in Desborough, U.S. Pat. No. 5,658,534 and Caza, U.S. Pat. No. 6,079,508.
The principal drawback of the aforementioned technique is non-homogeneous distribution of ultrasonic energy inside a reaction volume in longitudinal and transversal directions that leads to inefficient sonochemical reactions. The disadvantage is in the limited volume in which acoustic cavitation, hence chemical reaction, takes place.
The application of multiple transducers is used by Dion, U.S. Pat. No. 6,361,747, where multiple transducers are operating at a phase shift from one another, leading to inefficient and non-homogeneous ultrasonic energy coupling that arises from the interference of oscillations with phase deviations.
The purpose of technical solutions described in Dion U.S. Pat. No. 6,361,747 and in Desborough, U.S. Pat. No. 5,658,534 is to create a maximal intensity of ultrasonic oscillations in the center area (that is the area coinciding with the axis of the reactor) leading to a narrow focal zone (cavitation flux) in the center of the volume. The described reactors have a low resonant merit factor because the tube operates in the bending mode of operation and not in the mode of linear oscillations. Such reactors cannot be applied for efficient sonochemical processes, particularly for nano-particle production, which demand an essentially homogeneous distribution of ultrasonic energy throughout the reaction volume.
An additional drawback of the ultrasonic device described by Dion U.S. Pat. No. 6,361,747 is the following: for full energy transmission, it is necessary to provide very tight acoustic contact between ends (edges) of segmental radiators and tube surface, as well as between waveguide and acoustic transducer. The implementation of acoustic contact leads to high-energy losses and to conversion of this energy into high amounts of heat.
The transducers of ultrasound devices can be of various types. Most common transducers are piezo-electric ones. Therein, the generator of the ultrasound typically consists of a piezo-electric element, often of the sandwich type, coupled with a horn having a generally circular emitting face. Piezo-electric transducers, however, have a maximum power not more than 2 kW and a low oscillation amplitude dictated by the fragility of piezo-electric elements, which can be destroyed under prolonged operation. They are also not reliable compared to magnetostrictive transducers, to be described hereinafter, because their amplitude drifts under operation, causing transducer failure and lower energy output, leading to operation parameters that must be manually corrected. Similar properties are also possessed by electrostrictive materials polarized by high electrostatic fields.
Another type of transducer is that based on the use of a magnetostrictive material, viz. a material that changes dimensions when placed in a magnetic field, and conversely, changes the magnetic field within and around it when stressed. When a magnetostrictive material is subjected to an oscillating magnetic field, the material will alter its dimensions at the same frequency with which the magnetic field is alternated.
A magnetostrictive transducer must comprise a magnetostrictive element, e.g. a rod or another elongated element, located in a space in which an oscillating magnetic field is produced. In its simplest form, such a transducer would comprise a nucleus of magnetostrictive element and a coil disposed around said element and connected to a generator of oscillating electric current. However, different forms of transducers can be devised to satisfy particular requirements: for instance, U.S. Pat. No. 4,158,368 discloses a toroid-shaped core of magnetic metal, about which a coil is wound, which toroid defines with its ends an air gap in which a magnetostrictive rod is located.
The ultrasonic transducer transforms the electromagnetic power into ultrasonic power transmitted to an emitting tool—a horn (sonotrode). It will be said hereinafter that the horn emits the ultrasound into a reactor volume, but no limitation is intended by said expression, which is used only for the sake of brevity. Generally, the horns of the prior art have a slim frusto-conical shape or a stepped or exponential shape. In every case, they concentrate the ultrasonic oscillations and emit them from their extremity, which is generally circular and of reduced dimensions. The ultrasonic waves have, therefore, a high intensity only at the extremity of the horn and spread out from it in a conical configuration, so that they reach only certain regions of the reactor volume and at any point of said volume their intensity is reduced, generally in proportion to the square of the distance from the horn extremity. At their area of maximum intensity various phenomena occur, including heating, cavitation, evaporation, and so on, which absorb and waste a large portion of the ultrasonic energy, resulting in a process of low efficiency (ratio of power spent for required process to overall power), which is generally on the order of 20–30%. Additionally, some desired phenomena that are produced by the high energy density at the extremity of the horn may become reversed at a distance from said extremity: for instance, if it is desired to fragment solid particles, contained in a liquid phase, into smaller ones, such smaller particles produced near the extremity of the horn, migrate through the liquid phase and coalesce to some extent at a distance from said extremity, so that the final particles obtained are not as small as desired.
It is a purpose of this invention, therefore, to provide a sonochemical reactor that is free from the drawbacks of prior art ultrasonic devices.
It is another purpose of this invention to provide a sonochemical reactor with substantially homogeneous distribution of ultrasonic energy throughout the volume of the reactor.
It is a further purpose of the invention to provide such an ultrasonic device comprising a transducer that is inexpensive and durable and has a high oscillation amplitude, up to 45 microns.
It is a still further purpose of this invention to provide an ultrasonic device that emits the ultrasonic waves homogeneously in a radial direction, converting longitudinal oscillations into transversal type.
It is a still further purpose of this invention to provide a sonochemical reactor of high power, e.g., up to 5 Kw and more.
It is a still further purpose of this invention to provide a sonochemical reactor, which has at least 60% efficiency, e.g., 60–80%.
It is a still further purpose of this invention to provide a sonochemical reactor, in which there is no occurrence of undesired phenomena at a distance from the horn.
It is a still further purpose of this invention to provide a sonochemical reactor for the effective and high throughput production of nano-scale materials.
It is a still further purpose of this invention to provide a sonochemical reactor for the production of nano-powder materials.
It is a still further purpose of this invention to provide a sonochemical reactor for the production of nano-structured metal powders.
It is a still further purpose of this invention to provide a sonochemical reactor for the production of nano-structured metal oxide powders.
It is a still further purpose of this invention to provide a sonochemical reactor for the production of nano-structured metal hydroxide powders.
It is a still further purpose of this invention to provide a sonochemical reactor for treating agglomerated materials and effecting de-agglomeration.
It is a still further purpose of this invention to provide a means for the acceleration of chemical reactions.
SUMMARY OF THE INVENTION
The sonochemical reactor of this invention comprises a transducer and a horn (see FIG. 1 ), which are different from, and improved with respect to, the prior art, as will be explained hereinafter. The horn of this invention is mostly intended to be immersed in the reaction material. In the following description the reactor will be assumed to have an axis of symmetry and the horn also to have an axis of symmetry coinciding with the axis of symmetry of the reactor; however this is not to be construed as a limitation, since the invention covers an ultrasonic device as hereinafter defined and is not limited to the reactor with which said device is used, nor to the position in which said device is located with respect to the reactor, nor to the properties of the reaction material.
The transducer comprises preferably a magnetostrictive element of a special alloy, which alloy comprises iron, cobalt, and rare earth elements, such as, but not limited to, nickel, vanadium, dysprosium, terbium, etc. The shape of the transducer comprising a preferable magnetostrictive element may vary to satisfy particular requirements. Preferred shapes will be described hereinafter. The dimensions of any such element are calculated to resist metal fatigue and to give maximum oscillation amplitude. All the electromagnetically relevant parameters of the transducer, for instance the dimensions of the coil that generates the magnetic field, the intensity and frequency of the alternating current fed to said coil, and the like, must be determined to produce the desired magnetic field, and persons skilled in the art will have no difficulty in doing so. For purposes that will be described hereinafter, the ultrasound device of the invention may be combined with a source of exciting current, the frequency of which can be gradually varied. However, the optimum frequency for each specific device to be used for a specific process is generally determined and fixed in accordance. For example, such frequencies may be in the range of 10 to 40 KHz.
The horn of this invention, contrary to prior art horns, is of a hollow resonant type (see FIG. 2 ). The length of the horn is resonant, namely it is equal to half a wavelength or several half wavelengths in the horn material. Said horn is additionally characterized by an internal resonant cavity, consisting of several advantageous functions: 1) Said cavity reduces the thickness of the horn walls, thereby increasing the ease of horn wall motion and amplitude with a given driving force; 2) Said cavity causes an uneven transmittance of transducer power to the horn, forming a standing wave that forces the horn walls to vibrate; 3) Said cavity increases the horn vibrations through resonance that is the result of interaction between parallel vibrating walls. In a first embodiment of the invention, the shape of said cavity matches the outer shape of the horn, defining a uniform horn wall thickness. Therefore, since the horn is preferably cylindrical, the cavity is preferably of a cylindrical shape. In a second embodiment of the invention, said cavity comprises a plurality of cylindrically shaped sections, preferably equivalent, thereby providing additional advantages that will be explained hereinafter.
In a preferred embodiment, the resonant cavity comprises a central section of larger diameter and two symmetrical, extreme or end sections of smaller diameter. In a form of said preferred embodiment, the horn comprises a body, which defines the central section of the resonant cavity and one of its extreme sections, and a plug which defines the other extreme section of the resonant cavity and which is connected to the body, preferably screwed into it, at one end thereof. Preferably, the two extreme sections are symmetric to one another with respect to the central section.
Horns are generally made, in the art, of a titanium alloy, e.g. Ti-4V-6Al, but for the purposes of this invention the horn and the aforesaid plug are preferably made of stainless steel (316L/302 ASTM). The transducer is connected to one of the ends of the horn, preferably the end into which the plug, if any, is inserted, e.g. by a connecting insert, screwed into both the said end, preferably the said plug, of the horn and into the transducer.
The ultrasonic power generated by the transducer of the invention is emitted outwardly from the entire surface of the horn, comprising its sides, and not merely from its extremity, as in prior art horns. In the prior art horns, the only emitting surface is a narrow extremity and the ultrasonic waves spread out from it in a conical configuration; therefore the ultrasound has a high intensity at said extremity and becomes weaker as it spreads out from it, roughly inversely proportional to the square of the distance from said extremity. In the horn of the present invention the irradiating surface is practically the entire outer surface of the horn and the ultrasound intensity is substantially uniform throughout the reaction space, although it is still somewhat higher at the horn extremity, as will be explained hereinafter. This leads to a greatly increased efficiency, on the order of 60–80%, as has been said.
The internal volume of said reactor is characterized by resonant properties as well. The distance between the emitting surface of said horn and the reactor walls is equal to a whole number of half wavelengths in the contained liquid. The distance between the surface of the extremity of said horn and the bottom internal surface of said reactor volume is equal to whole number of half wavelengths in the contained liquids.
The generated acoustic standing wave in the reactor volume, which operates as a hollow resonator, in combination with uniform emission of ultrasound from the surface of the horn as well as from its extremity, provides homogeneous distribution of ultrasonic energy over the reactor volume.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a perspective view of a transducer, coupled with a horn, in accordance with an embodiment of the present invention;
FIG. 2 is an axial cross-sectional view of a horn according to an embodiment of the present invention;
FIG. 3 is an axial cross-sectional view of a horn according to a second embodiment of the present invention;
FIG. 4 is an axial cross-sectional view of a horn according to a third embodiment of the present invention;
FIG. 5 is an enlarged view of FIG. 4 , particularly illustrating the screw connection between the body and plug elements of the horn; and
FIG. 6 is a cross-sectional view of an embodiment of a reactor in which the transducer and horn of this invention are used.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates an ultrasonic device comprising a transducer, generally designated as 1 , and its connection to a horn, generally designated as 10 , in accordance with an embodiment of the invention. Transducer 1 is connected to and supported by base 5 by a weld, or any other suitable, connection. The transducer comprises a magnetostrictive element 2 , which in this embodiment comprises two vertical branches 3 and 3 ′ and two horizontal branches 4 and 4 ′ connecting said vertical branches; the lower branch 4 ′ being welded to base 5 .
Coil 6 comprises two branches 7 and 7 ′ wound about the vertical branches 3 and 3 ′ of the magnetostrictive element and connected at their ends 8 and 8 ′ to an AC power generator (not shown). The same electric current flows through both branches of coil 6 and generates the same magnetic field about branches 3 and 3 ′ of the magnetostrictive element.
Base 5 is of a height or length equal to a whole number of half-wavelengths, preferably one half-wavelength, of ultrasonic waves as generated by the transducer and corresponding to the frequency of alternating current flowing through coil 6 . A connecting insert 9 is screwed to horn 10 and to base 5 , wherein the screw connections are wound tight to ensure a strong mechanical coupling between transducer 1 and horn 10 . The horn, in this embodiment, has a resonant length equal to a whole number “n” of half-wavelengths in the horn material.
FIG. 2 is an axial (generally vertical) cross-section of a horn, generally designated as 11 . Horn 11 is cylindrical, except for a short, frusto-conical, bottom portion cut-off 13 of its bottom plate 12 . The connecting insert 9 is mounted by a threaded connection to top plate 14 of horn 11 . Horn 11 is hollow, filled generally with air, and defines a cylindrical resonant cavity 15 , coaxial with the outer surface of the horn, so that the longitudinal (generally vertical) walls of the horn are of a uniform thickness. Horn 11 is therefore, operating as a hollow resonator for ultrasonic oscillations.
Under the ultrasonic oscillations produced by the transducer, the horn walls oscillate elastically, expanding and contracting periodically substantially in the transversal direction according to Poisson's effect, wherein an efficient transformation of longitudinal ultrasonic oscillations received from the transducer into transversal ultrasonic oscillations of the external walls of the horn, generally defined as “Push-Pull”. The maximum amplitude of longitudinal mode of ultrasonic oscillations is at the top and bottom plates of the horn because resonant length of the horn is equal to a whole number of half-wavelengths in the horn material. The maximum amplitude of transversal mode of ultrasonic oscillations is situated practically halfway between the top and bottom plates on the side surface of the horn due to resonant conditions in the medium filled internal cavity of the horn, generally air.
The conditions defining the maximum amplitude of longitudinal oscillations to be at the extremities of the horn and maximum amplitude of transversal oscillations to be situated on the side surface, halfway between top and bottom plates of the horn, are the ones leading to homogeneous ultrasonic emission outwardly into the medium surrounding the horn. During application the horn is mounted in a reactor and immersed in a liquid medium, generating a process where said elastic oscillations of said horn produce alternate compression and decompression cycles on said medium; wherein homogeneous ultrasonic emission leads to homogeneous acoustic cavitation throughout the medium, a process that is extremely important for sonochemical applications.
The applicant has found, however, that it is advantageous to provide essentially cylindrical horns, the walls of which have portions of different thicknesses. In this case, elastic oscillations will be produced having different amplitudes along the horn, greater, in horn sections of equal lengths, where the horn walls are thinner. The applicant has found that, in this case, the ultrasonic energy produced and transferred to the reactor medium—“the output energy”—is greater than when the horn resonance chamber is cylindrical, all other things being equal. Such an embodiment is shown in FIG. 3 . The horn 16 has the same outer shape as the horn 11 , but the internal resonant cavity comprises a central section 17 and two symmetric sections 18 and 18 ′ of smaller diameter than said central section 17 and connected thereto by curved annular surfaces 19 and 19 ′. The whole resonant cavity is symmetric with respect to a transversal plane passing through the center of section 17 . The walls of the horn are thinner where they define said section 17 .
However, making a horn as shown in FIG. 3 would require providing at least two halves or unequal portions, boring them to define the various parts of the resonant cavity, and then connecting them by welding or the like. Such a connection would not adequately resist the stresses caused by ultrasonic, elastic oscillations. Therefore, a preferred embodiment of a horn, having a resonant cavity comprising the same sections shown in FIG. 3 , is illustrated in FIGS. 4 and 5 .
FIG. 4 , and its enlarged FIG. 5 , illustrate a horn 20 , comprising a body 21 , defining the central section of the resonance chamber 22 , and a terminal section 23 of said resonance chamber 22 . The horn further comprises a plug 24 screwed into the body 21 , which defines the second terminal section 25 of the resonant cavity. The two terminal sections 23 and 25 are of the same length and diameter. Connection insert 9 is screwed into said plug 24 and extends outwardly from said plug, preferably by one-half its length, to provide an external section onto which the base 5 can be screwed firmly to connect the horn to the transducer, as shown in FIG. 1 . Central section 22 of the resonant cavity blends with the terminal sections 23 and 25 through annular sections 27 .
For example, in the embodiment illustrated, the sections of the resonant cavity may have the following dimensions: the central section may have a diameter of 15 to 45 mm and a length of 60 to 105 mm; the terminal sections may have a diameter of 8 to 28 mm and a length of 20 to 90 mm.
In the embodiment illustrated, body 21 of the horn is connected with plug 24 by means of a square screw thread 28 (see FIG. 5 ). The ultrasonic radiation intensity, supposed to be high, is distributed throughout the reactor volume as homogeneously as possible. The energy levels should preferably be from 3 to 7 W per square centimeter of the horn's outer surface. When the reactor chamber is filled with liquid, said homogeneous intensity distribution can be achieved by the ultrasonic resonance of the liquid in addition to homogeneous ultrasonic emission from the horn. For example, the energy intensity may reach high levels, such as 0.2–0.6 W per cubic centimeter of the horn volume.
In order to reach a homogeneous volume density of the ultrasonic energy inside the reactor volume, the reactor chamber comprises a hollow acoustic resonator, wherein the distance between the emitting surface of the horn and the reactor walls is equal to a whole number of half wavelengths in the contained liquid. The distance between the horn tip (extremity) and the bottom internal surface of the reactor volume is equal to a whole number of half wavelengths in the contained liquid.
It should be mentioned that the important condition of homogeneous ultrasonic energy distribution throughout the internal reactor volume is achieved by a homogeneous emission of ultrasonic energy from the side and bottom surfaces of the horn.
In a preferred design, the length of the horn should be equal to a whole number of ultrasonic radiation half-waves. The wavelength λ of the ultrasonic radiation is given by λ=v/γ, where γ is the ultrasonic frequency, and v is the ultrasound propagation velocity in the horn material.
The intensity I of the ultrasonic radiation corresponding to an energy W, assumed to be homogeneously distributed, is I=W/S, wherein S is the area from which the ultrasound is irradiated. In ideal cases, the intensity I can be calculated from the formula I=vργ 2 A 2 , where v is the ultrasound velocity in the medium, p is the density of the medium, γ is the ultrasonic frequency and A is the amplitude of ultrasonic waves.
In solid horn designs of the prior art it is possible to observe weak oscillations and cavitation on the side surface of the horn. Those weak radial oscillations constitute the manifestation of the Poisson effect, according to the formula: χ=−ε′/ε, where χ is the Poisson coefficient, ε′ and ε are respectively the radial (transversal) and the longitudinal modules. In ultrasonic oscillations the speed of deformations is very high, and the material of the horn can be considered incompressible.
The amplitude of the radial elastic oscillations can be calculated from the formulae:
G=E/ 2(1+χ);
E=K/ 3(1+2χ);
σ=Kε;
where E is Young's modulus, K is the volume elasticity module; G is the module displacement, χ is the Poisson coefficient, σ is the stress and ε is the strain.
In solid horns, radial oscillations are small because of tangent stress relaxations in the entire metal volume. For excluding relaxation phenomena, the horn mass has to be reduced while maintaining the surface area, the horn construction should therefore be tubular. In relatively thin walls, the radial amplitude may reach 0.5 of the longitudinal amplitude. Therefore the parameters of the horn should be determined according to: 1. The desired amplitude of radial oscillations; 2. The desired ultrasonic power to be emitted from the outer surface of the horn; 3. The surface area that will provide the desired ultrasonic intensity; and 4. The fatigue resistance of the horn material to the ultrasonic wave propagation.
FIG. 6 is a cross-sectional view of an embodiment of a reactor that can be used in various ultrasonic applications. The reactor, generally illustrated as 30 , which may be manufactured, by example, from Pyrex glass, is mounted in housing 31 , and comprises upper flange 43 and lower flange 42 . Ultrasonic device 33 is supported by flange 32 . All said flanges are made, by example, of polypropylene. Transducer 44 is connected by a connecting insert 16 to horn 45 . Thermometer 34 and an optional stirrer are connected to the reactor through the top of reactor 30 . Cooling liquid is introduced into housing 31 through inlet tube 35 , situated in flange 42 , and is withdrawn from housing 31 by discharge tube 35 ′, situated in flange 43 . A circuit for the protection of the horn against chemical corrosion, not shown, has terminals indicated by 40 and 41 . The means for feeding the exciting current to the transducer are not shown. Connection to pumps is indicated by 46 . The means for supplying electric power to the coil and the means for feeding material to be treated by ultrasound are not shown, as they change from case to case.
To produce nano-metal oxides or hydrates, a metal salt solution (generally a chloride) is subjected to extremely high ultrasound energy in the presence of a basic solution, such as, by example, an alkali hydroxide. A 10-liter reactor as hereinbefore described, capable of producing energy up to 0.6 W/cm 3 , is suitable for this purpose. Under such conditions, highly active radicals are rapidly created inside cavitation bubbles that explode rapidly, leaving nuclei of nano-particles. In such a sono-reaction, one mole of metal salt yields up to several hundred grams of nano-powder, 5 to 60 nm crystallite size, in a short reaction time.
Examples of nano-particle compounds, produced sonochemically, are oxides, such as FeO, Fe 2 O 3 , Fe 3 O 4 , NiO, Ni 2 O 3 , CuO, Cu 2 O, Ag 2 O, CoO, Co 2 O 3 and hydroxide crystal hydrates, such as Fe(OH) 3 , Co(OH) 3 , NiO(OH). BaTiO 3 can be sonochemistry produced as well.
Examples of metal nano-particles produced sonochemically are Fe, Co, Cu, Ag, Ni, Pd, etc.
The reactor of the invention is an effective unit for acceleration of chemical reactions. For example, the reduction of metal salts or oxides to a metallic powder, in relatively high amounts (1 mole) is completed in 5–10 minutes. Such powders consist of ultra fine metallic or non-metallic particles in the nano-scale range (5–100 nm). The resulting products may be used in a wide range of applications, including pigments, catalysts, magnetic media, optoelectronic materials, cosmetics, chemical polishes, abrasives, composites and coatings.
The following, non-limited examples illustrate embodiments of such processes.
EXAMPLE 1
Production of Nano Iron Hydroxide Powder
The iron hydroxide is produced from an iron salt, in this example iron chloride, and a base, particularly an alkali hydroxide, in this example sodium hydroxide, according to the following reaction:
2FeCl 3 +6NaOH→2Fe(OH) 3 +6NaCl
The reagents are prepared by weighing with an analytical balance and preparing water solutions of iron chloride and sodium hydroxide.
The reaction is carried out under high power ultrasound according to the following parameters:
Reaction composition: iron chloride—80 gr.
1. sodium hydroxide—60 gr. 2. distilled water—950 gr.
Time of reaction—5 minutes
The product is Nano iron hydroxide powder, having particle size below 100 nm.
EXAMPLE 2
Production of Nano-Amorphous Nickel Hydroxide Ni(OH) 2
The nickel hydroxide is produced from a nickel salt, in this example nickel chloride, and a base, in this example sodium hydroxide, according to the following reaction:
NiCl 2 +2NaOH→Ni(OH) 2 +2NaCl
The reagents are prepared by weighing with analytical balance and preparing water solutions of nickel chloride and sodium hydroxide.
The reaction is carried out according to the following parameters:
Reaction volume—1 liter
Reaction composition: nickel chloride—70 g
a. sodium hydroxide—25 g b. distilled water—900 ml
Time of reaction—5 minutes
The product nickel hydroxide is a green amorphous material having surface area (BET)>350 m 2 /gr and particle size (HRSEM) of 20–60 nm.
EXAMPLE 3
Production of Nano-Crystalline Cobalt Powder
The cobalt is produced from a cobalt salt, in this example cobalt chloride, and a powder of a metal capable of reducing said salt to cobalt metal (hereinafter indicated by “M”), according to the following reaction:
CoCl 2 +M→Co+MCl 2
The reaction is carried out according to the following parameters:
Reaction volume—1 liter
Reaction composition: cobalt chloride—240 g
a. M—reducing metal b. suitable solvent—1 liter
Time of reaction—5 minutes
The product is hexagonal cobalt powder, having a specific weight of 8.9 g/cc and a black color, and particle size 10–40 nm.
Other metals can be produced by similar reactions.
EXAMPLE 4
Production of Nano-Crystalline Iron Oxide Powder Fe 2 O 3
80 g of anhydrous FeCl 3 were dissolved in 800 ml of water. 60 g of NaOH were added to 100 ml of water at room temperature. The solution of FeCl 3 was mixed with the solution of NaOH under ultrasound and a gelled solution of precipitates was obtained.
The gelled solution was filtrated with suction and washed thoroughly with distilled water until a test with AgNO 3 reagent is negative, to remove any residual free chlorine. The dried precipitates were then placed into a high temperature oven for the heat treatment, and the temperature of the oven was increased at a rate of 5° C./min to 600° C. to calcine the precipitates for 1 hour and then they were cooled at room temperature to obtain red hematite iron oxide Fe 2 O 3 nano-powder, with particle size 20–100 nm.
While embodiments of the invention have been described for the purpose of illustration, it will be understood that the invention may be carried into practice with many modifications, adaptations and variations, without exceeding the scope of the claims.
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Ultrasound device having a reaction chamber, which includes a magnetostrictive transducer and a horn transmitting ultrasound radiation substantially uniformly throughout the reaction chamber. The horn is hollow and is constituted by a cylinder having an empty inner chamber at its core defining a resonance chamber, which may be cylindrical and may comprise a plurality of sections of cylindrical shape or a central section of larger diameter and two terminal sections of smaller diameter.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to vacuum cleaners and, more specifically, relates to a nozzle height adjustment and conversion valve arrangement which converts an upright vacuum cleaner for hose operation.
2. Summary of the Prior Art
The use of hose conversion valves with upright vacuum cleaners is old and well known. Conversion arrangements have taken many forms such as use of insertable conversion couplings for valve actuation, off the floor hose manipulation conversion, valve actuation manipulation, pedal conversion valve actuation, cleaner handle valve actuation and nozzle movement conversion valve actuation. Each of these conversion arrangements is also known where there is some incident of nozzle adjustment upwardly to move a cleaner agitator off the floor when converting to the hose mode. Heretofore, however, no known valve conversion arrangement has been devised which reciprocates so as to function most smoothly with a reciprocating type nozzle height elevation means.
Accordingly, it is an object of the invention to provide a reciprocating conversion valve operating in conjunction with a nozzle height elevation means.
It is an additional object of the invention to provide reciprocation nozzle height elevating means operative in conjunction with a conversion valve.
It is a still further object of the invention to provide an efficiently operating connecting arrangement disposed in driving relationship between a nozzle height elevating means and a cleaner conversion valve.
It is also a object of the invention to provide an improved cleaner conversion valve arrangement operating in conjunction with a nozzle height elevation means.
SUMMARY OF THE INVENTION
An upright cleaner suction nozzle is disclosed which conventionally rotatably mounts an agitator within a suction cavity formed at the front end of the nozzle. The suction nozzle is supported on wheels for easy traverse over a floor or rug including a pair of intermediately disposed wheels, mounted on a pivoting strut so as to provide for height adjustment of the nozzle. A stepped camming arrangement is mounted in a tracklike guide in the suction nozzle so as to be reciprocally movable transverse to the fore and aft direction of the nozzle to interpose itself between the nozzle body and the pivoting strut to move the pivoting strut with or against the weight of the nozzle body. A suction duct is disposed to extend along one side of the nozzle and communicates at its forward end with the agitation containing suction cavity. A gate valve is also mounted in a guide in the suction nozzle to move reciprocatorily within the nozzle body also transverse to its fore and aft direction to telescopically move into and out of the suction duct to open or close it. The gate valve is driven in its movement through an integral driving tab on it by reciprocal movement of the height adjustment arrangement for the nozzle by means of a driving connection therebetween. A lost motion mechanism is provided in this driving connection to accommodate final maximum height adjustment of the suction nozzle. An angled cam formed on the suction nozzle adjacent the guide for the gate valve permits the connecting means to override the driving tab during opening and closing of the gate valve to arrest its movement intermediate the width of the nozzle.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference now may be had to the accompanying Drawings for a better understanding of the invention, both as to its organization and function, with the illustration being of a preferred embodiment, but being only exemplary, and in which:
FIG. 1 is a bottom plan view of an upright cleaner suction nozzle incorporating the invention and with the bottom plate removed;
FIG. 2 is a partial plan view of the structure showing portions of the height elevation means, driving connection and gate valve in closed position;
FIG. 3 is a view similar to the full line position of FIG. 2 but showing the driving connection only moved partly up the camming ramp;
FIG. 4 is a similar view of the height elevation means, driving connection and gate valve with the dashed line position showing a slight leftward movement of the height elevation means and driving connection in a gate valve opening direction and with the full line position showing the height elevation means and driving connection removed from and overriding the gate valve driving tab to permit further adjusting movement of the height elevation means leftwardly;
FIG. 5 is a partial side elevation cross sectional view of the invention taken generally on line 5--5 of FIG. 1 and showing the mounting of the height elevation mechanism and driving connection;
FIG. 6 is a front elevational view of the height elevation mechanism and driving connection taken on line 6--6 of FIG. 1;
FIG. 7 is a front elevational, partially cross sectional view of the gate valve and its suction nozzle mounting taken on line 7--7 of FIG. 1;
FIG. 8 is a rear perspective view of the height elevation means and driving connection structure of the instant invention, shown inverted with respect to its installed position.
FIGS. 9-12 are partial fragmentary showings of the height elevation means of the invention taken looking in the direction of line 9--9 in FIG. 1 and showing higher and higher nozzle height adjustment in moving from FIG. 9-FIG. 12.
DETAILED DESCRIPTION OF THE INVENTION
A vacuum nozzle 10 of a vacuum cleaner 11, best shown in FIG. 1, is disclosed which includes an agitator 12 disposed in the front of the nozzle in a suction chamber 14. A motor-fan housing cover well 16 obscures the downwardly depending motor and bag housing (neither shown) pivotally attached to vacuum nozzle on leftward and rightward trunnions 18, 20, riveted in enveloping relationship around similarly shaped lugs on the motor housing.
The suction nozzle 10 is supported for movement over a floor or carpet by intermediately disposed wheels 22, 22, serving as the front wheels of the cleaner 11 and disposed rearwardly of the agitator 12, and rear wheels (not shown) mounted, conventionally, in rear wheel wells 24, 24. The intermediately disposed wheels 22, 22 are pivotally mounted to suction nozzle 10 through a bracket 25. An axle 26 extends through an integral elongated tubular portion 28 of bracket 25 to mount the wheels 22, 22 outboard of the elongated tubular portion 28. Bracket 25 is roughly H-shaped with a thickened, ribbed cross bar 30 extending rearwardly from the elongated tubular portion 28. Cross bar 30 terminates in a pair of integral sidewardly extending pintles 32, 32 mounted in pivot pintle wells 34, 34 formed in vacuum cleaner nozzle 10 in housing cover well 16.
A nozzle height adjustment means 36 is interposed between the suction nozzle 10 and the pivoted wheel carrying bracket 25 to provide pivoting movement inwardly (upwardly) and outwardly (downwardly) of the wheels 22, 22 to raise or lower the vacuum cleaner nozzle 10 relative to its support surface. This height adjustment means bears against an integral upwardly or inwardly extending nose 38 formed at the front of the pivoting bracket 25, intermediate the ends of tubular portion 28. Adjustment of the wheels 22, 22 may also be had conventionally by a right angle crank link 40 pivoted (not shown) to the bracket 25 and abuttingly driven (by the motor housing) to pivot against the bracket 25 outwardly and force the wheels 22, 22 downwardly when the motor housing is placed in its storage position. A small upstanding support bracket 42, integral with pivoting bracket 25, pivotally mounts this crank link 40.
A duct 44 is also formed in the vacuum cleaner nozzle 10 which openly communicates with vacuum chamber 14 at a port 45 and extends rearwardly therefrom to terminate in an integral hose duct coupling elbow 46 that bends upwardly and extends through a top wall 48 of vacuum cleaner nozzle 10. The duct hose connecting elbow 46 is attachable, as is conventional, to a flexible hose or the like (not shown) for off the floor cleaning. The bottom or outerside of the duct 44 is formed by the covering bottom plate (not shown) of the vacuum cleaner nozzle 10.
A drive connecting means 50 (e.g., FIGS. 2-4), formed as an integral part of an actuating piece 52 of plastic which also contains, integrally, the nozzle height adjusting means 36, is disposed so as to engage a gate valve 54. This gate valve is movable into and out of the duct 44 to sealing close this duct relative to a fluid communication between it and agitator containing vacuum cleaner chamber 14. When this gate valve is closed, suction is applied solely to coupling elbow 46 (FIG. 1) and thereby available for off the floor cleaning through a suction port 56 leading to a fan (not shown) of the motor-fan system (not shown) of the cleaner 11. When the gate valve 54 is open, as is conventional, the end of the hose (not shown) attached to hose coupling elbow 46 must be sealed so full suction is available for cleaner floor operation.
Gate valve 54 (FIG. 7) is generally formed by a vertically extending thin, ribbed face wall 58 having intermediate, vertically extending ribs 60, 61 and a transverse, intermediate, horizontally extending rib 62. A peripheral border 64 extends around face wall 58 to complete its outline. The ribs and border of gate valve 54 extend inwardly and outwardly, equally, relative to the planar extent of face wall 58 on both of its sides to strengthen it and to functionally cooperate with the suction nozzle 10 in which it is mounted. At the leftward or inner end of gate valve 54, face wall 58 includes a small rectangular aperture 66 intermediate its height. Immediately inwardly of the aperture and extending from the border 64 is disposed a short small tab 68 that extends in the aft direction of the vacuum nozzle 10. As will be apparent later, the tab serves as a detent arrangement for the drive connecting means 50 while the rectangular aperture serves as a clearance for molding. The gate valve 54 is generally completed by a leftwardly extending elongated tang 70 that includes at its end a thickened bulbous detent portion 72.
Gate valve 54 (FIG. 1) is guided in its reciprocating, rectilinear motion between open and closed position at its bottom by an upwardly opening guide track formed by a rearward spaced wall 74 of suction nozzle 10 and a vertically extending wall 78, forming the rear side of the agitator chamber 14, between which is disposed face wall 58 of gate valve 54. The walls 74 and 78 are spaced sufficiently far enough apart to provide a slight clearance beyond the thickness of the border 64 and rib 60 of face wall 58. At its top, gate valve 54 received guidance through the integral, transversely extending tang 70 (FIG. 7), riding in a track formed by the short depending wall 76 of suction nozzle 10 and the vertically extending wall 78, with this wall giving some guidance to the gate valve 54 nearly along its entire length.
At an inner side wall 77 of the duct 44 (FIGS. 2 and 3), near agitator chamber 14, additional guidance is afforded to the movement of the gate valve 54 by a slit 79 formed by a short vertically extending wall 80 parallel to and spaced from a downward step 81 (FIG. 1) of rear border wall 78 of agitation chamber 14. Between the two walls of the duct 44 a rectangular opening 82 communicates with the duct 44 and through this opening gate valve 54 reciprocates to open and close duct 44. The vertical rib 60 (FIG. 7) of gate valve 54 is disposed within slit 79 when the valve is closed, with this slit slightly wider than the rib 60, so that some sealing is obtained around gate valve 54. When the gate valve 54 is opened, the vertical, outer end portion of border 64 is disposed in this slit.
The nozzle height adjusting means 36 (e.g., FIG. 3) includes a linear cam 84 having a series of concave cam steps 86, 88, 90 and 92 which adjust the wheels 22 inwardly and outwardly of the suction nozzle 10 as the distance set by the cam steps between a bottom side 94 of the nozzle 10 and the nose 38 on wheel carrying pivoted bracket 25 increases or decreases. Movement of linear cam 84 is occasioned by movement of a linear cam slider 96 FIGS. 5 and 6, disposed on the upper side of suction nozzle 10, and including an operator contactable slide piece 98 mounted therewith by a detenting arrangement (not shown) within the operator contactable slide piece 98. The slide piece 98 detentingly engages with an upstanding centrally located post 100 on the slider 96.
The slide 96 is abuttingly captivated to slide along the top surface of the suction nozzle 10 by attachment of it to the actuating piece 52 which is disposed on the opposite side of the suction nozzle 10. Connection between the slide 96 and the actuating piece 52 is afforded by a pair of barbed tangs 102, 102, integral with actuating piece 52 and extending downwardly from its ends and mountingly inserted into end, through apertures 103, 103 in slide piece 96. Clearance for the tangs 102, 102 in their movement across suction nozzle 10 is provided by an extending slot 104 formed in vacuum nozzle 10 and extending transversely along it, this slot and the portion of suction nozzle 10 forming the border between linear cam slider 96 and actuating piece 52 (i.e. linear cam 84) forming the guide for these two parts.
To arrest the movement of actuating piece 52 and provide positive dwell points for it as it translates across the suction nozzle 10 in effecting actuation of nozzle height adjusting means 36, a height elevation detent means 105 (FIG. 4) comprising a series of fixed detents 106, 108, 110 and 112 is formed on a cross piece 114, integral with and extending transversely across the suction nozzle above the wheels 22, 22. These detents corresponding, respectively, with cam steps 92, 90, 88, and 86 and their engagement with nose 38. An engaging tab 116, cantilever mounted on a transversely extending, integral arm 118 of actuating piece 52 engages in these detents. Due to the inherent resiliency of the plastic actuating piece 52 and the fact that the arm 118 is in compressed condition as it rides along the cross piece 114 positive engagement occurs.
A generally, somewhat similar detented nozzle height adjusting arrangement is shown in U.S. Pat. No. 4,171,554, issued Oct. 23, 1979 and owned by a common assignee.
In order to provide for a positive dwell point at the location of the actuating piece 52 in the suction nozzle 10 when the gate valve 54 is in closed position relative to the duct 44 an additional detent 120 is formed in cross piece 114, rightwardly removed from the detents 106, 108, 110, and 112. Detent 120 corresponds to the gate valve close position.
The drive connecting means 50 works in the following manner. When the actuating piece 52 has moved rightwardly so as to place cam step 92 beneath nose 38 (highest nozzle elevation) and engage tab 116 in detent 106 and raise the nozzle 10 to its maximum height (FIG. 3), an integral contilevered arm 122 of actuating piece 52 which extends transversely along its front side is beginning to move to a position to engage tab 68 of gate valve 54 to close it.
Integral cantilevered arm 122 is spring baised forwardly by a torsion spring 124 acting between a flat 126 in actuating piece 52, through mounting hole 128 in it, and cantilevered arm 122 having a notch 130 in which a spring end 132 of torsion spring 124 engages. This spring forces cantilevered arm 122 against the rear side of the short vertical guidance wall 76 or an extension wall 136 stepped down from but inwardly flush with it. This occurs by abutment of a forward integral projection 134 of cantilevered arm 122, alternately, against one of them. The wall 136, at its rightward end, terminates in a cam face 138 that angles outwardly to terminate adjacent the back side of the gate valve 54. Thus, movement of drive connecting means 50 rightwardly from the FIG. 3 position causes projection 134 and a cam slanting face 140 on projecton 134 to move outwardly along cam face 138, as driven by torsion spring 124, until a flat face 142 of projection 134 is far enough outwardly displaced to engage tab 68 of gate valve 54 (FIG. 4). Then, movement of the drive connecting means 50 further rightwardly drive the gate valve 54 to closed position in the duct 44 (FIG. 2).
Movement of the nozzle height adjusting nose 38 rightwardly past the maximum height position of FIG. 3 is along a flat face extension 143 of linear cam 84.
Movement of gate valve 54 leftwardly to open position is occasioned by a second, integral projection 144 situated rightwardly of spaced from projection 134 on cantilever arm 122. Projection 144 (FIG. 4) also includes a flat face 146, with flat face 146 confronting flat face 142 to form an elongated cam dwell slot 148 therebetween. Projection 144 is shaped with a smooth leading edge 150 at its forward, rightward side to guide this projection rightwardly over tab 68 in the event of misassembly of the nozzle height adjustment means 36 and gate valve 54. Since the cam dwell slot 148 provides a dead space between the faces 142, 146 initial leftward opening movement of the drive connecting means 50 from valve closed position (dashed position FIG. 4) does not initiate opening of valve gate 54 until face 146 engages the rightward side of gate valve tab 68.
Projection 134 through its abutting flat face 146 then remains engaged with valve gate projection 68 until valve gate 54 is again opened. At this time, cam slanting face 140 of drive connecting means projection 134 again moves against cam face 138 to force rearward pivoting movement of cantilevered arm 122 (FIG. 3) and driving disengagement of projection 144 with tab 68. Further movement of drive connecting means 50 leftwardly leaves the gate valve 54 in an open, stable position while drive connecting means projection 144 passes inwardly behind gate valve tab 68 and drive connection projection 134 slides in abutting relationship against the rear side of wall 136 (full line position, FIG. 4). The gate valve 54 remains open while the actuating piece 52 shifts farther leftwardly so that the nozzle height adjusting means 36 may place the suction nozzle 10 in a lower and lower position.
The structure of the invention is completed by a pair of dwell detents 152, 154 (FIG. 7), formed on the bottom side of the track between short vertical guide wall 76 and rear border wall 78 of agitator chamber 14. These detents are engaged by bulbous portion 72 of integral gate valve 54, through elongated tang 70, to thereby provide for more substantial positive location of gate valve 54 at its limits of travel.
It should be clear that the structure described fully fulfills the objects of the invention set out at the beginning of the Specification and the invention advantageously provides a combined nozzle height elevation arrangement and valve conversion arrangement. Also, not in limitation but as an example, a releasable camming arrangement has been devised so that the "throw" necessary for height adjustment of the nozzle does not require the provision of tracking means and clearances for the movable valve closure across most of the nozzle width and the consequent complications and weakening of the body structure of the suction nozzle. Also, an engaging projection arrangement that positively engages the valve closure member in both directions of its movement has been devised. But, at the same time, a dwell spot has been built into the projection arrangement to accommodate the spatial requirements for operation of the releasing valve closure cam arrangement. Accordingly, in view of the description offered, many modifications to the invention could occur to one skilled in the art which would still fall within its spirit and purview.
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A cleaner suction nozzle is provided in which provisions are made for a nozzle height elevation arrangement and a hose conversion valve arrangement. The hose conversion valve arrangement works in conjunction with the nozzle height elevation arrangement so that the suction nozzle can be elevated from the floor to disengage the cleaner agitator and then hose conversion of the cleaner can occur almost simultaneously.
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FIELD OF THE INVENTION
The invention relates to a foundation construction device for making trenches in the soil comprising a frame, at least one soil-removing tool arranged on the frame and a control device for controlling the foundation construction device in the trench.
BACKGROUND ART
Such foundation construction devices for making trenches are lowered on a carrier device whilst being suspended thereon. Through rotating movements of cutting wheels, grabs or scoops the soil is removed in a generally rectangular cross-sectional surface so that a trench filled with suspension is produced in the soil. In order to make a trench wall this procedure can be repeated in a horizontally spaced position.
The soil can consist of different sand layers, stone layers, rock and cavities. This can give rise to undesirable deviations of the foundation construction devices. Even minor changes of direction of the foundation construction device may, in greater trench depths, lead to considerable gaps in the trench wall.
From DE-C-36 15 068 a cable-guided trench wall grab is known, on the grab frame of which a guide frame is longitudinally movable on the outside. The guide frame is lowered with the grab into the trench where it is braced against the walls of the trench by means of extendable spacer plates. In the guide frame the grab frame can be guided in the vertical direction during the movements required to strip the soil. In doing so the bracing of the guide frame in the trench is controlled such that the grab axis is always located in the centre of the trench. To this end the spacer plates are extended on either side of the grab axis equidistant thereto either by means of levers actuated through cylinder-piston units or directly by cylinder-piston units that can be controlled separately for each spacer plate. By using displacement measuring devices that indicate the position of the cylinder-piston units and an inclination measuring instrument that indicates the position of the grab frame to the vertical line a position of the grab in the trench can be controlled to a certain degree.
From the disclosed document EP-A-0 518 298 a trench wall cutter and a cutting method for making trench walls with random angles of inclination are known. For this purpose control flaps are arranged on a vertically movable cutting frame, which, by projecting as far as beyond the outer border of the cutting frame, can be driven through hydraulic cylinders. In the cutting frame an inclinometer is arranged for directional correction. The hydraulic cylinders can in addition have a displacement pick-up und a pressure switch for the position of the control flaps. The control flaps can be prestressed against the trench wall either at the lower end or at the upper end thereof, whereby a torque acting in a predetermined direction on the cutting frame is generated.
SUMMARY OF THE INVENTION
The invention is based on the object to provide a foundation construction device having a simple design which can be controlled in a precise and reliable manner in the trench.
In accordance with the invention the object is solved by a device having the features of claims 1 or 7 . Preferred embodiments are stated in the dependent claims.
The foundation construction device according to the invention for making trenches in the soil is characterized in that the control device has at least two control flaps, which are supported pairwise opposite each other on the frame and are movable by means of at least one common adjusting cylinder, a lever mechanism and a distributing device, and in that the distributing device is designed to variably distribute the force and/or the adjusting path of the at least one common adjusting cylinder to the control flaps disposed opposite each other.
A basic idea of the invention resides in the fact that the soil-removing tool is guided along the previously produced trench wall according to a predetermined work path and that the soil-removing tool is re-aligned into a desired position in the case of an undesired deviation occurring. For the alignment opposite control flaps can be extended to a different degree by means of an adjusting cylinder. The force and/or the adjusting path of the adjusting cylinder are distributed to a varying extent to the control flaps by means of a controllable distributing device. As a result, the design of the foundation construction device is simplified whilst still maintaining a good controllability.
A preferred embodiment of the invention resides in that the lever mechanism is designed as a knee-lever mechanism having two articulated levers, each of which is linked to a control flap. Through the knee-lever mechanism the articulated levers can be pivoted at an equal distance or at a varying one so that the linked control flaps can be extended at an equal distance or at a varying one from the centre and at an equal distance or offset to each other in the vertical height.
According to the invention a further development resides in that the distributing device has a control member which is arranged in an adjustable manner, more particularly in a turnable manner, between the articulated levers and the at least one adjusting cylinder. In accordance with the position of the control member it transmits the force or the adjusting movement of the piston of the adjusting cylinder to the articulated levers.
According to an embodiment of the invention it is preferred that the control member is connected to an actuating rod, on which the at least one adjusting cylinder engages in an offset manner to a centre axis of the actuating rod. As a result of the offset engagement of the adjusting cylinder with respect to the centre axis of the actuating rod this actuating rod can be turned by the adjusting cylinder itself.
A particularly preferred further development of the invention resides in the fact that two adjusting cylinders are provided which engage on the actuating rod at different positions. The adjusting cylinders engage on opposite sides of the actuating rod on lever arms so that when the pistons are extended from the adjusting cylinders it is not only possible that the rod can be turned about its own axis but also that the forces are applied in an oblique downward directed manner.
Furthermore, a preferred embodiment of the invention resides in that on both sides of the actuating rod a control member is each arranged, with at least four control flaps being operable. Through the respective control member a displacement and/or a turning of the actuating rod is transmitted to the pivoting movement of the articulated levers.
Moreover, the foundation construction device according to the invention for making trenches in the soil is also characterized in that the control device has at least one guide wheel which is arranged on the frame in an extendable and retractable manner. The at least one guide wheel is located on the side of the foundation construction device that extends perpendicularly to the sides of the control flaps. The guide wheel serves to support the foundation construction device laterally on the trench wall and can be employed for the lateral correction of the position of the foundation construction device.
A preferred embodiment of the invention resides in that the guide wheel is rotatably supported on a swivel arm which can be pivoted through an actuating member. The swivel arm is pivotably supported on the frame on the other end with respect to the end where the guide wheel is rotatably supported. As actuating member e.g. an adjusting cylinder can be employed.
In accordance with the invention a further development resides in that a guide wheel is each arranged on two opposite sides. The guide wheels can be pivoted to the same extent or to a varying one through the swivel arm. As a consequence, during the production of the trench a defined lateral displacement of the foundation construction device and therefore a precise correction of the position of the foundation construction device in the trench are rendered possible.
According to the invention the foundation construction device for making trenches in the soil is designed as a trench wall cutter or a trench wall grab. These require a particularly precise guidance.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following the invention will be described further by way of preferred embodiments which are schematically shown in the drawings.
FIG. 1 shows a perspective view of a foundation construction device according to the invention.
FIG. 2 shows a perspective view of a variant of a control flap device according to the invention when located in the retracted position.
FIG. 3 shows a perspective view of the variant of the control flap device according to the invention from FIG. 2 when located in the extended position.
FIG. 3 a shows a lateral view of the foundation construction device according to the invention from FIG. 1 during the correction of an obliquely cut trench.
FIG. 4 shows a perspective partial view of a foundation construction device according to the invention with a guide wheel device located in the retracted position.
FIG. 5 shows a perspective partial view of the foundation construction device according to the invention with the guide wheel device from FIG. 4 located in the extended position.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 a foundation construction device 10 according to the invention is shown which is designed in this case as a trench wall cutter. It includes several rotatably driven cutting wheels as soil-removing tools 14 , a frame 12 and a control device comprising a control flap device 1 and a guide wheel device 5 . For the attachment to cable mountings two bolts located in attachment slots 31 , 32 are provided. Upon an increasing depth of the trench first the control flap device 1 and then the guide wheel device 5 can be additionally employed for guidance or for correcting the direction of the soil-removing tool.
In FIGS. 2 and 3 a preferred variant of the control flap device in accordance with the invention is shown in perspective view. The control flap device 1 consists of a pair of two control flaps 16 , 18 disposed opposite each other with their rear, adjusting cylinders 20 attached to the frame 12 on a side thereof, actuating rods 26 having lever arms 27 and lever mechanisms. The control flap 16 , 18 has a flap contact surface 19 , at the end of which end inclinations 35 are formed. The contact surfaces 19 rest against the trench wall for directional correction. At the rear of the control flap 16 , 18 the said flap 16 and 18 respectively has a central, perpendicularly disposed control flap ridge 17 , to which the articulated levers 22 are linked. In addition, a V-shaped ridge indentation 34 is provided for the articulated lever 22 in its retracted position as well as a U-shaped ridge indentation 33 and respectively a ridge sloping 36 is provided for the actuating rods 26 in their retracted position.
When the pistons of the upper adjusting cylinders 20 are extended, the upper knee-lever, consisting of the articulated lever 22 and the lever arm 27 , causes the two actuating rods 26 together with the upper ends of the control flaps 16 , 18 to be pressed apart.
When the two pistons of the lower adjusting cylinders 20 , by being extended in an equal manner, exert an oblique, downward directed pressure predetermined by the lever arms 27 , the lower actuating rod 26 moves downwards and extends the lower ends of the control flaps 16 , 18 .
If, through its extension, a single piston of a lower adjusting cylinder 20 exerts further pressure onto the lever arm 27 , while the piston of the other adjusting cylinder stops, the control member 24 is turned as a result of the force acting outwards and downwards in an oblique manner. Consequently, the articulated levers 22 have a different angle of attack with respect to the plate-shaped control member 24 , which leads to a different distribution of force to the articulated levers 22 .
For the retraction of the control flaps 16 , 18 the pistons of the lower adjusting cylinders 20 are retracted again, whereby the actuating rod and with it the control member 24 are lifted.
In FIG. 3 a an inclined position of the control flaps 16 , 18 with respect to the frame 12 with the soil-removing tool 14 is shown in a lateral view of the foundation construction device from FIG. 1 . In this case only the lower actuating rod 26 and the control member 24 located below the lower articulated levers 22 are operated. Through the turning and/or displacement of the actuating rod 26 the control member 24 linked to the articulated levers 22 has been adjusted too.
In FIGS. 4 and 5 a guide wheel device 5 according to the invention is illustrated in a perspective view. While the control flap device 1 aligns the foundation construction device on its front and rear on the trench wall, the guide wheel device 5 is able to guide or align the foundation construction device on its sides on the trench wall. The guide wheel device 5 comprises guide wheels 50 that are rotatably supported on the swivel arms 52 , pressing rods 53 that extend obliquely upwards and are each displaceable in a rod guide groove 55 of the frame posts 57 up to an upper stop, and a carriage 54 guided between two frame posts 57 , to which the two pressing rods are linked. If the carriage 54 is for example moved upwards through the piston of a cylinder, the pressing rods 53 linked to the carriage 54 extend along a rod guide groove 55 in a horizontally positioned direction. In doing so the swivel arm 52 , which is linked to the other side of the pressing rod 53 and is also linked to the frame 12 , is pivoted laterally in an obliquely upward directed manner. Once the carriage 54 is moved downwards again, the swivel arms 52 with the guide wheels 50 are lowered back into the vertical position.
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The invention relates to a foundation construction device for making trenches in the soil comprising a frame, on which a soil-removing tool is arranged, and a control device for aligning the foundation construction device in the trench having two control flaps, which are supported pairwise opposite each other on the frame, and having at least one extendable and retractable guide wheel arranged on the frame.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and the benefit of U.S. patent application Ser. No. 13/764,769, entitled “METHODS AND SYSTEMS FOR TREATING CARBONACEOUS MATERIALS,” filed Feb. 11, 2013, which is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The subject matter disclosed herein relates to methods for treating carbonaceous materials, and more particularly to methods for treating carbonaceous materials which improve the removal of ash from carbonaceous materials, and systems related thereto.
[0003] Different technologies are used to generate energy from organic or fossil-based carbonaceous materials such as coal. Different types of coal, such as lignite, or brown coal, subbituminous coal, bituminous coal, or black coal, anthracite and/or graphite, are utilized in energy producing systems. These different types of coal are categorized, or ranked, according to their particular physical properties, e.g., “low-rank coal” and “high-rank coal”.
[0004] Varying amounts of ash are present in naturally occurring carbonaceous materials such as coal. Ash is the non-combustible residue of mineral matter present in the carbonaceous material. Some coal materials have an ash content of greater than 20%, or even greater than 50%. The greater the ash content of the raw coal material, the lower amount of coal that will be available for energy production. High ash contents are also generally undesirable because of the potential for contamination of the equipment used in the energy production due to impurities present in the ash.
[0005] Carbonaceous materials such as coal are therefore subjected to an ash removal treatment on. Ash is separated from coal based upon differences between the inherent surface properties of the ash, which is hydrophilic, i.e., attracts water, and the coal, which is hydrophobic, i.e. repels water. Coal washing and/or flotation columns, for example, are used to separate the ash from the coal by taking advantage of the hydrophilic nature of the surface of the ash and the hydrophobic nature of the surface of the coal. Therefore, the amount of ash which is removed from coal using an ash-removal treatment is limited by the extent of these inherent surface properties.
[0006] Consequently, the ash content of coal materials which have a significant amount of ash cannot be sufficiently lowered using an ash removal treatment without the use of one or more additives. Various additives are employed in order to enhance the separation of the hydrophobic coal from the hydrophilic ash in order to provide a coal material with suitably low ash content for use in energy production. Such additives represent a significant cost in materials and/or process efficiency.
[0007] It is therefore desirable to provide a method for treating carbonaceous materials in order to improve the removal of ash from carbonaceous materials, and systems related thereto, which solve one or more of the aforementioned problems.
BRIEF DESCRIPTION OF THE INVENTION
[0008] According to one aspect of the invention, a method for treating a carbonaceous material comprises heating a carbonaceous material to form a mixture of the carbonaceous material and a tar; cooling the mixture of the carbonaceous material and the tar, and coating a surface of the carbonaceous material with the tar to form a tar-coated carbonaceous material.
[0009] According to another aspect of the invention, a system for treating a carbonaceous material comprises a heating region, the heating region being operative to heat a carbonaceous material to form a mixture of the carbonaceous material and a tar; a cooling region, the cooling region being operative to cool the mixture of the carbonaceous material and the tar and to coat a surface of the carbonaceous material with the tar to form a tar-coated carbonaceous material.
[0010] These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0012] FIG. 1 is a block flow diagram of a method for treating a carbonaceous material; and
[0013] FIG. 2 is a schematic diagram of a system for treating a carbonaceous material.
[0014] The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Embodiments described herein generally relate to methods for treating a carbonaceous material and systems related thereto. A method for treating a carbonaceous material is provided to modify the surface of the carbonaceous material in order to improve the separation of ash from the carbonaceous material.
[0016] Referring to FIG. 1 , the method for treating a carbonaceous material comprises heating a carbonaceous material. Upon heating, a tar is released from the carbonaceous material to form a mixture of the carbonaceous material and the tar. The method further comprises cooling the mixture of the carbonaceous material and the tar. Upon cooling, at least a portion of the tar released from the carbonaceous material coats at least a portion of a surface of the carbonaceous material to form a tar-coated carbonaceous material.
[0017] The carbonaceous material is any carbon-rich and/or hydrocarbon-based material. In one embodiment, the carbonaceous material comprises coal. In another embodiment, the carbonaceous material comprises low-rank coal, high-rank coal, or a combination comprising at least one of the foregoing. In yet another embodiment, the carbonaceous material comprises lignite, or brown coal, subbituminous coal, bituminous coal, or black coal, anthracite, graphite or a combination comprising at least one of the foregoing.
[0018] In one embodiment, the carbonaceous material comprises crushed coal. The coal is crushed using any appropriate crushing method and/or equipment, such as for example, a coal crusher, a coal shredder and/or a coal grinder. The coal is ground, crushed and/or shredded into smaller particles prior to heating.
[0019] The carbonaceous material comprises varying amounts of ash, including for example, high ash, e.g., greater than about 30% total ash content, and low ash, e.g., less than about 30% total ash content. In one embodiment, the carbonaceous material has a total ash content of about 10% to about 80% prior to heating. In another embodiment the carbonaceous material has a total ash content of about 10% to about 50% prior to heating. In yet another embodiment, the carbonaceous material has a total ash content of about 30% to about 50% prior to heating.
[0020] The carbonaceous material is heated as a solid or a suitable solvent is mixed with the carbonaceous material to form a solution or a wet slurry. In one embodiment, the carbonaceous material is heated in a solid phase and/or in a dry state. In another embodiment, the carbonaceous material is mixed with water or another suitable solvent to form a solution or a wet slurry prior to heating.
[0021] The carbonaceous material is heated at a pressure which is sufficient to release a tar, or oil, from within the carbonaceous material. The tar, or oil, is an organic material which is derived from the carbonaceous material. In one embodiment, the heating of the carbonaceous material is carried out at a pressure of less than about 5 atmospheres. In another embodiment, the heating of the carbonaceous material is carried out at a pressure of from about 1 to about 5 atmospheres.
[0022] The carbonaceous material is heated to a temperature effective to release tar, or oil, from the carbonaceous material. In one embodiment, the carbonaceous material is heated to a temperature of from about 300° C. to about 500° C. In another embodiment, the carbonaceous material is heated to a temperature of from about 350° C. to about 450° C. In yet another embodiment, the carbonaceous material is heated to a temperature of from about 375° C. to about 425° C.
[0023] At temperatures lower than about 300° C., an insufficient amount of tar is released from the carbonaceous material and/or the tar released will be less complex in composition, and therefore less hydrophobic than tar released at a temperature of greater than 300° C. and less than 500° C. At temperatures higher than about 500° C., the tar released from the carbonaceous material will not adequately coat the carbonaceous material or at least a portion of the carbonaceous material, e.g., reaction of the tar is promoted above these temperatures.
[0024] The heating of the carbonaceous material is accomplished using any suitable heating method and/or heat source. Examples of suitable heating methods and/or heat sources include pyrolysis, flash pyrolysis, partial oxidation, microwave energy, other conventional heating methods and/or heat sources or a combination comprising at least one of the foregoing.
[0025] In one embodiment, the heating of the carbonaceous material is accomplished using microwave energy. The microwave energy used to heat the carbonaceous material is supplied by a microwave energy generation device, such as a magnetron in a microwave oven. Wave energy generated by the magnetron is transferred to the carbonaceous material using for example, a wave guide or a wave tube.
[0026] The amount of microwave energy and the frequency of the microwave energy are selected to release the tar from the carbonaceous material at a desired temperature. In one embodiment, the microwave energy may be generated in a range of from about 100 kilo Watt per pound (kW/lb) to about 1,000 kilo Watt per pound (kW of power per lb of carbonaceous material). In another embodiment, the frequency of the microwave energy generated is about 800 MHz or about 2.45 GHz. The heating of the carbonaceous material is carried out in the presence or absence of a resonator.
[0027] Microwave energy is transferred through the carbonaceous material electro-magnetically, not as a convective force or a radiative force. Therefore, the rate of heating is not limited by surface transfer, and the uniformity of heat distribution is greatly improved. Heating times can be reduced to less than 1% of that required using other heating techniques. In one embodiment, the heating of the carbonaceous material with microwaves is precisely controlled with respect to the amount of heat applied, such that a precise temperature may be maintained at all times. In other words, substantially all portions of the carbonaceous material are exposed to the same temperature. For example, particles of the carbonaceous material form aggregates, or “lumps”. The center of each “lump” of carbonaceous material is at the same temperature as the surface of that lump. Thus, the tar released from the carbonaceous material, under the effect of the heat generated by microwaves, is not subjected to any temperatures higher than that which is needed to release the tar. In addition, since the uniformity of heat distribution is improved due to the generation of the microwave energy, the tar is released from the carbonaceous material more uniformly.
[0028] The carbonaceous material is heated in the presence or absence of additives, such as additional tar, which increase the hydrophobicity of the carbonaceous material or otherwise enhance the separation of carbonaceous material from ash. In one embodiment, the mixture of carbonaceous material and the tar is devoid of tar from any source external to the carbonaceous material, i.e., not already present within the carbonaceous material prior to heating or which is not derived from the particular carbonaceous material used in the method upon heating. In this embodiment, the only tar present in the mixture of the carbonaceous material and the tar is the tar that was released from the carbonaceous material upon heating.
[0029] In another embodiment, additional tar from an external source other than the carbonaceous material is added to the carbonaceous material prior to heating and/or to the mixture of the carbonaceous material and the tar formed during and/or after heating the carbonaceous material. In another embodiment, the additional tar is derived from a carbonaceous material and/or is a biomass material.
[0030] The mixture of the carbonaceous material and the tar is cooled by removing, discontinuing or lowering the heat temperature from the heat source described above and/or by transporting the mixture of carbonaceous material and the tar to a region which is not subjected to such heat from said heat source. In one embodiment, the mixture of the carbonaceous material and the tar is cooled to a temperature of between about 0° C. and about 300° C. In another embodiment, the mixture of the carbonaceous material and the tar is cooled to a temperature of between about 0° C. and about 200° C. In yet another embodiment, the mixture of the carbonaceous material and the tar is cooled to a temperature of between about 0° C. and about 100° C. In one embodiment, the cooling of the mixture of the carbonaceous material and the tar directly follows the heating of the carbonaceous material.
[0031] Upon cooling of the mixture of the carbonaceous material and the tar, at least a portion of a surface of the carbonaceous material is coated with at least a portion of the tar. The tar released from the carbonaceous material is hydrophobic in nature. The resulting tar-coated carbonaceous material is thus a surface-modified carbonaceous material. The coated tar increases the number of hydrophobic functional groups on the surface of the carbonaceous material, thereby increasing the overall hydrophobicity of the surface of the carbonaceous material. The increased hydrophobicity of the surface of the carbonaceous material improves the separation of the hydrophobic tar-coated carbonaceous material from the hydrophilic ash in a subsequent ash removal process.
[0032] In one embodiment, a surface of the tar-coated carbonaceous material is about 10% to about 80% more hydrophobic than the surface of the carbonaceous material prior to being subjected to said heating, cooling and coating. In another embodiment, a surface of the tar-coated carbonaceous material is about 20% to about 80% more hydrophobic than the surface of the carbonaceous material prior to being subjected to said heating, cooling and coating. In yet another embodiment, a surface of the tar-coated carbonaceous material is about 30% to about 80% more hydrophobic than the surface of the carbonaceous material prior to being subjected to said heating, cooling and coating.
[0033] In another embodiment, the carbonaceous material is partially coated with the tar released from the carbonaceous material. In yet another embodiment, the carbonaceous material is uniformly coated with the tar released from the carbonaceous material. In still another embodiment, the carbonaceous material is heated using microwave energy and is uniformly coated with the tar released from the carbonaceous material. In still yet another embodiment, the carbonaceous material is crushed coal which is heated using microwave energy and uniformly coated with the tar released from the carbonaceous material.
[0034] The tar-coated carbonaceous material is subsequently subjected to at least one ash removal process with or without the use of additives to enhance the separation of the tar-coated carbonaceous material from the ash. In one embodiment, the tar-coated carbonaceous material is devoid of any additive to enhance the separation of the carbonaceous material from the ash. In another embodiment, the tar-coated carbonaceous material further comprises at least one additive to enhance the separation of the tar-coated carbonaceous material from the ash.
[0035] Referring back to FIG. 1 , in one embodiment, the method further comprises removing ash from at least a portion of the tar-coated carbonaceous material. The tar-coated carbonaceous material is subjected to any ash removal process suitable to separate the tar-coated carbonaceous material from the ash mixed therewith on the basis of the differences between hydrophobic and hydrophilic surface properties. In one embodiment, removing ash from the tar-coated carbonaceous material is accomplished by a hydro-treatment. The hydro-treatment involves washing the tar-coated carbonaceous material with water or another suitable solvent, for example in a separation or flotation column. As the tar-coated carbonaceous material is washed, e.g., with water, the hydrophobic tar-coated carbonaceous material is separated from the hydrophilic ash mixed therewith.
[0036] The method described herein allows for greater removal of ash from a carbonaceous material when compared to a carbonaceous material which is not subjected to said method. In one embodiment, the tar-coated carbonaceous material is subjected to a hydro-treatment to remove ash in which a total ash content of the tar-coated carbonaceous material is reduced to about 0% to about 50%. In another embodiment, the tar-coated carbonaceous material is subjected to a hydro-treatment to remove ash in which a total ash content of the tar-coated carbonaceous material is reduced to about 30% to about 50%. In yet another embodiment, the tar-coated carbonaceous material is subjected to a hydro-treatment to remove ash in which a total ash content of the tar-coated carbonaceous material is reduced to about 0% to about 30%. In still another embodiment, the tar-coated carbonaceous material is subjected to a hydro-treatment to remove ash in which a total ash content of the tar-coated carbonaceous material is reduced to about 5% to about 20%. In still yet another embodiment, the tar-coated carbonaceous material is subjected to a hydro-treatment to remove ash in which a total ash content of the tar-coated carbonaceous material is reduced to about 15% or less.
[0037] Referring to FIG. 2 , a system for treating a carbonaceous material is provided. A system 10 for treating a carbonaceous material comprises a heating region 20 , the heating region 20 being operative to heat a carbonaceous material (not shown) to form a mixture of the carbonaceous material and a tar; and a cooling region 30 , the cooling region 30 being operative to cool the mixture of the carbonaceous material and the tar and to coat at least a portion of a surface of the carbonaceous material with at least a portion of the tar to form tar-coated carbonaceous material. The cooling region 30 is disposed downstream of the heating region 20 .
[0038] In one embodiment, the system 10 further comprises a carbonaceous material processing column 40 which contains the carbonaceous material and a transport system 50 which transports the carbonaceous material to the heating region 20 and from the heating region 20 to the cooling region 30 . In another embodiment, the transport system 50 is a conveyor belt.
[0039] In one embodiment, the system 10 further comprises a heating unit 60 , which supplies heat to the heating region 20 . In one embodiment, the heating unit 60 controls the heat supplied to the heating region 20 . In another embodiment, the system 10 further comprises an optional collecting region 70 . The collecting region 70 collects the tar-coated carbonaceous material subsequent to the heating, cooling and coating of the carbonaceous material in the heating region 20 and cooling region 30 , respectively. The collecting region 70 is disposed downstream of the heating region 20 and the cooling region 30 .
[0040] In one embodiment, the system 10 further comprises a feedback loop 80 . The feedback loop 80 senses the temperature in the heating region 20 and supplies this information to the heating unit 60 . The heating unit 60 uses information from the feedback loop 80 to regulate the temperature in the heating region 20 .
[0041] In one embodiment, the system 10 further comprises an ash removal region 90 in which ash is removed or separated from the tar-coated carbonaceous material. The ash removal region 90 is disposed downstream of the heating region 20 and the cooling region 30 , as well as the optional collecting region 70 .
[0042] In one embodiment, the system 10 further comprises additional equipment including, but not limited to, feed hoppers, crushers, grinders, mixers, conical separators, control units, cooling units, collection units, transport devices, shredders, heaters, screw feeders and/or other related equipment.
[0043] The methods and systems described herein pre-treat the carbonaceous material using tar released or derived from the carbonaceous material itself to partially or uniformly coat the carbonaceous material. The resulting surface-modified, tar-coated carbonaceous material has an increased overall hydrophobicity, which improves the separation of ash from carbonaceous materials which have undesirably high ash contents in an ash removal process. The methods and systems described herein thereby make such ash-containing carbonaceous materials suitable for subsequent use in a process which uses low ash coal, e.g., to generate energy. In this manner, the methods and systems provided herein allow for the use of relatively high-ash containing carbonaceous materials which would otherwise be rendered unsuitable due to their high ash content. The methods and systems described herein are also used to treat carbonaceous materials with or without the use of additional tar from an external source other than the carbonaceous material and/or with or without the use of other additives.
[0044] While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
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A method for treating a carbonaceous material including heating a carbonaceous material to move at least a portion of tar through the carbonaceous material toward a surface of the carbonaceous material to form a tar coating on the surface. The method also includes cooling the carbonaceous material and the tar coating on the surface to form a tar-coated carbonaceous material, wherein at least the portion of tar that forms the tar coating on the surface remains in contact with the carbonaceous material while the carbonaceous material is heated to form the tar coating and while the carbonaceous material and the tar coating are cooled to form the tar-coated carbonaceous material.
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CLAIM OF PRIORITY
The present application claims priority from Japanese patent application serial no. 2007-204867 filed on Aug. 7, 2007, the contents of which are hereby incorporated by reference into this application.
FIELD OF THE INVENTION
The present invention relates to an apparatus and control method for controlling an automatic transmission particularly a gear type automatic transmission used in an automobile.
BACKGROUND OF THE INVENTION
In recent years, an automated manual transmission (hereafter, abbreviated as “automated MT”) has been developed in an automobile technical field. This is a system used for automating operation of a clutch configured with a friction mechanism and operation of a synchromesh as a gear change mechanism in a gear type transmission which originally used to be used as a manual transmission. In the automated MT, when shifting is started, a clutch for transferring/interrupting torque of an engine as a driving force source is disengaged and a synchromesh is switched, and then the clutch is engaged again.
In JP-A-2000-234654 and JP-A-2001-295898, twin-clutch automated MTs are disclosed; the twin-clutch automated MT has two clutches for transferring input torque to a transmission and drive torque is alternately transferred by the two clutches. In the twin-clutch automated MT, when shifting is started, a first clutch that has been transferring torque before the shifting, is gradually disengaged, and a second clutch for the next gear position is gradually engaged; and drive torque is changed from the one equivalent to the current gear ratio to the one equivalent to the next gear ratio. As a result, interruption of the drive torque is avoided and smooth shifting can be achieved.
With respect to the above-mentioned twin-clutch automated MT, a so-called pre-shift control is disclosed in JP-A-10-318361 and JP-A-2003-269592. The pre-shift control is carried out to shorten a time required for shifting to the next gear position. That is, the pre-shift control is done such that, when a gear position is in some position, a next gear position is predicted; a transmission input shaft whose clutch has not been used for a current gear position is selectively coupled to a transmission output shaft by a synchromesh and they are thereby allowed to stand by in the next gear position.
The pre-shift control where the gear position is pre-shifted to the next position makes it possible to enhance a response for gear shifting when the prediction comes true. However, provided that a driver's request shift operation is done by the driver during the pre-shift control for the next shifting, an operation of the synchromesh according to the driver's request shift must be started after the pre-shift control is achieved. And then, when the operation of the synchromesh is completed, the clutch to clutch shift in engagement is started. As a result, the response is degraded.
The invention is to provide a control apparatus for twin-clutch automatic transmissions possible to advance start timing of pre-shift control and enhance the response when a shifting request continuously occurs.
SUMMARY OF THE INVENTION
The invention to achieve the above object is configured as follows. A shift control apparatus for automatic transmissions is comprised of: plural friction transfer mechanisms (for example, clutches) for transferring power of a driving force source and interrupting this transfer; plural transmission input shafts respectively coupled with the friction transfer mechanisms; and plural gear trains for selectively coupling together the transmission input shafts and a transmission output shaft by the selecting operation of plural synchromeshes.
Furthermore, the shift control apparatus is configured such that: a desired gear position is achieved by coupling together the transmission input shaft with which one friction transfer mechanism is coupled and the transmission output shaft through a gear train and engaging the one friction transfer mechanism and disengaging the other friction transfer mechanism; and
standby control is carried out by predicting a next gear position and operating a predetermined synchromesh based on a result of the prediction to couple together the transmission input shaft with which the friction transfer mechanism having not been used for the achievement of the desired gear position is coupled and the transmission output shaft through a predetermined gear train and bring the transmission input shaft and the transmission output shaft into standby state.
Furthermore, the shift control device apparatus is configured so as to carry out timing with which operation for synchromesh coupling by the standby control is started, under condition of determining that the friction transfer mechanism having not been used for achievement of the desired gear position has been disengaged regardless of completion of the achievement of the desired gear position.
According to the invention, pre-shift operation is started when it is determined that the disengagement of the clutch on standby has been completed even during shifting.
Therefore, the timing of start of pre-shift control can be advanced, and thus the response can be enhanced when a shifting request continuously occurs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a skeleton diagram illustrating the configuration of an automatic transmission in an embodiment of the invention;
FIG. 2 is a block diagram illustrating a relation of input/output signals of a transmission control unit 100 and an engine control unit 101 used in a control apparatus for automatic transmissions in an embodiment of the invention;
FIG. 3 is a flowchart illustrating an outline of the details of control by the control apparatus for automatic transmissions in an embodiment of the invention;
FIG. 4 is a flowchart illustrating the details of the engagement permission determination processing for a standby gear illustrated in FIG. 3 ;
FIG. 5 is a time diagram illustrating an example of first pre-shift control by the control apparatus for automatic transmissions in an embodiment of the invention;
FIG. 6 is a time diagram illustrating an example of second pre-shift control by the control apparatus for automatic transmissions in an embodiment of the invention; and
FIG. 7 is a time diagram illustrating an example of third pre-shift control by the control apparatus for automatic transmissions in an embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereafter, detailed description will be given to embodiments of the invention with reference to FIG. 1 to FIG. 6 .
First, description will be given to an example of the configuration of a control apparatus for automobiles of the invention having an automatic transmission with reference to FIG. 1 .
FIG. 1 is a skeleton diagram of an example of the configuration of a system, illustrating a control apparatus for automobiles of the invention having an automatic transmission in an embodiment.
An automobile is provided with an engine 7 as a driving force source, an engine speed sensor (not shown) for measuring a speed of the engine 7 , an electronic throttle (not shown) for controlling engine torque, and a fuel injection system (not shown) for injecting a quantity of fuel appropriate to an intake air flow rate. The intake air flow rate, fuel quantity, ignition timing, and the like are controlled by an engine control unit 101 , and the torque of the engine 7 can be thereby accurately controlled. There are different types of the fuel injection system, for example, an inlet port injection type in which fuel is injected toward an inlet port and a direct injection type in which fuel is directly injected into a cylinder. It is advantageous to use an engine of such a type that fuel consumption can be reduced and favorable exhaust performance can be obtained by comparing the operating ranges (range determined by engine torque and engine speed) required of both types-engine. The driving force source need not be a gasoline engine and any of a diesel engine, a natural gas engine, an electric motor, and the like can be used for this purpose.
An automatic transmission 50 is provided with a first clutch 8 , a second clutch 9 , a first input shaft 41 , a second input shaft 42 , an output shaft 43 , a first drive gear 1 , a second drive gear 2 , a third drive gear 3 , a fourth drive gear 4 , a fifth drive gear 5 , a reverse drive gear (not shown), a first driven gear 11 , a second driven gear 12 , a third driven gear 13 , a fourth driven gear 14 , a fifth driven gear 15 , a reverse driven gear (not shown), a first synchromesh 21 , a second synchromesh 22 , a third synchromesh 23 , a rotation sensor 31 , a rotation sensor 32 , and a rotation sensor 33 . Torque of the engine 7 can be transferred to the first input shaft 41 and this transfer can be interrupted, by engaging or disengaging the first clutch 8 . The torque of the engine 7 can be transferred to the second input shaft 42 and this transfer can be interrupted, by engaging or disengaging the second clutch 9 . In the example, a multiple wet clutch is used for the first clutch 8 and the second clutch 9 . Instead, a single dry clutch may be used, and any types of friction transfer mechanism can be used. They can also be constructed of electromagnetic powder clutches.
The second input shaft 42 is comprised of a hollow-shaft. The first input shaft 41 is inserted through the second input shaft 42 and can be moved freely relative to the second input shaft 42 in a direction of rotation.
The first drive gear 1 , third drive gear 3 , fifth drive gear 5 and reverse drive gear (not shown) are fixed on the second input shaft 42 , and can be freely rotated relative to the first input shaft 41 . The second drive gear 2 and fourth drive gear 4 are fixed on the first input shaft 41 , and can be moved freely relative to the second input shaft 42 in the direction of rotation.
The sensor 31 is to sense a rotational speed of the first input shaft 41 , and the sensor 32 is to sense a rotational speed of the second input shaft 42 .
The output shaft 43 is provided with the first driven gear 11 , second driven gear 12 , third driven gear 13 , fourth driven gear 14 , fifth driven gear 15 , and reverse driven gear (not shown). The first driven gear 11 , second driven gear 12 , third driven gear 13 , fourth driven gear 14 , fifth driven gear 15 , and reverse driven gear (not shown) are provided such that they can be freely rotated relative to the output shaft 43 .
The sensor 33 is to sense a rotational speed of the output shaft 43 .
Of these gears, the first drive gear 1 is meshed with the first driven gear 11 and the second drive gear 2 is meshed with the second driven gear 12 . Further, the third drive gear 3 is meshed with the third driven gear 13 and the fourth drive gear 4 is meshed with the fourth driven gear 14 . Furthermore, the fifth drive gear 5 is meshed with the fifth driven gear 15 . The reverse drive gear (not shown), an idler gear (not shown), and the reverse driven gear (not shown) are engaged with each other.
The first synchromesh 21 is provided between the first driven gear 11 and the third driven gear 13 to selectively allow the first driven gear 11 to engage with the output shaft 43 or allow the third driven gear 13 to engage with the output shaft 43 .
The third synchromesh 23 is provided between the second driven gear 12 and the fourth driven gear 14 to selectively allow the second drive gear 12 to engage with the output shaft 43 and allow the fourth driven gear 14 to engage with the output shaft 43 .
The second synchromesh 22 is provided to allow the fifth driven gear 15 to engage with the output shaft 43 .
Currents of an electromagnetic valve 105 c and an electromagnetic valve 105 d provided in hydraulic equipment 105 are controlled by a transmission control unit 100 . A position or load of the first synchromesh 21 is thereby controlled through a hydraulic piston (not shown) and a shift fork (not shown) provided in a shift actuator 61 . The first driven gear 11 or the third driven gear 13 is thereby allowed to engage with the output shaft 43 . As a result, torque of the second input shaft 42 can be transferred to the output shaft 43 through the first drive gear 1 , the first driven gear 11 and the first synchromesh 21 or through the second drive gear 3 , the second driven gear 13 and the first synchromesh gear 21 . For example, provided that the current of the electromagnetic valve 105 d is increased, a load is applied in such a direction that the first synchromesh 21 is moved toward the first driven gear 11 ; and provided that the current of the electromagnetic valve 105 c is increased, a load is applied in such a direction that the first synchromesh 21 is moved toward the third driven gear 13 . The shift actuator 61 is provided with a position sensor 61 a (not shown) for measuring the position of the first synchromesh 21 .
Currents of an electromagnetic valve 105 e and an electromagnetic valve 105 f provided in the hydraulic equipment 105 are controlled by the transmission control unit 100 . A position or load of the second synchromesh 22 is thereby controlled through a hydraulic piston (not shown) and a shift fork (not shown) provided in a shift actuator 62 . The fifth driven gear 15 is thereby allowed to engage with the output shaft 43 . As a result, torque of the second input shaft 42 can be transferred to the output shaft 43 through the fifth drive gear 5 , the fifth driven gear, and the second synchromesh 22 . The shift actuator 62 is provided with a position sensor 62 a (not shown) for measuring the position of the second synchromesh 22 .
Currents of an electromagnetic valve 105 g and an electromagnetic valve 105 h provided in the hydraulic equipment 105 are controlled by the transmission control unit 100 . A position or load of the third synchromesh 23 is thereby controlled through a hydraulic piston (not shown) and a shift fork (not shown) provided in a shift actuator 63 . The second driven gear 12 or the fourth driven gear 14 is thereby allowed to engage with the output shaft 43 . As a result, torque of the first input shaft 41 can be transferred to the output shaft 43 through the second drive gear 2 , the second driven gear 12 and the third synchromesh 23 or the fourth drive gear 4 , the fourth driven gear 14 and the third synchromesh 23 . The shift actuator 63 is provided with a position sensor 63 a (not shown) for measuring the position of the third synchromesh 23 .
As mentioned above, the torque of the transmission input shaft 41 is transferred from the first drive gear 1 , second drive gear 2 , third drive gear 3 , fourth drive gear 4 , or fifth drive gear 5 to the transmission output shaft 43 through the first driven gear 11 , second driven gear 12 , third driven gear 13 , fourth driven gear 14 , and fifth driven gear 15 . Then, the torque is transferred to an axle (not shown) through a differential gear (not shown) coupled with the transmission output shaft 43 .
Further, a current of an electromagnetic valve 105 a provided in the hydraulic equipment 105 is controlled by the transmission control unit 100 . A pressure plate (not shown) provided in the first clutch 8 is thereby controlled to control the transfer torque of the first clutch 8 .
Furthermore, a current of an electromagnetic valve 105 b provided in the hydraulic equipment 105 is controlled by the transmission control unit 100 . A pressure plate (not shown) provided in the second clutch 9 is thereby controlled to control the transfer torque of the second clutch 9 .
A range position signal indicating the shift lever position, P range, R range, N range, D range, or the like, is inputted from a lever device 301 to the transmission control unit 100 .
The transmission control unit 100 and the engine control unit 101 transmit and receive information to and from each other through a communication means 103 .
The shift actuator 61 is controlled by the electromagnetic valve 105 c and the electromagnetic valve 105 d to mesh the first synchromesh 21 with the first driven gear 11 . In this state, when the second clutch 9 is engaged, 1st gear running is carried out.
The shift actuator 63 is controlled by the electromagnetic valve 105 g and the electromagnetic valve 105 h to mesh the third synchromesh 23 with the second driven gear 12 . In this state, when the first clutch 8 is engaged, 2nd gear running is carried out.
Furthermore the shift actuator 61 is controlled by the electromagnetic valve 105 c and the electromagnetic valve 105 d to mesh the first synchromesh 21 with the third driven gear 13 . In this state, when the second clutch 9 is engaged, 3rd gear running is carried out.
The shift actuator 63 is also controlled by the electromagnetic valve 105 g and the electromagnetic valve 105 h to mesh the third synchromesh 23 with the fourth driven gear 14 . In this state, when the first clutch 8 is engaged, 4th gear running is carried out.
The shift actuator 62 is controlled by the electromagnetic valve 105 e and the electromagnetic valve 105 f to mesh the second synchromesh 22 with the fifth driven gear 15 . In this state, when the second clutch 9 is engaged, 5th gear running is carried out.
The shift actuator 62 is controlled by the electromagnetic valve 105 e and the electromagnetic valve 105 f to mesh the second synchromesh 22 with the reverse driven gear (not shown). In this state, when the second clutch 9 is engaged, reverse gear running is carried out.
In this example, up shift from the 1st gear to the 2nd gear is carried out as follows. In the 1st gear running before the up shift, the first synchromesh 21 is meshed with the first driven gear 11 by controlling the shift actuator 61 by the electromagnetic valve 105 c and the electromagnetic valve 105 d and engaging the second clutch 9 by the electromagnetic valve 105 b . In this state, the shift actuator 63 is controlled by the electromagnetic valve 105 g and the electromagnetic valve 105 h to mesh the third synchromesh 23 with the second driven gear 12 . Furthermore, the first clutch 8 is gradually engaged and the second clutch 9 is gradually disengaged.
In this example, the hydraulic equipment with the electromagnetic valve and hydraulic piston is used as a mechanism for operating the first synchromesh 21 , second synchromesh 22 , and third synchromesh 23 . An electric motor and a reduction gear may be used as the mechanism in place of the electromagnetic valve and the hydraulic piston or an electric motor and a drum may be used as the mechanism. Further, any other mechanism may be used for controlling the synchromesh 21 , 22 , and 23 . Provided that an electric motor is used as the mechanism, various motor scan be applied. For example, the motor may be a so-called direct-current motor in which a magnet is used as stator and a motor winding is used as rotor or may be a so-called permanent-magnet synchronous motor in which a motor winding is used as stator and a magnet is used as rotor.
In this example, the hydraulic equipment with the electromagnetic valve is used as a mechanism for operating the first clutch 8 and the second clutch 9 . Instead of it, the clutches may be operated by using an electric motor and a reduction gear or using pressure plates of the clutches. The pressure plates may be controlled by an electromagnetic coil. Any other mechanism may be used for controlling the first clutch 8 and the second clutch 9 .
FIG. 2 illustrates relations of input/output signals between the transmission control unit 100 and the engine control unit 101 . The transmission control unit 100 is configured by a control unit having an input unit 100 i , an output unit 100 o , and a computer 100 c . Similarly, the engine control unit 101 is also configured by a control unit having an input unit 101 i , an output unit 101 o , and a computer 101 c . An engine torque command value TTe is transmitted from the transmission control unit 100 to the engine control unit 101 using the communication means 103 . The engine control unit 101 controls intake air flow rate, fuel quantity, ignition timing, and the like (not shown) of the engine 7 so that TTe is attained. The engine control unit 101 is provided therein with a determination means (not shown) for determining engine torque that becomes input torque to the transmission. The speed Ne of the engine 7 and the engine torque Te produced by the engine 7 are determines by the engine control unit 101 and are transmitted to the transmission control unit 100 by using the communication means 103 . As the engine torque determination means, a torque sensor may be used or an estimating means using a parameter of the engine, such as the injection pulse width of injectors, the pressure in an intake pipe, engine speed, or the like, may be used.
The transmission control unit 100 performs the following operation to obtain a desired first clutch transfer torque: it controls the voltage V_cla applied to the electromagnetic valve 105 a and thereby controls the current of the electromagnetic valve 105 a to engage or disengage the first clutch 8 .
Furthermore the transmission control unit 100 performs the following operation to obtain a desired second clutch transfer torque: it controls the voltage V_clb applied to the electromagnetic valve 105 b and thereby controls the current of the electromagnetic valve 105 b to engage or disengage the second clutch 9 .
Furthermore the transmission control unit 100 performs the following operation to achieve a desired position of the first synchromesh 21 : it controls the voltages V 1 _slv 1 , V 2 _slv 1 applied to the electromagnetic valves 105 c , 105 d and thereby controls the current of the electromagnetic valves 105 c , 105 d to mesh or disengage the first synchromesh 21 .
Furthermore the transmission control unit 100 performs the following operation to achieve a desired position of the second synchromesh 22 : it controls the voltages V 1 _slv 2 , V 2 _slv 2 applied to the electromagnetic valves 105 e , 105 f and thereby controls the current of the electromagnetic valves 105 e , 105 f to mesh or disengage the second synchromesh 22 .
The transmission control unit 100 adjusts the voltages V 1 _slv 3 , V 2 _slv 3 applied to the electromagnetic valves 105 g , 105 h to achieve a desired position of the third synchromesh 23 . It thereby controls the current of the electromagnetic valves 105 g , 105 h to mesh or disengage the third synchromesh 23 .
The transmission control unit 100 is provided with a current sensing circuit (not shown). It controls the current of each electromagnetic valve by varying voltage output such that the current of each electromagnetic valve becomes equal to a target current.
The transmission control unit 100 takes in first input shaft speed signal NiA, second input shaft speed signal NiB, and output shaft speed signal No from the rotation sensor 31 , rotation sensor 32 , and rotation sensor 33 , respectively. Further, it takes in the following signals: a range position signal RngPos indicating the shift lever position, P range, R range, N range, D range, or the like, from the lever device 301 ; an accelerator pedal position signal Aps from an accelerator pedal position sensor 302 ; and an on/off signal Brk from a brake switch 304 for detecting whether or not a brake pedal has been depressed.
In this example, a so-called manual mode function is also provided in addition to automatic mode function and a driver manually instructs up shift/down shift. Consequently, the transmission control unit 100 takes in on/off signals UpSw, DnSw from an up-switch 306 and a down-switch 307 , respectively.
Further, the transmission control unit 100 takes in the following signals from a sleeve # 1 position sensor 61 a , a sleeve # 2 position sensor 62 a , and a sleeve # 3 position sensor 63 a : a sleeve # 1 position signal RPslv 1 , a sleeve # 2 position signal RPslv 2 , and a sleeve # 3 position signal RPslv 3 respectively indicating the stroke positions of the first synchromesh 21 , second synchromesh 22 , and third synchromesh 23 .
For example, when a driver sets the shift range to D range or the like and depresses the accelerator pedal, the transmission control unit 100 determines that the driver is willing to start up or accelerate his/her automobile. When the driver depresses the brake pedal, it determines that the driver is willing to decelerate or stop his/her automobile. Then, it sets an engine torque command value TTe, a first clutch target transfer torque TTs 1 , and a second clutch target transfer torque TTs 2 so as to carry out the driver's intention.
Further, it sets a gear position as a target from a vehicle speed Vsp computed from an output shaft speed No and an accelerator pedal position Aps. Then, it sets the following so as to perform the operation of shifting to the set gear position: an engine torque command value TTe; a first clutch target transfer torque TTs 1 ; a second clutch target transfer torque TTs 2 ; a target sleeve # 1 (a sleeve # 1 corresponds to the first syncromesh 21 ) position TPslv 1 ; a target sleeve # 2 (a sleeve # 2 corresponds to the second syncromesh 22 ) position TPslv 2 ; and a target sleeve # 3 (a sleeve # 3 corresponds to the third syncromesh 23 ) position TPslv 3 .
The transmission control unit 100 outputs the following so as to achieve the set first clutch target transfer torque TTs 1 , second clutch target transfer torque TTs 2 , target sleeve # 1 position TPslv 1 , target sleeve # 2 position TPslv 2 , and target sleeve # 3 position TPslv 3 : voltages V_cla, V_clb, V 1 _slv 1 , V 2 _slv 1 , V 1 _slv 2 , V 2 _slv 2 , V 1 _slv 3 , V 2 _slv 3 applied to the electromagnetic valves 105 a , 105 b , 105 c , 105 d , 105 e , 105 f , 105 g , 105 h.
Description will be given to the concrete details of pre-shift control by a control apparatus for automatic transmissions in this embodiment with reference to FIG. 3 to FIG. 7 .
FIG. 3 is a flowchart illustrating the outline of the details of entire pre-shift control by a control apparatus for automatic transmissions in an embodiment of the invention.
The flow of the pre-shift control is comprised of Step 301 (target standby position computation), Step 302 (target standby gear engagement in completion determination), Step 303 (standby-side clutch disengagement completion determination), and Step 304 (standby gear engagement control).
Contents of the processing in FIG. 3 are programmed in the computer 100 c of the transmission control unit 100 , and this processing is repeatedly carried out at predetermined intervals. That is, the following processing of Steps 301 to 304 is carried out by the transmission control unit 100 .
At Step 301 (target standby position computation), a target standby gear position tGP_stb as a target value of the gear position in which a gear should be kept on standby in preparation for the next shifting operation is set. It is set based on a range position signal RngPos, an up switch Up signal Sw, a down switch signal DnSw, an accelerator pedal position signal Aps, a vehicle speed signal Vsp, a brake on/off signal Brk, and the like.
At Step 302 (target standby gear engagement incompletion determination), the following processing is carried out: when a sleeve position as a synchromesh position pertaining to the target standby gear position tGP_stb set at Step 301 is in a mesh position, it is determined that standby gear engagement has been completed and the pre-shift control is terminated; and when the sleeve position is not in a mesh position, the flow proceeds to Step 303 .
At Step 303 (standby gear engagement permission determination), it is determined whether or not the engagement of a standby gear has been permitted. When the engagement of the standby gear has been permitted, the flow proceeds to Step 304 . When the engagement of the standby gear is not permitted, the pre-shift control in the relevant cycle of execution is terminated.
At Step 304 (standby gear engagement control), an engagement load is set by a function using a sleeve position as input. With respect to this function, it is desirable to take the following measure: when a distance from the neutral position to a sleeve position is small (in proximity to the neutral; hereinafter the distance is called in abbreviated form as sleeve position), it takes a relatively small value; when the sleeve position is in an intermediate range (in proximity to the synchronization position), it takes a relatively large value; and when the sleeve position is large (in proximity to the mesh position), it takes a relatively small value again. In consideration of the durability of the synchromeshes, it is desirable that the function should be set so that it takes as small a value as possible with which a standby gear can be engaged.
Detailed description will be given to Step 303 (standby gear engagement permission determination) in FIG. 3 with reference to FIG. 4 .
At Step 401 , it is determined whether or not the current mode is automatic shift mode. When the current mode is automatic shift mode, the flow proceeds to Step 402 . When the current mode is not automatic shift mode, for example, when the current mode is manual shift mode, the flow proceeds to Step 405 .
At Step 402 , it is determined whether or not shifting has been completed. That is, it is determined whether or not the clutch to clutch shift in engagement was completed and a desired gear position has been achieved. When shifting has been completed, the flow proceeds to Step 403 . When shifting has not been completed, the flow proceeds to Step 404 .
At Step 403 , the engagement of the stand by gear is permitted. At Step 404 , the engagement of the standby gear is not permitted.
At Step 405 , it is determined whether or not the disengagement of the clutch on standby coupled with the transmission input shaft having the target standby gear position tGP_stb set at Step 301 has been completed. When it is determined that the disengagement of the clutch on standby has been completed, the flow proceeds to Step 406 . When the disengagement of the clutch on standby has not been completed, the flow proceeds to Step 407 .
At Step 406 , the engagement of the stand by gear is permitted. At Step 407 , the engagement of the standby gear is not permitted.
The example in FIG. 4 is constructed such that the timing of permission for the engagement of a standby gear is varied according to whether the current mode is automatic shift mode or any other mode. Instead, the timing of permission for the engagement of a standby gear may be varied according to any other condition, for example, oil temperature.
Description will be given to an example of first pre-shift control carried out when it is constructed as illustrated in FIG. 3 and FIG. 4 with reference to FIG. 5 .
FIG. 5 is a time diagram illustrating an example of the first pre-shift control in an automobile equipped with a control apparatus for automatic transmissions in an embodiment of the invention. This example of the first pre-shift control illustrates the following: the details of pre-shift control carried out when the vehicle is running in the 1st gear and the target standby gear position, which is a target value of the gear position in which a gear should be kept on standby in preparation for the next shifting operation, is changed from N to 2nd gear; and the details of control carried out when the gear position is shifted from 1st gear to 2nd gear based on a shifting request that subsequently occurs.
In FIG. 5 , FIG. 5(A) indicates a target gear position tGP_nxt; FIG. 5(B) indicates a target standby gear position tGP_stb; and FIG. 5(C) indicates a sleeve 1 position RPslv 1 . 3rd indicates the engagement position on the 3rd gear side; N is the neutral position; and 1st indicates the mesh position on the 1st gear side. FIG. 5(D) indicates a sleeve # 3 position RPslv 3 . 4th indicates the engagement position on the 4th gear side; N indicates the neutral position; and 2nd indicates the mesh position on the 2nd gear side. FIG. 5(E) indicates first clutch torque and second clutch torque.
Before time t 1 , the various positions are set as follows and the vehicle is running in the 1st gear: the target gear position tGP_nxt is 1st for “1st gear” as indicted in FIG. 5(A) ; the target standby gear position tGP_stb is N for “neutral” as indicated in FIG. 5(B) ; the sleeve # 1 position RPslv 1 is 1st for the engagement position on the 1st gear side as indicated in FIG. 5(C) ; and the sleeve # 3 position RPslv 3 is N for the neutral position as indicated in FIG. 5(D) .
At time t 1 , the target standby gear position tGP_stb in FIG. 5(B) is shifted from N for “neutral” to 2nd for “2nd gear” by the processing of Step 301 (target gear position computation) in FIG. 3 . Then, the determination of Step 402 or Step 405 is carried out according to whether or not the result processing of Step 401 in FIG. 4 is automatic shift mode. In the processing of either step, the positive determination is made at time t 1 . Therefore, it is determined at Step 303 (standby gear engagement permission determination) that the engagement of the standby gear has been permitted. Then, shifting of the sleeve 3 position RPslv 3 in FIG. 5(D) from N for the neutral position to 2nd for the engagement position on the 2nd gear side is started by the processing of Step 304 (standby gear engagement control).
When the shifting of the sleeve # 3 position RPslv 3 to 2nd is completed at time t 2 , the pre-shift control in FIG. 3 is terminated.
When the target gear position tGP_nxt in FIG. 5(A) is shifted from 1st for “1st gear” to 2nd for “2nd gear” at time t 3 , shifting is started. When the preparation for clutch operation is completed at time t 4 , the second clutch torque is reduced to start disengagement and further the first clutch torque is gradually increased to start engagement. When the clutch to clutch shift in engagement is completed at time t 5 , so-called inertia phase control is carried out to control speed of rotation. At time t 6 , the shifting is completed.
Description will be given to an example of second pre-shift control carried out when it is constructed as illustrated in FIG. 3 and FIG. 4 with reference to FIG. 6 .
FIG. 6 is a time diagram illustrating an example of the second pre-shift control in an automobile equipped with a control apparatus for automatic transmissions in an embodiment of the invention. This example of the second pre-shift control illustrates the following: the details of pre-shift control carried out when the vehicle is running in the 1st gear in automatic shift mode and the target standby gear position, which is a target value of the gear position in which a gear should be kept on standby in preparation for the next shifting operation, is changed from N to 2nd gear; and the details of pre-shift control carried out when, immediately after the shifting from 1st gear to 2nd gear is started based on a shifting request that subsequently occurs, a request to shift the target standby gear position from 2nd gear to 3rd gear occurs.
In FIG. 6 , the time on the horizontal axis is the same as that in FIG. 5 .
FIG. 6(A) , FIG. 6(B) , FIG. 6(C) , FIG. 6(D) , and FIG. 6(E) respectively indicate the same signals as in FIG. 5(A) , FIG. 5(B) , FIG. 5(C) , FIG. 5(D) , and FIG. 5(E) .
The contents before time t 4 are the same as those illustrated in FIG. 5 .
At time t 5 , the target standby gear position tGP_stb in FIG. 6(B) is shifted from 2nd for “2nd gear” to 3rd for “3rd gear.” Since it is determined at Step 401 in FIG. 4 that the current mode is automatic shift mode, the determination of Step 402 is carried out. At time t 5 , the determination of Step 402 becomes negative, namely the determination is that the shifting is being done at present. Therefore, it is determined at Step 303 (standby gear engagement permission determination) that the engagement of the standby gear has not been permitted. When the shifting is completed at time t 7 , the positive determination is made at Step 402 . Therefore, it is determined at Step 303 (standby gear engagement permission determination) that the engagement of the standby gear has been permitted. Then, shifting of the sleeve # 1 position RPslv 1 in FIG. 5(C) from 1st for the engagement position on the 1st gear side to 3rd for the engagement position on the 3rd gear side is started by the processing of Step 304 (standby gear engagement control).
When the shifting of sleeve # 1 position RPslv 1 to 3rd is completed at time t 8 , the pre-shift control in FIG. 3 is terminated. At time t 7 , the target gear position tGP_nxt in FIG. 6(A) is shifted from 2nd for “2nd gear” to 3rd for “3rd gear.” However, the shifting of the sleeve # 1 position RPslv 1 to 3rd has not been completed at time t 7 -t 8 , and shifting is not started. When the shifting of the sleeve 1 position RPslv 1 to 3rd is thereafter completed at time t 8 , shifting is started.
Description will be given to an example of third pre-shift control carried out when it is constructed as illustrated in FIG. 3 and FIG. 4 with reference to FIG. 7 .
FIG. 7 is a time diagram illustrating an example of the third pre-shift control in an automobile equipped with a control apparatus for automatic transmissions in an embodiment of the invention. This example of the third pre-shift control illustrates the following: the details of pre-shift control carried out when the vehicle is running in the first gear in manual shift mode and the target standby gear position, which is a target value of the gear position in which a gear should be kept on standby in preparation for the next shifting operation, is changed from N to 2nd gear; and the details of pre-shift control carried out when immediately after the shifting from 1st gear to 2nd gear is started based on a shifting request that subsequently occurs, a request to shift the target standby gear position from 2nd gear to 3rd gear occurs.
In FIG. 7 , the time on the horizontal axis is the same as that in FIG. 5 .
FIG. 7(A) , FIG. 7(B) , FIG. 7(C) , FIG. 7(D) , and FIG. 7(E) respectively indicate the same signals as in FIG. 5(A) , FIG. 5(B) , FIG. 5(C) , FIG. 5(D) , and FIG. 5(E) .
The contents before time t 6 are the same as those illustrated in FIG. 5 . FIG. 7 is different from FIG. 6 in that the following operation is performed. At time t 6 , it is determined at Step 401 in FIG. 4 that the current mode is manual shift mode. Therefore, the determination of Step 405 is carried out. Because of the disengagement of second clutch torque, the positive determination is made at step 405 . Consequently, it is determined at Step 303 (standby gear engagement permission determination) that the engagement of the standby gear has been permitted. Then, shifting of the sleeve 1 position RPSlv 1 in FIG. 7(C) from 1st for the engagement position on the 1st gear side to 3rd for the engagement position on the 3rd gear side is started by the processing of Step 304 (standby gear engagement control).
When the shifting of the sleeve 1 position RPslv 1 to 3rd is completed at time t 7 , the pre-shift control in FIG. 3 is terminated. At time t 7 , the target gear position tGP_nxt in FIG. 6(A) shifted from 2nd for “2nd gear” to 3rd for “3rd gear.” Since the shifting of the sleeve 1 position RPslv 1 to 3rd has been completed, shifting is immediately started.
When a control apparatus for automatic transmissions is constructed as mentioned above, it is possible to advance the timing of start of pre-shift control and enhance the response when a shifting request continuously occurs.
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A shift control apparatus for an automatic transmission includes a pre-shift device that operates a predetermined synchromesh, based on a prediction by a predicting device. It thereby couples together a transmission input shaft (with a friction transfer mechanism that has not been used to effect a current gear position) and a transmission output shaft, through a predetermined gear train, and brings them into a standby state. The time when it is determined that the friction transfer mechanism that has not been used to effect of the current gear position has been disengaged is taken as the timing with which the synchromesh coupling operation by the standby control is started, regardless of the completion of the achievement of the current gear position.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to systems for removing water from outdoor conveyor belts and particularly to a system in which the operable power need only be electrically operated solenoid valves and a pressurized source of liquid.
2. Background of the Invention
It is not uncommon to employ long conveyor belts outdoors, thus being subjected to rain, and not infrequently to be filled or partially filled by such. This produces very substantial weight on the belt and, of course, if the material being conveyed has a density less than water, it tends to float, substantially interfering with the conveyance process. Obviously, one can detect the presence of water and operate a pump or pumps to remove it. One problem with this approach is that often there are a number of positions along the belt which need to be emptied, and the cost of such may be almost prohibitive. A second problem arises from the fact that, typically, electrically powered pumps would be employed, and this means that they either have to be housed or weathering of them produces not infrequent service problems.
It is the object of this invention to provide a simple and inexpensive system which is quite weather tolerant.
SUMMARY OF THE INVENTION
In accordance with this invention, a siphon tube is arranged to be vertically movable so that its inlet may be moved in and out of liquid in a conveyor belt. A sensor senses when liquid has risen to a selected level in the conveyor belt, and means are provided to fill the tube, thereby increasing its weight and causing it to be lowered into the liquid in the conveyor belt. As a result liquid in the conveyor belt is siphoned off. As a further feature of this invention, the siphon tube is supported by counterweights which are within a tubular housing, and the service water is fed into this housing and thus reducing the effective weight of the counterweights and thereby aiding the process effecting downward movement of the siphon tube.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial view, partially broken away, of the siphon assembly illustrating the siphon tube in a raised postion.
FIG. 2 is a pictorial view, partially broken away, of the siphon assembly illustrating the siphon tube in a lowered position.
FIG. 3 is a broken away view of a portion of the siphon tube illustrating the pressure responsive valve and discharge outlet.
FIG. 4 is an electrical diagram of control circuitry for the system shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, conveyor assembly 10, of the type used for outdoor materials handling, is shown partially broken away and its belt 12 partially filled with a fluid 14, typically rain water. A fluid removal apparatus 16 in accordance with this invention is mounted to a support 18, for example, supporting conveyor 10 via axles 20 and rollers 22 and automatically removes fluid 14 from conveyor 10 when this fluid reaches a predetermined level.
Apparatus 16 includes a base assembly 24 having upright tubular supports 26 and 28, and it movably supports a siphon tube assembly 30. Base assembly 24 is mounted to support 18 of conveyor 10 by a pair (only one being shown) of mounting arms 32. In addition, base assembly 24 is supported by base members 34 and 36 on a structural base, not shown. These base members also cap or seal the bottom of tubular supports 26 and 28.
Siphon tube or pipe assembly 30 is constructed of glued sections of PVC, ABS, etc. It is generally configured as shown in FIGS. 1 and 2 and includes a siphon pipe 38 having as its right end 40 a large diameter suction opening 42 which is set from 1/4" to 1/2" above belt 12 so as to draw water 14 from belt 12 when a selected level is sensed. Siphon pipe 38 extends upward through pipe section 44, L 46, then through horizontal section 48, through L 50, then through vertical section 52, and finally through L 54 and horizontal pipe section 56 to a desired drain point 60. A normally closed pressure operated valve 62 is positioned in section 64 near the drain point. Valve 62, illustrated in FIG. 3, typically would have a flap 66 and biasing spring 68, and biasing spring 68 would be such as to open flap 66 under a head pressure which is reached when siphon pipe 38 is full, with flap 66 thus resisting the hydrostatic pressure until the release pressure is reached.
An annular spray head 70 is mounted near inlet 42 of siphon pipe 38, and its function is to effect a spray which moves small debris away from inlet 42 as tube 38 is lowered into water 14 in belt 12. It is fed by a service tube 72. Service water to tube 72 is supplied water through connector 84, flexible tube 82, and pipe 80 from solenoid valve 74. It is a normally closed valve and is operated by normally open float switch 76 and serially connected, normally closed limit switch 78 through which A.C. power is supplied as illustrated in FIG. 4. Trunk line 80 also supplies water from connector 84 to the interior of siphon tube 38 and through tubes 136 and 138 to the interior of columns 26 and 28.
Siphon pipe assembly 30 is slidably supported on tubular supports 26 and 28 of base assembly 24, also constructed of glued sections of PVC, by upper and lower supports 88a and 88b. Upper support 88a is formed by a union 90a cemented to vertical section 52 of siphon pipe 38 and two T's 92 a and 94a which are machined to slide on supports 26 and 28 and are glued to both sides of union 90a. Lower support 88b is like top support 88a and components cover like designations with the suffixes "a" and "b."
Crossed cords 96 and 98 extend upward from T's 92a and 94a and into PVC pipe section 100 through opening 101. Cord 96 continues around pulley 102 in pipe section 100 and cord 98 around pulley 104 in pipe section 100. Cord 96 then continues to the left and cord 98 to the right. Cord 96 passes over pulley 106 supported by pipe L 108 and down through pipe section 110 of support 26 to counterweight 112.
Similarly, cord 98 passes over pulley 114 supported by pipe L 116 and then passes down through pipe section 118 of tubular support 28 to counterweight 120 (FIG. 1). In this manner, counterweights 112 and 120 provide a lifting effect to siphon pipe assembly 30. The pulleys are pivotally supported by their shafts in openings 112a, 112b, and 122c in the PVC pipe.
With no fluid (to reduce the effective weight of the counterweights) in tubular supports 26 and 28, weights 112 and 120 will assume the position shown, holding siphon tube assembly 30 in the elevated position (FIG. 1). This is the normal inoperative posture of the system.
Operation is initiated by float switch assembly 124. This assembly employs a float ball 126 on arm 128 and switch 76, and the assembly is mounted, by means not shown, to a position illustrated in FIGS. 1 and 2. When not in use, and optionally, float switch assembly may be pivoted by a hydraulic cylinder 130 upward and out of the way of material being conveyed on belt 12 by, for example, hydraulic cylinder 130 powered by means not shown. In such event, auxiliary means would be provided to remove power from float switch assembly 124.
Prior to the installation of base assembly 24, the elevation of siphon tube assembly 30, in its lower position, should be determined by selecting the distance at which suction inlet 42 would come to rest above belt 12 of conveyor assembly 10 when suction pipe assembly 30 is in its lowered position. Arms 32 (only one being shown) are then fixedly secured to support 18 so that when suction assembly 30 is lowered, the desired height of suction inlet 42 is achieved by virtue of T's 92b and 94b of siphon assembly 30 resting on the top edges of machined T's 134a and 134b which support base assembly 24 on arms 32.
To examine operation, under normal conditions wherein the water level on conveyor belt 12 is below the closing point of normally open float switch 76, siphon tube assembly 30 would be in a raised position, as shown in FIG. 1, and remain in this position until the level of fluid in conveyor belt 12 lifts float 126 to a predetermined level, thereby closing switch 76. Switch 76 then, through normally closed limit switch 78, energizes solenoid valve 74, allowing service water from hose 82 to flow into distribution tubes 136 and 138. Tubes 136 and 138 supply service water into hollow column supports 26 and 28, thereby submerbing counterweights 112 and 120, causing them to become "lighter" with respect to siphon tube assembly 30 which they counterbalance. Air from column supports 26 and 28 escapes from pulley cord opening 101. Simultaneously, tube 80 supplies service water into pipe 38 of siphon tube assembly 30 via hose 82 and orifice 86, causing it to fill with service water, thereby siphon tube assembly 30 becoming "heavier" than the effective weights (in water) of counterweights 112 and 120. This change in the balance between counterweights 112 and 120 and siphon tube assembly 30 results in the latter being lowered by gravity from its normally raised position via cords 96 and 98 and the pulleys. It moves downward until it bottoms out on T's 134a and 134b. In this manner, the mouth or opening 42 of siphon tube 38 is limited to a selected clearance with conveyor belt 12.
Service water also flows through line 72 and emerges as a spray from spray head 70, and this spray moves debris, which may block the downward movement of pipe 44, from around siphon opening 42. Service water continues to flow into and fill suction tube 38 through orifice 86 until it fills and the resulting pressure operates discharge valve 62 open. When valve 62 opens, the water in now filled siphon tube 38 rushes out discharge opening 60, creating a vacuum at suction inlet 42, thereby initiating a siphoning action to siphon fluid 14 from conveyor belt 12.
Simutaneously with the bottoming out of siphon tube assembly 30 and essentially simultaneous creation of the siphoning action, solenoid valve 74 is de-energized by limit switch 78 which is operated open by arm 79 on siphon tube assembly 30 when siphon tube assembly 30 reaches a selected lower excursion, thereby preventing additional water from entering tube 38 or columns 26 and 28 and shutting off the spray from spray head 70.
Fluid continues to be siphoned from conveyor belt 12 until the fluid level in belt 12 falls below suction opening 42, thus breaking the siphoning action. When this occurs the service water in columns 26 and 28 drains back through distribution tubes 136 and 138, into distribution tube 80 up through hose 82, out into the interior of tube 38 via orifice 86, and is discharged through still-open valve 62 and out opening 60. This draining action in columns 26 and 28 causes counterweights 112 and 120 to no longer be submerged, thereby becoming "heavier" with respect to drained siphon tube 38, causing siphon tube assembly 30 to be moved by gravity to its normally raised position via cords 96 and 98. While switch 78 would close, float switch 76 would open, preventing solenoid valve 74 from energizing at this time. Thus, the system would remain at rest until, again, typically due to rain, water would rise in conveyor belt 12, whereupon the drainage cycle would be repeated.
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A conveyor belt dewatering system in which a siphon tube or pipe is vertically moveable on a tubular support whereby selectively its inlet is lowered into a conveyor belt. Counterweights counter the weight of the siphon tube, these weights being positioned in the tubular support. A source of service water is turned on by a float switch sensing water is the conveyor belt, the service water being used to submerge the weights and lessen their effect and at the same time be supplied to the siphon tube to increase its weight, whereby a siphon tube is lowered into the conveyor belt and siphoning from it commenced.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is the US national stage of PCT application PCT/EP2008/008645, filed 13 Oct. 2008, published 4 Jun. 2009 as WO2009/058138, and claiming the priority of German patent application 102007057607.4 itself filed 28 Nov. 2007.
FIELD OF THE INVENTION
The invention relates to a method of operating a mobile radio network which has two or more supply layers, wherein the supply layers are superimposed and are each formed by a plurality of transmitting stations.
BACKGROUND OF THE INVENTION
Modern mobile radio networks are very frequently subdivided into different supply layers. In this case, the different layers may use the same technologies, for example microcell networks in which one layer forms the macrocell layer and a further supply layer forms the microcell layer. However, different supply layers may also use different technologies, for example in the case of dual mode networks, in which GSM forms one supply layer and UMTS forms a second supply layer. It is likewise possible to combine supply layers using the same and different technologies.
This means that the supply layers are each formed by a plurality of individual transmitting stations, thus ensuring that the mobile radio network services are provided covering an area, with the spatial coverage of the supply layers being superimposed.
Modern transmitting stations are able to switch off superfluous capacities in times when the call level and load level are low. In the case of GSM transmitting stations, for example, individual radio-frequency carriers are deactivated. In the case of UMTS networks, it is likewise possible to deactivate individual radio-frequency amplifiers. In addition, in the case of UMTS transmitting stations, baseband processing capacity can be deactivated.
The known methods have the disadvantage that the switching-off actions are always carried out within a transmitting station. A further disadvantage is that only parts of the capacity are deactivated, and the basic supply for the transmitting station is not adversely affected, in order to ensure area-coverage supply with the corresponding service.
OBJECT OF THE INVENTION
The object of the invention is to provide a method which makes it possible to reduce the power consumption in a mobile radio network in times when the call level and load level are low, and thus reduce the overall operating costs, while at the same time ensuring the fundamental and continuous availability of the services offered.
SUMMARY OF THE INVENTION
It is particularly advantageous in this case, that, in the case of the method of operating a mobile radio network which has two or more supply layers where the supply layers are superimposed and are each formed by a plurality of transmitting stations, a first supply layer is defined as the standard layer which ensures the availability of the mobile radio network, and in that a second supply layer is switched off at least partially and/or temporarily.
The method according to the invention therefore deactivates entire transmitting stations or entire layers, and reactivates them when required. Only a monitoring unit within or else outside the transmitting station remains active, in order to allow the transmitting station to be activated again. Since the overall transmitting station or supply layer is deactivated, the supply to the transmitting station is also switched off. This considerably reduces the power consumption since individual transmitting stations, or a supply layer, are or is not just partially switched off, but are or is completely switched off. in this case, the fundamental availability is always ensured by the standard layer, which is operated all the time.
Individual transmitting stations in a network having a plurality of layers can be switched off when the load is low or there is no load. In order to ensure that the switching off of individual transmitting stations does not restrict the supply area and the general network availability of the mobile radio network, it is necessary to define a default layer in which no transmitting stations are switched off. This default layer guarantees the supply and general network availability.
Preferably, the load in the mobile radio network is monitored, and the second supply layer or individual transmitting stations in the second supply layer are switched off if a definable load lower limit is undershot.
In this case, the second supply layer can provide the same services as the standard layer in particular using the same technology as the standard layer. It is also possible for the second or a further supply layer to provide a different service than the standard layer, in particular using a different technology than the standard layer, and for this second or further supply layer to be switched off when the service which is provided by this layer is not demanded at that time or has not been demanded over a definable time period.
The conditions for reactivation of transmitting stations differ in accordance with the following applications. When transmitting stations which use a different technology than the default layer, that is to say the standard layer, are switched off, it may be worthwhile reactivating these transmitting stations even for the situation in which at least one terminal which supports this technology is active in the supply area. This is the case in is particular when the switched-off transmitting station supports a technology which supports functions or services which are not supported by the current transmitting station in the default layer.
Transmitting stations using the same technology can be reactivated when a load limit is exceeded in the current transmitting station. This therefore results in a network with different service layers. In general, no transmitting stations are switched off in the default layer. The load layer which can be switched off contains transmitting stations using the same technology as the default layer. The criterion for switching off transmitting stations in this layer is a low call level in the default layer and load layer. The trigger condition for reactivating transmitting stations in the load layer is an increased call level in the default layer, that is to say in the first supply layer, the standard layer. The service layer which can be switched off, that is to say the second or further supply layer, contains transmitting stations using different technology than the default layer, and supports different services and functions. The condition for switching off transmitting stations in this layer is inactivity over a certain time, or finding that the service offered by this layer is currently not being demanded. The condition for reactivation of a transmitting station in this layer is activity of a terminal which supports the technology of the service layer which can be switched off, in the default layer or load layer in the supply area of the transmitting station to be switched on.
Load monitoring is preferably carried out for each transmitting station, and in particular individual transmitting stations can be temporarily switched off.
A transmitting station is preferably switched off by continuously reducing the output transmitted power to zero, and not by suddenly switching off the transmitting station.
One problem of switching off an individual transmitting station is that all the terminals which are registered with the transmitting station to be switched off will search for another available transmitting station at the same time, and will register there. This may possibly produce a sudden signaling load. In order to avoid these signaling peaks, it is proposed that the transmitting stations not be switched off at a defined time, but that the output power of the transmitting station be slowly reduced to zero, that is to say be reduced continuously rather than suddenly. In consequence, the terminals will not all change transmitting station at the same time. Terminals which are further away from the transmitting station will change earlier than terminals which are located close to the transmitting station.
The first supply layer may be formed by GSM transmitting stations. The second and/or a further supply layer may likewise be formed by GSM transmitting stations. Alternatively or cumulatively, a second and/or a further supply layer may be formed by UMTS transmitting stations. This allows widely differing services to be provided, and allows load peaks in the mobile radio network to be coped with by spatial superimposition with identical transmitting stations and technologies.
The switching state of transmitting stations in the second and/or a further supply layer or of individual transmitting stations in the second and/or a further supply layer is preferably monitored by a monitoring unit, and in particular the standard layer may have monitoring units such as these.
Transmitting stations in a second and/or a further supply layer in the mobile radio network can be switched on when a definable load level is exceeded and/or when particular services which are offered by these transmitting stations are called up in the mobile radio network.
In one preferred embodiment, the current switching state of a transmitting station is transmitted by means of a protocol to a monitoring unit when a request and/or a switching instruction of a monitoring unit has been received and/or when the switching state of the transmitting station has changed after receiving a switching instruction.
In order to reactivate individual transmitting stations in the load layer or service layer, it is necessary to inform the relevant transmitting stations that a criterion for reconnection in the default layer or in the load layer has been reached. In this case, it should be noted that the criterion for switching on a transmitting station in the load layer may occur only in the default layer. The criterion for switching on a transmitting station in the service layer may occur in the default layer and load layer. It is also necessary for the transmitting stations in the default layer to manage the switched-on state of the transmitting stations in the service layer and load layer. Transmitting stations in the load layer must manage the switched-on state of transmitting stations in the service layer. This is necessary in order that these transmitting stations will generate appropriate commands to the transmitting stations to be switched on when a switch-on trigger occurs, that is to say when the switch-on condition occurs. It should be noted that only the states of transmitting stations which have the same supply area need be managed.
A protocol between the transmitting stations is useful in order to signal changes in the switched-on state to the corresponding transmitting stations or monitoring units. Furthermore, the protocol supports a command for switching on the transmitting station in the situation when the appropriate trigger condition (switch-on condition) is reached. Furthermore, the protocol is intended to support commands for checking the switched-on status of individual transmitting stations (NodeB).
The protocol preferably supports the following communications and commands:
Check of the switched-on state:
POWER STATUS REQUEST checks the switched-on state of a transmitting station.
POWER STATUS RESPONSE contains the current switched-on state of a transmitting station.
Information interchange relating to switching off a transmitting station:
POWER SWITCHOFF indicates that the trigger condition for switching off a transmitting station has been reached, and switches off the transmitting station.
POWER SWITCHOFF ACK acknowledges reception of a POWER SWITCHOFF message.
Check of the switched-on state in the case of a switch-on command:
POWER SWITCHON REQUEST requests reactivation of a transmitting station.
POWER SWITCHON ACK contains the indication that a transmitting station has been switched on successfully.
BRIEF DESCRIPTION OF THE DRAWING
The method will be explained in the following text and is illustrated in the figures, in which
FIG. 1 shows a schematic illustration of the configuration of a mobile radio network with a plurality of supply layers; and
FIG. 2 shows an illustration of the communication between two transmitting stations.
DETAILED DESCRIPTION
FIG. 1 shows a schematic illustration of the configuration of a mobile radio network with a plurality of supply layers 1 , 2 , 3 .
The mobile radio network is formed by a plurality of layers 1 , 2 , 3 , with a first supply layer, which defines default layer 1 as the standard layer 1 , ensuring that the mobile radio services are available all the time and are therefore always kept in operation. In addition, FIG. 1 shows a second supply layer 2 , specifically the additional load layer 2 , which is based on the same technology as the standard layer 1 , in the illustrated example GSM. Furthermore, the mobile radio network has a further supply layer 3 in the form of a service layer 3 which can be switched off and provides a different service than the standard layer 1 , and which is illustrated by way of example as a UMTS network.
The supply layers 1 , 2 , 3 are each formed by a multiplicity of individual base stations (NodeB) in order to ensure supply covering an area as far as possible, wherein the layers 1 , 2 , 3 are spatially superimposed, that is to say the radio ranges of the base stations of the various layers 1 , 2 , 3 at least partially cover one another. The spatial (geographic) coverage of the standard layer 1 and load layer 2 makes it possible to cope with load peaks that occur, and the spatial (geographic) coverage of the standard layer 1 and service layer 3 allow different services, in this case GSM and UMTS connections to be offered in the same region.
As shown in FIG. 1 , the layers may use the same technologies, for example microcell networks in which a first layer 1 forms the macrocell layer, and a further supply layer 2 forms the microcell layer. However, different supply layers may also use different technologies, for example in the case of dual mode networks in which GSM forms a supply layer 1 and UMTS a second or further supply layer 3 . The configuration illustrated in FIG. 1 shows a combination of supply layers using the same technology (layers 1 , 2 ) and different technology (layer 3 ), which is likewise possible.
Individual transmitting stations in the network with a plurality of layers 1 , 2 , 3 can be switched off when the load is low or there is no load. In order to ensure that switching off individual transmitting stations does not restrict the supply region and the general network availability of the mobile radio network, it is necessary to define a default layer 1 in which no transmitting stations are switched off. This default layer 1 , that is to say the standard layer 1 , guarantees the supply and the general network availability.
The conditions for reactivation of transmitting stations are distinguished in accordance with the following applications. When transmitting stations which use a different technology (layer 3 ) than the default layer 1 are switched off, it may be worthwhile to actually reactivate these transmitting stations in the situation when at least one terminal, that is to say a mobile radio terminal which supports this technology, becomes active in the supply area. This is the case when the switched-off transmitting station supports a technology which supports functions or services which are not supported by the current transmitting station in the default layer 1 .
Transmitting stations using the same technology (layer 2 ) can be reactivated when a load limit is exceeded in the current transmitting station. This results in a network with different service layers 1 , 2 , 3 . Generally, no transmitting stations are switched off in the default layer 1 . The load layer 2 which can be switched off contains transmitting stations using the same technology as the default layer 1 . The criterion for switching off transmitting stations in this layer (load layer 2 ) is a low call level in the default layer 1 and load layer 2 . The trigger condition, that is to say the switch-on condition for reactivation of transmitting stations in the load layer 2 is an increased call level in the default layer 1 .
The service layer 3 which can be switched off contains transmitting stations using different technology than the default is layer 1 and supports different services and functions. The condition for switching off transmitting stations in this layer 3 is inactivity over a certain time. The condition for reactivation of a transmitting station in this layer 3 is activity of a terminal which supports the technology of the service layer 3 which can be switched off and is registered in the default layer 1 or load layer 2 in the supply area of the transmitting station which can be switched on in the service layer 3 .
FIG. 2 shows communication protocols between a first transmitting station in the standard layer 1 , which has a monitoring unit, and a second transmitting station in a second layer 2 or further layer 3 .
In order to reactivate individual transmitting stations in the load layer 2 or service layer 3 it is necessary to inform the relevant transmitting stations that a criterion for reconnection has been achieved in the default layer 1 and/or in the load layer 2 .
In this case, it should be noted that the criterion for switching on a transmitting station in the load layer 2 can occur only in the default layer 1 . The criterion for switching on a transmitting station in the service layer 3 may occur in the default layer 1 and load layer 2 .
It is also necessary for the transmitting stations in the default layer 1 to manage the switched-on state of the transmitting stations in the service layer 3 and load layer 2 . Transmitting stations in the load layer 2 have to manage the switched-on state of transmitting stations in the service layer 3 . This is necessary in order to ensure that these transmitting stations generate appropriate commands to the transmitting stations to be switched on when a switch-on trigger is reached, that is to say on reaching a switch-on condition. In this case, it should be noted that only the states of transmitting stations which have the same supply area need be managed.
A protocol is necessary between the transmitting stations in order to signal changes in the switched-on state to the corresponding transmitting stations. Furthermore, the protocol supports a command for switching on the transmitting station for the situation in which the corresponding trigger condition is reached. The protocol is furthermore intended to support commands in order to check the switched-on status of individual transmitting stations (NodeB).
RIM (RAN Information Management) can be used as a basis for a protocol such as this, as defined in 3GPP TS 48.018: “General Packet Radio Service (GPRS); BSS GPRS Protocol (BSSGP)”.
Based on RIM, additional Application Power Saving is carried out using the commands illustrated in FIG. 2 :
POWER STATUS REQUEST checks the switched-on state of a transmitting station. POWER STATUS RESPONSE contains the current switched-on state of a transmitting station as a response. POWER SWITCHOFF indicates that the trigger condition for switching off a transmitting station has been reached, and switches off the transmitting station. POWER SWITCHOFF ACK acknowledges reception of a POWER SWITCHOFF message. POWER SWITCHON REQUEST requests the reactivation of a transmitting station. POWER SWITCHON ACK contains the indication that a transmitting station has been successfully switched on.
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The invention relates to a method for operating a mobile communications network having two or more supply levels ( 1, 2, 3 ), wherein the supply levels ( 1, 2, 3 ) overlap and are each formed by a plurality of transmission stations, wherein a first supply level ( 1 ) is defined as the standard level ( 1 ), which guarantees the availability of the mobile communications network, and a second supply level ( 2, 3 ) is at least partially and/or temporarily deactivated.
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CLAIM OF PRIORITY
This application claims benefit from U.S. Provisional Application No. 60/386,179, filed Jan. 25, 2002. The complete disclosures of all of the above-listed patents and patent applications are incorporated herein by reference.
TECHNICAL FIELD
This invention relates to electrically conductive fabrics, and more particularly to electrically conductive fabrics suitable for use in clothing articles worn to provide shielding against electromagnetic radiation (EMI).
BACKGROUND
Human exposure to electromagnetic radiation can be minimized through utilization of an EMI shield. Specially manufactured clothing or fabric comprised of conductive elements can be used to provide such shielding. Shielding can be provided to protect against electromagnetic radiation in clothing by providing the clothing fabric with a metallic coating or metallic electro-chemical deposition, or by incorporating surface-metallized or other conductive fibers into the fabric construction, or by forming the fabric from yarns or threads containing metallic fibers. While articles of fabric may be effective, at varying degrees, at shielding a wearer from EMI radiation, the articles need also be flexible and stretchy rather than too stiff or “boardy”. Such stiff or “boardy” clothing decreases a wearer's comfort level during wearing.
SUMMARY
In one aspect, the invention features an electrically conductive fabric for use in articles of clothing worn for shielding against electromagnetic radiation. The electrically conductive fabric includes a knit body having two broad surfaces. On at least one of the broad surfaces, there is a fleece or raised surface. The knit body is made up of electrically conductive stitch yarns and non-conductive loop yarns that are knit together to form the body. The non-conductive fibers of the loop yarns are finished upon at least one of the broad surfaces to form the fleece or raised surface. Embedded among the non-conductive fibers are the electrically conductive stitch yarns, which are between and spaced from the broad surfaces.
In another aspect, the invention features articles of wearing apparel comprising an electrically conductive fabric for shielding a wearer against electromagnetic radiation. The fabric includes a knit body having a first broad surface and an opposite, second broad surface. At least one of the broad surfaces has a fleece or a raised surface. The knit body is formed of stitch yarns and loop yarns where the stitch yarns include electrically conductive fibers and the loop yarns include non-conductive fibers. The non-conductive fibers are finished upon at least one of the broad surfaces to form the fleece or raised surface. The electrically conductive fibers of the stitch yarns are embedded among the non-conductive fibers, the conductive fibers being between and spaced apart from the broad surfaces.
Implementations of these aspects of the invention may include one or more other features. For example, the loop yarns may overlap the stitch yarns on both the broad surfaces of the knit body forming a barrier of non-conductive material about the stitch yarn. By forming this protective barrier of non-conductive material, each of the broad surfaces can be finished to form the fleece or raised surface on both broad surfaces of the fabric body. Additionally, the stitch yarn may also comprise non-conductive fibers, including stretchy materials, to allow for varying distributions of electrically conductive elements along the knit body. The fleeced surface may also be formed upon the knit body in a manner to avoid damage to conductivity performance of the electrically conductive fibers of the stitch yarn.
Additional implementations may include electrically conductive fibers of various materials including conductive, continuous filaments, staples, stainless steel fibers, silver-coated nylon yarns, polyester fibers, silver-embedded fibers and/or Nano-tube carbon particle-embedded fibers. The denier of the loop yarns and stitch yarns may also vary. The loop yarn may include spun yarns having a denier between about 40 denier to 300 denier. The stitch yarn may include a spun yarn or a filament yarn having a denier between about 50 denier to 150 denier. The stitch yarn may also include various stretchy materials such as spandex, for example, providing added comfort.
Further implementations may include varying additional parameters of the fabric body. For example, the conductive fibers can have a resistivity between about 10 3 to 10 9 ohms/cm and/or the conductive fibers may only be used as the stitch yarn. Also, the number of conductive elements per unit length may vary depending on the particular application, for example, the fabric body may have 20 conductive fibers per centimeter. In addition to the spacing of conductive elements, it may be preferable, depending on the application, to position the fabrics in either a symmetrical pattern and/or an asymmetrical pattern along at least a portion of the fabric body. By varying at least one of the parameters noted above, a fabric body can be created that is tailored to a particular application.
Implementations of aspects of the invention may also include finishing the loop yarns to create the fleece or raised surface by employing certain methods including napping, sanding, and/or brushing, as examples. Preferably, the fabric is formed using standard reverse plaiting circular knitting. Additionally, the conductive fabric can be treated to render the fabric, for example, either hydrophilic or hydrophobic. Furthermore, the conductive elements may form a mesh to provide an electrical connection between conductive fibers and/or the conductive fabric may include buses that connect conductive fibers. The buses may be formed of stitching of conductive yarn and/or of a narrow conductive fabric, as examples. The buses may be attached by, for example mechanical fasteners, such as snaps and/or the buses may be attached by stitching. The buses may be formed along edge regions of the fabric body and/or they may be spaced-apart along the body of the fabric.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of an electrically conductive fabric of the invention particularly suited for use in clothing articles worn for personal protection or shielding against electromagnetic radiation (EMI).
FIG. 2 is a somewhat diagrammatic perspective view of an article of clothing, in this embodiment, a coverall, formed of electrically conductive fabric of the invention, to be worn for personal protection, i.e., shielding, against electromagnetic radiation (EMI).
FIG. 3 is a similar view of articles of clothing, in this embodiment, pants and a shirt, formed of electrically conductive fabric of the invention, to be worn for personal protection, i.e., shielding, against electromagnetic radiation (EMI).
FIG. 4 is an end section view of the electrically conductive fabric of the invention, taken at the line 4 — 4 of FIG. 1 .
FIG. 5 is a side section view of the electrically conductive fabric of the invention, taken at the line 5 — 5 of FIG. 1 .
FIG. 6 is a perspective view of a segment of a circular knitting machine, and FIGS. 7-13 are sequential views of a cylinder latch needle in a reverse plaiting circular knitting process, e.g., for use in forming an electric heating/warming composite fabric article of the invention.
FIGS. 14 and 15 are somewhat diagrammatic perspective views of other embodiments of the electrically conductive fabric of the invention.
Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
This patent application is related to earlier patent applications filed by me jointly with Vikram Sharma, as follows: U.S. application Ser. No. 09/296,375, filed Apr. 22, 1999 (now abandoned); U.S. application Ser. No. 09/395,326, filed Sep. 13, 1999 (now U.S. Pat. No. 6,160,246, issued Dec. 12, 2000); U.S. application Ser. No. 09/468,627, filed Dec. 21, 1999 (now U.S. Pat. No. 6,215,111, issued Apr. 10, 2001); and U.S. application Ser. No. 09/703,089, filed Oct. 31, 2000 (now U.S. Pat. No. 6,307,189, issued Oct. 23, 2001; the complete disclosures of all of which are incorporated herein by reference.
Referring to FIGS. 1-3 , the invention relates to an improved electrically conductive fabric 10 particularly suited for use in clothing, e.g., coveralls 12 ( FIG. 2 ) or pants 14 and shirt or blouse 16 (FIG. 3 ), worn to provide personal protection or shielding against electromagnetic radiation (EMI).
Referring next to FIGS. 1 , 4 and 5 , the improved electrically conductive fabric 10 of the invention, suitable for use in clothing to be worn for personal protection or shielding against electromagnetic radiation (EMI), consists of a fabric body 20 formed, e.g., by reverse terry circular knitting with electrically conductive elements 22 incorporated into the fabric as the stitch yarn and extending generally between edge regions 24 , 26 of the fabric to provide shielding. Non-conductive yarns 28 are incorporated as stitch yarn 40 and loop yarn 42 , the loop yarns overlaying the stitch yarns at the technical face 30 and forming loops 44 ( FIG. 7 ) at the technical back 32 of the fabric body 20 . The fibers of the non-conductive yarns 28 , preferably of the loop yarn 42 , are then napped at the technical face 30 and technical back 32 to form a layer of fleece 46 , 48 at each face, which keeps the electrically conductive shielding elements 22 away from the wearer's skin, including for enhancement of wearer comfort, and also protects the electrically conductive elements 22 from physical abrasion. According to the invention, the napping of fibers of non-conductive yarns 28 at the technical face 30 and technical back 32 is also performed in a manner to avoid damage to the conductivity of the electrically conductive elements 22 . In preferred embodiments, the electrically conductive elements 22 of the stitch yarn 40 may be continuous filaments or may be a blend of staples (conductive or conductive and non-conductive) of relatively short length, e.g., stainless steel yarn/fibers, silver-coated nylon yarns, or polyester or other synthetic fibers with silver or Nano-tube carbon particles embedded therein. An example is BEKITEX® textile yarn made out of nylon fibers and stainless steel fibers, available from N. V. Bekaert S. A., of Zwevegem, Belgium.
Referring also to FIGS. 6-13 , in a preferred embodiment, the fabric body 20 is formed by joining a stitch yarn 40 and a loop yarn 42 in a standard reverse plaiting circular knitting (terry knitting) process, e.g. as described in “Knitting Technology,” by David J. Spencer (Woodhead Publishing Limited, 2nd edition, 1996), the entire disclosure of which is incorporated herein by reference. Referring again to FIGS. 1 , 4 , and 5 , in the terry knitting process, the stitch yarn 40 forms the technical face 30 of the resulting fabric body 20 and the loop yarn 42 forms the opposite technical back 32 , where it is formed into loops 44 extending over the stitch yarn 40 . In the fabric body 20 formed by reverse plaiting circular knitting, the loop yarn 42 is preferentially exposed outwardly from the planes of both surfaces 30 , 32 and, on the technical face 30 , the loop yarn 42 covers the stitch yarn 40 . As a result, during napping of the opposite fabric surfaces to form a fleece, the loop yarn 42 protects the electrically conductive elements 22 knitted into the fabric body 20 in the stitch yarn position.
The loop yarn 42 forming the technical back 32 of the knit fabric body 20 can be made of any synthetic or natural material. The cross section and luster of the fibers or the filament may be varied, e.g., as dictated by requirements of the intended end use. The loop yarn 42 can be a spun yarn made by any available spinning technique, or a filament yarn made by extrusion. The loop yarn denier is typically between 40 denier to 300 denier. A preferred loop yarn is a 200/100 denier T-653 Type flat polyester filament, e.g. as available commercially from E. I. duPont de Nemours and Company, Inc., of Wilmington, Del.
The stitch yarn 40 forming the technical face 30 of the knit fabric body 20 can be also made of non-conductive yarn, such as synthetic or natural materials in a spun yarn or a filament yarn. The denier is typically between 50 denier to 150 denier. A preferred yarn is a 70/34 denier filament textured polyester, e.g. as available commercially from UNIFI, Inc., of Greensboro, N.C.
The resistivity of the electrically conductive elements 22 can be selected in the range, e.g., of from about 10 3 ohms/cm to about 10 9 ohms/cm on the basis of end use requirements of the fabric 10 . However, electrically conductive elements 22 performing outside this range can also be employed, where required or desired.
As mentioned above, in a preferred method of the invention, the fabric body 20 is formed by reverse plaiting on a circular knitting machine. This is principally a terry knit, where the loops formed by the loop yarn 42 cover the stitch yarn 40 on the technical face 30 . The electrically conductive elements 22 are incorporated into the knit fabric body 20 formed on the circular knitting machine at a predetermined spacing or distance apart, D (FIG. 5 ). In a fabric body 20 of the invention, the spacing, D, is typically a function, e.g., of the requirements of EMI shielding desired in the clothing articles to be formed. For example, the spacing of electrically conductive elements 22 may be the range of about 0.02 inch (i.e., with about 50 electrically conductive elements/inch or about 20 electrically conductive elements/cm). However, other spacing may be employed, depending on the conditions of intended or expected use, including the conductivity of the electrically conductive elements 22 . The electrically conductive elements 22 may be spaced symmetrically from each other, or the electrically conductive elements 22 may be spaced asymmetrically, with varying spacing, if desired.
Also as mentioned above, a preferred position of the electrically conductive elements 22 is in the stitch position of the circular knitted construction. The electrically conductive elements 22 may then be knit symmetrically, i.e., at a predetermined distance, D, apart, in each repeat, i.e., the electrically conductive elements 22 can be in stitch position at any feed repeat of the circular knitting machine. If desired, e.g., in order to maximize EMI shielding, the electrically conductive elements 22 may be used entirely as the stitch yarn 40 . Alternatively, the feed position may be varied, and the electrically conductive elements 22 may be knit asymmetrically, with the elements more closely or widely spaced, e.g., as desired or as appropriate to the intended product use. Again, the specific number of feeds, and the spacing of the electrically conductive elements 22 , is dependent on the end use requirements.
Furthermore, the shielding provided by the fabric at a given electromagnetic frequency can be optimized by varying certain parameters such as the conductivity of the conductive elements, the gauge of the knitting machine and the distribution of the conductive elements in the fabric construction. For example, the resistivity of the conductive elements can be varied between 10 3 ohms/cm to 10 9 ohms/cm and/or the gauge of the knitting machine can be varied between 12 to 40. As noted above, the distribution of the electrically conductive elements may be symmetrical or asymmetrical, depending on the end use requirements. Additionally, the spacing of the electrically conductive elements may be increased or decreased. By varying knitting parameters, an EMI shielding fabric, such as an article of clothing, can be created having varying shielding effects along the fabric body.
Preferably the knitted fabric body 20 incorporating the electrically conductive elements 22 is next subjected to finishing. During the finishing process, the fabric body 20 may go through processes of, e.g., sanding, brushing, napping, etc., to generate a fleece 46 , 48 . The fleece 46 , 48 may be formed on one face of the fabric body 20 , e.g., on the technical back 32 , in the loop yarn 42 , or, preferably, a fleece 46 , 48 may be formed on both faces of the fabric body 20 , including on the technical face 30 , in the overlaying loops 44 of the loop yarn 42 and/or in the stitch yarn 40 . In either case, the process of generating the fleece 46 , 48 on the face or faces of fabric body 20 is preferably performed in a manner to avoid damage to the electrically conductive elements 22 that are part of the construction of the fabric body 20 . In particular, the fleece 46 , 48 is formed in a manner that avoids damage to the electrically conductive elements 22 that would result in a reduction in conductivity, or would sever the electrically conductive elements 22 completely, which could result in loss of electrical flow, and shielding, in a region of the clothing. The fabric body 20 may also be treated, e.g., chemically, to render the material hydrophobic or hydrophilic.
Referring to FIG. 14 , electrical connection between electrically conductive elements 22 may be provided by formation of buses 50 , 52 along the edge regions 24 , 26 of the fabric body 20 and/or spaced-apart in the body, e.g., as described in Rock et al. U.S. Pat. 6,373,034, issued Apr. 16, 2002, the complete disclosure of which is incorporated herein by reference, and/or by joining of elements of fabric 20 at clothing seams, e.g., as described in Dordevic U.S. Pat. No. 5,103,504. The buses 50 , 52 may be formed by stitching a conductive yarn along the body to connect the conductive elements, or a bus element, e.g. a narrow strip of conductive fabric, may be attached to the fabric, e.g. with mechanical fasteners, such as snaps, or by stitching. Referring to FIG. 15 , the electrically conductive elements may also have the form of a mesh or grid 200 , preferably with electrical interconnection achieved at intersections 202 of warp and weft electrically conductive elements 204 , 206 , respectively, in the fabric body 20 ″.
A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, the textile structure can contain a stretchy material, such as spandex, as an example, in the stitch yarn at various predetermined spaced-apart locations throughout the fabric to further improve the comfort level. Further, any type of yarn may be employed.
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An electrically conductive fabric for use in articles of clothing worn for shielding against electromagnetic radiation includes a knit body with a first broad surface and an opposite, second broad surface where at least one of the surfaces includes a fleece or raised surface. The conductive fabric further includes stitch yarns of electrically conductive fibers and loop yarns comprising non-conductive fibers. The non-conductive fibers of the loop yarns are finished upon at least one of the first broad surface and second broad surface to form the fleece or raised surface, with electrically conductive fibers of the stitch yarns being embedded among the non-conductive fibers and between and spaced from the first and the second broad surfaces.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is related to, claims the earliest available effective filing date(s) from (e.g., claims earliest available priority dates for other than provisional patent applications; claims benefits under 35 USC §119(e) for provisional patent applications), and incorporates by reference in its entirety all subject matter of the following listed application(s) (the “Related Applications”) to the extent such subject matter is not inconsistent herewith; the present application also claims the earliest available effective filing date(s) from, and also incorporates by reference in its entirety all subject matter of any and all parent, grandparent, great-grandparent, etc. applications of the Related Application(s) to the extent such subject matter is not inconsistent herewith.
[0002] U.S. provisional patent application No. 61/463114, entitled “Customizable Yo-Yo System”, naming Joyce A. Amaral, John V. Marcantonio, and Todd M. Rywolt as inventors, filed 11 Feb. 2011
BACKGROUND
[0003] 1. Field of Use
[0004] These teachings relate generally to a Yo-Yo system and in particular to a customizable. Yo-Yo system
[0005] 2. Description of Prior Art (Background)
[0006] Among the significant features of a yo-yo is the manner in which the dynamic manner in which the yo-yo engages the string to initiate the rewinding and retrieval of the yo-yo. It is desirable for the yo-yo to catch the string in a consistently responsive manner in order to enhance the player's control over the yo-yo. In some cases, it may be preferred for the yo-yo to have a “hair trigger” response in which very slight manipulation of the string is required to cause the string to become caught in the yo-yo to effect the retrieval. Others may prefer a less sensitive trigger reaction in which a more distinct manipulation is necessary in order to initiate the retrieval. Regardless of the degree of responsiveness, it is important that the response is consistent so that the player can best control the yo-yo.
[0007] Other significant features of a yo-yo include the peripheral entry to the string slot between the yo-yo halves and the weight of the yo-yo halves. These features contribute to the feel and responsiveness of the player's retrieval command (slackening the string to relieve it of all tension) and are, in part, a matter of personal preference and skill and may depend on the types of tricks to be performed.
[0008] Over the years, many different shapes have been employed for the yo-yo's side portions. Traditional yo-yos will usually feature substantially planar side portions that have a bulge in the area of the rim to provide an improved weight distribution that increases spin time and stability. Butterfly yo-yos feature side portions that are stretched outwardly, away from the center of the yo-yo, thereby increasing the width of the yo-yo and giving the yo-yo a butterfly shape when viewed in cross-section.
[0009] It is also known to use different materials for, or on, the rim portion of each of a yo-yo's side portions. For example, while most yo-yos have rim portions made of a hard plastic material, it is known to employ rubber either as the rim material, or in the form of an o-ring that is placed on the periphery of each of a yo-yo's side portions.
[0010] The different shapes and materials employed in a yo-yo's side portions not only make the yo-yo distinctive, they also affect the yo-yo's performance. For example, a user performing looping tricks with a yo-yo will usually prefer a traditionally shaped yo-yo that has substantially planar side portions. Such a shape is best at looping since the weight distribution is close to the tether's (string's) attachment point on the yo-yo, thereby enabling the yo-yo to flip over relatively easily during each loop. For yo-yo tricks in which the user attempts to catch the spinning yo-yo on a medial portion of the tether, a butterfly shaped yo-yo is preferred. The more widely spaced-apart side portions improve the yo-yo's stability whereby the yo-yo is less prone to tilt off the tether. Furthermore, the wider stance of a butterfly-shaped yo-yo facilitates a user being able to land the yo-yo on a medial portion of the tether.
[0011] To take advantage of the different yo-yo performance characteristics provided through the use of side portions of different shapes and/or materials and/or that have different tether engagement adaptations, many experienced yo-yo players will own a large variety of different yo-yos. This enables the player to pick a yo-yo from his or her collection that will work best for the particular trick(s) that the player wishes to perform. However, the costs involved in buying and maintaining a large number of yo-yos can be considerable. In addition, transporting a large number of yo-yos can be bothersome and is usually accomplished using a bulky and expensive transport case specially adapted for carrying yo-yos.
[0012] Prior art solutions for yo-yo customization, such as U.S. Pat. No. 7,125,310 to Van Dan Elzen (Van Dan Elzen) provide minor customization with removable disks forming a part of the yo-yo rim; or U.S. Pat. No. 6,579,142 to Rehkemper et al. (Rehkemper), disclosing a modular yo-yo which can be disassembled by the user. However, these prior art solutions, on the one hand, do not provide enough customization, and on the other hand too much customization. Rehkemper's yo-yo, for example, discloses a myriad of small parts for custom building a yo-yo. In addition to none of the small parts being easily identified for its yo-yo performance characteristics it would take a sophisticated user a considerable amount of time and patience to assemble. Similarly, Van Dan Elzen's yo-yo allows for replacement of a disk forming a part of the rim but is silent as to other customizable features of a yo-yo and how those customizable features are readily identified.
[0013] It is desirable, therefore, to provide a customizable yo-yo system where the features of a yo-yo are readily identifiable and customizable by the user to provide yo-yos to meet the user's yo-yo performance preference. It is also desirable to provide a set of yo-yos having customizable and interchangeable components to allow for performance customization ranging from basic yo-yo performance to very advanced yo-yo performance.
BRIEF SUMMARY
[0014] The foregoing and other problems are overcome, and other advantages are realized, in accordance with the presently preferred embodiments of these teachings.
[0015] In accordance with one embodiment of the present invention a customizable yo-yo system includes a plurality of yo-yos where each of the plurality of yo-yos includes a plurality of matching weighted shells, a plurality of matching pads, a plurality of matching spacers, a bearing, and an axle with a blind threaded hole for engaging a hex screw when the yo-yo is in an assembled condition. Each of the plurality of matching weighted shells, the plurality of matching pads, and the plurality of matching spacers are weighted and sized for different skill levels and each of the corresponding pluralities are interchangeable.
[0016] The invention is also directed towards a yo-yo system having interchangeable components wherein each of the interchangeable components is associated with a yo-yo performance characteristic. The yo-yo system includes: a basic skill yo-yo having matching dins weighted for a basic or beginner performance; matching spacers selected for basic or beginner performance; a bearing and an axle and screw for threadably securing the basic skill yo-yo in an assembled condition. The yo-yo system also includes an intermediate skill yo-yo having matching rims weighted for a intermediate performance; matching spacers selected for intermediate performance; another bearing and an another axle and screw for threadably securing the intermediate skill yo-yo in an assembled condition. Lastly, the yo-yo system includes an advanced skill yo-yo having matching, rims weighted for an advanced performance; matching spacers selected for advanced performance; another bearing and an another axle and screw for threadably securing the advanced skill yo-yo in an assembled condition. Each of the aforementioned yo-yo components are interchangeable. For example the matching rims weighted for a basic or beginner performance are interchangeable with the matching rims weighted for intermediate performance. In addition, each of the aforementioned yo-yo components are color coded, or otherwise marked, to indicate its respective skill level.
[0017] In accordance with another embodiment of the present invention a customizable yo-yo system is provided. The customizable yo-yo system includes a plurality of interchangeable weighted rims, wherein each of the weights of plurality of weighted rims comprises substantially the range of 57 gram weights to 69 gram weights. The customizable yo-yo also includes a plurality of interchangeable spacers, wherein each of the widths of the plurality of interchangeable spacers comprises substantially the range of 3 mm width to 4 mm widths. The yo-yo system also includes a plurality of pads, wherein each of the pads comprises a responsive characteristic ranging from basic to very advanced. In addition, each of the aforementioned yo-yo components are color coded, or otherwise marked, to indicate its respective skill level.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0019] FIG. 1 is an exploded view of the customizable features of a basic yo-yo in accordance with the present invention;
[0020] FIG. 2 is an exploded view of the customizable features of an advanced yo-yo in accordance with the present invention; and
[0021] FIG. 3 is an exploded view of the customizable features of a very advanced yo-yo in accordance with the present invention.
DETAILED DESCRIPTION
[0022] Referring to FIG. 1 there is shown an exploded view of the customizable features of a basic yo-yo in accordance with the present invention. The basic yo-yo 10 includes basic axle 11 , a basic first half shell 12 enclosing a basic first weight 12 a, a basic second half shell 13 enclosing a basic second weight I 3 a, a basic first pad 17 , a basic first spacer 14 , a bearing 15 , a basic second spacer 16 , a basic second pad 17 a, and a basic hex screw 19 . It will be appreciated that each of the parts shown in FIG. 1 are color coded, or otherwise marked, to represent a basic skill level associated with each of the parts. For example, the basic axle 11 , the basic first half 12 enclosing the basic first weight 12 a, the basic second half 13 enclosing the basic second weight 13 a, the basic first pad 17 , the basic first spacer 14 , the basic second spacer 16 , the basic second pad 17 a, and the basic hex screw 19 may be color coded green to represent a yo-yo suitable for basic tricks.
[0023] Still referring to FIG. 1 , the basic axle 11 may be any suitable shaft with one end comprising or including a square or hex head 11 a for fitting in a recessed portion of either the basic first half 12 or the basic second half 13 . The other end of the basic axle 11 includes a blind threaded hole for engaging the basic hex screw 19 to threadably secure the yo-yo in its assembled condition. It will be appreciated that either hex head 11 a or hex screw 19 may be slotted to permit tightening with a screwdriver or coin.
[0024] Still referring to FIG. 1 , the basic first half shell 12 and the basic second half shell 13 may be any suitable shell material for enclosing the basic first weight 12 a and the basic second weight 13 a, respectively. Also, for example the basic first half shell 12 and the basic second half shell 13 may be a substantially transparent polycarbonate shell allowing the user to view the color coded basic first weight 12 a or the color coded basic second weight 13 a, respectively. It will be appreciated that the basic first half shell 12 and the basic second half shell 13 may be any suitable material and likewise color coded to indicate the weight of the shell enclosing the basic first weight 12 a or the basic second weight 13 a, respectively.
[0025] It will also be appreciated that the basic first shell 12 and the basic first weight 12 a can be an integrated or single piece unit. For example the basic first shell 12 and the basic first weight 12 a can be any suitable material such as aluminum. It will also be understood that basic first shell 12 and the basic first weight 12 a are substantially balanced around a center axis of the assembled basic first shell 12 and the basic first weight 12 a. Likewise, the basic second shell 13 and the basic second weight 13 a may be similarly constructed.
[0026] Likewise, still referring to FIG. 1 , the basic first weight 12 a can be any suitable material such as anodized aluminum color coded to indicate a particular feature associated with the basic first weight 12 a. For example, the basic first weight 12 a can be anodized aluminum color coded green and visible through the basic first half shell 12 to indicate a lightly weighed rim on the order of approximately 59 grams suitable for basic performance. Again, the basic second shell 13 and the basic second weight 13 a may be similarly constructed.
[0027] Still referring to FIG. 1 , the basic first pad 17 may be any suitable material such as silicone or other rubber. It will be understood that the basic first pad 17 hardness and texture is selected to provide a very responsive return feature associated with basic performance. It will also be appreciated that the basic first pad 17 may be color coded, for example, green, or otherwise marked, to correspond to basic performance. The basic second pad 17 a is similarly constructed.
[0028] Still referring to FIG. 1 , the basic first spacer 14 and the basic second spacer 16 may be any suitable material having a thickness of approximately 3.3 mm each. It will be appreciated that when the yo-yo is assembled the basic first spacer 14 and basic second spacer 16 help determine the space between the basic first half shell 12 and the basic second half shell 13 when the yo-yo is assembled. It will be further appreciated that a narrower space between the basic first half shell 12 and the basic second half shell 13 corresponds to a more responsive yo-yo. Similar to the aforementioned yo-yo parts, the basic first spacer 14 and the basic second spacer 16 may be color coded, for example, green, or otherwise marked, to correspond to basic performance.
[0029] Still referring to FIG. 1 , the bearing 15 may be any suitable bearing such as a 6 mm bearing.
[0030] Referring also to FIG. 2 there is shown an exploded view of the customizable features of an intermediate yo-yo in accordance with the present invention. The intermediate yo-yo 20 includes intermediate axle 21 , an intermediate first half shell 22 enclosing a intermediate first weight 22 a, an intermediate second half shell 23 enclosing a intermediate second weight 23 a, an intermediate first pad 27 , an intermediate first spacer 24 , a bearing 25 , an intermediate second spacer 26 , an intermediate second pad 27 a, and an intermediate hex screw 29 . It will be appreciated that each of the parts shown in FIG. 2 are color coded, or otherwise marked, to represent an intermediate skill level associated with each of the parts. For example, the intermediate axle 21 , the intermediate first half 22 enclosing the intermediate first weight 22 a, the intermediate second half 23 enclosing the intermediate second weight 23 a, the intermediate first pad 27 , the intermediate first spacer 24 , the intermediate second spacer 26 , the intermediate second pad 27 a, and the intermediate hex screw 29 may be color coded blue to represent a yo-yo suitable for intermediate tricks.
[0031] Still referring to FIG. 2 , the intermediate axle 21 may be any suitable shaft with one end comprising or including a square or hex head 21 a for fitting in a recessed portion of either the intermediate first half 22 or the intermediate second half 23 . The other end of the intermediate axle 21 includes a blind threaded hole for engaging the intermediate hex screw 29 to threadably secure the yo-yo in its assembled condition. It will be appreciated that either hex head 21 a or hex screw 29 may be slotted to permit tightening with a screwdriver or coin.
[0032] Still referring to FIG. 2 , the intermediate first half shell 22 and the intermediate second half shell 23 may be any suitable shell material for enclosing the intermediate first weight 22 a and the intermediate second weight 23 a, respectively. Also, for example the intermediate first half shell 22 and the intermediate second half shell 23 may be a substantially transparent polycarbonate shell allowing the user to view the color coded intermediate first weight 22 a or the color coded intermediate second weight 23 a, respectively. It will be appreciated that the intermediate first half shell 22 and the intermediate second half shell 23 may be any suitable material and likewise color coded to indicate the weight of the shell enclosing the intermediate first weight 22 a or the intermediate second weight 23 a, respectively.
[0033] It will also be appreciated that the intermediate first shell 22 and the intermediate first weight 22 a can be an integrated or single piece unit. For example the intermediate first shell 22 and the intermediate first weight 22 a can be any suitable material such as aluminum. It will also be understood that intermediate first shell 22 and the intermediate first weight 22 a are substantially balanced around a center axis of the assembled intermediate first shell 22 and the intermediate first weight 22 a. Likewise, the intermediate second shell 23 and the intermediate second weight 23 a may be similarly constructed.
[0034] Likewise, still referring to FIG. 2 , the intermediate first weight 22 a can be any suitable material such as anodized aluminum color coded to indicate a particular feature associated with the intermediate first weight 22 a. For example, the intermediate first weight 22 a can be anodized aluminum color coded blue and visible through the intermediate first half shell 22 to indicate a lightly weighed rim on the order of approximately 64 grams suitable for intermediate performance. Again, the intermediate second shell 23 and the intermediate second weight 23 a may be similarly constructed.
[0035] Still referring to FIG. 2 , the intermediate first pad 27 may be any suitable material such as silicone or other rubber. It will be understood that the intermediate first pad 27 hardness and texture is selected to provide a very responsive return feature associated with intermediate performance. It will also be appreciated that the intermediate first pad 27 may be color coded, for example, blue, or otherwise marked, to correspond to intermediate performance. The intermediate second pad 27 a is similarly constructed.
[0036] Still referring to FIG. 2 , the intermediate first spacer 24 and the intermediate second spacer 26 may be any suitable material having a thickness of approximately 3.76 mm each. It will be appreciated that when the yo-yo is assembled the intermediate first spacer 24 and intermediate second spacer 26 help determine the space between the intermediate first half shell 22 and the intermediate second half shell 23 when the yo-yo is assembled. It will be further appreciated that the space between the intermediate first half shell 22 and the intermediate second half shell 23 defined by the intermediate first spacer 24 and the intermediate second spacer 26 corresponds to a less responsive or sensitive yo-yo than the basic yo-yo shown in FIG. 1 which allows for intermediate class yo-yo tricks. Similar to the aforementioned yo-yo parts, the intermediate first spacer 24 and the intermediate second spacer 26 may be color coded, for example, blue, or otherwise marked, to correspond to intermediate performance.
[0037] Still referring to FIG. 2 , the bearing 25 may be any suitable bearing such as a 6 mm bearing.
[0038] Referring also to FIG. 3 there is shown an exploded view of the customizable features of an advanced yo-yo in accordance with the present invention. The advanced yo-yo 30 includes advanced axle 31 , an advanced first half shell 32 enclosing a advanced first weight 32 a, an advanced second half shell 33 enclosing a advanced second weight 33 a, an advanced first pad 37 , an advanced first spacer 34 , a bearing 35 , an advanced second spacer 36 , an advanced second pad 37 a, and an advanced hex screw 39 . It will be appreciated that each of the parts shown in FIG. 3 are color coded, or otherwise marked, to represent an advanced skill level associated with each of the parts. For example, the advanced axle 31 , the advanced first half 32 enclosing the advanced first weight 32 a, the advanced second half 33 enclosing the advanced second weight 33 a, the advanced first pad 37 , the advanced first spacer 34 , the advanced second spacer 36 , the advanced second pad 37 a, and the advanced hex screw 39 may be color coded black to represent a yo-yo suitable for advanced tricks.
[0039] Still referring to FIG. 3 , the advanced axle 31 may be any suitable shaft with one end comprising or including a square or hex head 31 a for fitting in a recessed portion of either the advanced first half 32 or the advanced second half 33 . The other end of the advanced axle 31 includes a blind threaded hole for engaging the advanced hex screw 39 to threadably secure the yo-yo in its assembled condition. It will be appreciated that either hex head 31 a or hex screw 39 may be slotted to permit tightening with a screwdriver or coin.
[0040] Still referring to FIG. 3 , the advanced first half shell 32 and the advanced second half shell 33 may be any suitable shell material for enclosing the advanced first weight 32 a and the advanced second weight 33 a, respectively. Also, for example the advanced first half shell 32 and the advanced second half shell 33 may be a substantially transparent polycarbonate shell allowing the user to view the color coded advanced first weight 32 a or the color coded advanced second weight 33 a, respectively. It will be appreciated that the advanced first half shell 32 and the advanced second half shell 33 may be any suitable material and likewise color coded to indicate the weight of the shell enclosing the advanced first weight 32 a or the advanced second weight 33 a, respectively.
[0041] It will also be appreciated that the advanced first shell 32 and the advanced first weight 32 a can be an integrated or single piece unit. For example the advanced first shell 32 and the advanced first weight 32 a can be any suitable material such as aluminum. It will also be understood that advanced first shell 32 and the advanced first weight 32 a are substantially balanced around a center axis of the assembled advanced first shell 32 and the advanced first weight 32 a. Likewise, the advanced second shell 33 and the advanced second weight 33 a may be similarly constructed.
[0042] Likewise, still referring to FIG. 3 , the advanced first weight 32 a can be any suitable material such as anodized aluminum color coded to indicate a particular feature associated with the advanced first weight 32 a. For example, the advanced first weight 32 a can be anodized aluminum color coded black and visible through the advanced first half shell 32 to indicate a lightly weighed rim on the order of approximately 68 grams suitable for advanced performance. Again, the advanced second shell 33 and the advanced second weight 33 a may be similarly constructed.
[0043] Still referring to FIG. 3 , the advanced first pad 37 may be any suitable material such as silicone or other rubber. It will be understood that the advanced first pad 37 hardness and texture is selected to provide a very responsive return feature associated with advanced performance. It will also be appreciated that the advanced first pad 37 may be color coded, for example, black, or otherwise marked, to correspond to advanced performance. The advanced second pad 37 a is similarly constructed.
[0044] Still referring to FIG. 3 , the advanced first spacer 34 and the advanced second spacer 36 may be any suitable material having a thickness of approximately 3.96 mm each. It will be appreciated that when the yo-yo is assembled the advanced first spacer 34 and advanced second spacer 36 help determine the space between the advanced first half shell 32 and the advanced second half shell 33 when the yo-yo is assembled. It will be further appreciated that the space between the advanced first half shell 32 and the advanced second half shell 33 defined by the advanced first spacer 34 and the advanced second spacer 36 corresponds to a less responsive or sensitive yo-yo than the intermediate yo-yo shown in FIG. 2 which allows for advanced class yo-yo tricks. Similar to the aforementioned yo-yo parts, the advanced first spacer 34 and the advanced second spacer 36 may be color coded, for example, black, or otherwise marked, to correspond to advanced performance.
[0045] Still referring to FIG. 3 , the bearing 35 may be any suitable bearing such as a 6 mm bearing.
[0046] Still referring to FIG. 1 , FIG. 2 and FIG. 3 it will be appreciated that any of the yo-yo parts shown and discussed herein may be interchanged to assemble a yo-yo having specific desired performance features. For example, the lightly weighted basic first half shell 12 and the basic second half shell 13 may be interchanged with the more heavily weighed advanced first half shell 32 and the advanced second half shell 33 to assemble yo-yos having mixed performance characteristics. It will also be appreciated that each of the yo-yo parts are color coded, or otherwise marked, to readily identify the yo-yo's performance characteristics.
[0047] For example, the play attributes of an interchangeable yo-yo system form a customizable mix of play experiences and performance attributes inclusive of, but not limited to the following:
[0048] 1. Different weighted yo-yo halves—when combined with the many internal part combinations (bearings and rubber return pads) different spin characteristics will become possible—some mixed combinations capable of longer spin times and/or greater RPMs. These weighted yo-yo halves are used to customize the play experience. Example: for many players, heavier yo-yos are more stable and allow for easier string tricks combinations. For others, a lighter yo-yo is easier to use and presents better for other types of string trick play. With the use of this system, exact player preference becomes achievable.
[0049] 2. Spacers—the yo-yo system contains numerous spacers each with the same internal diameter but with different overall widths. When combined with the other interchangeable parts, the spacers will provide an array of different play experiences. Narrow spacers will provide for more responsive play, while wider spacers can provide for less responsive play and longer spin times. With the multiple spacer possibilities, a player's skill set can grow more easily and their exact play preferences can be obtained.
[0050] 3. Return Systems—the yo-yo system contains up to 3 or more sets of rubber return pads each made out of a different material with different shore hardness and textures. These return pads will allow a player to customize the behavior of the yo-yo so that its spin and responsiveness meets their play needs. Since these pads can also be mixed and matched, the return settings with this customizable/interchangeable design can allow for a very diverse range of play.
[0051] 4. Axle system—Three or more axle systems will be used to allow for the parts to be interchangeable with other yo-yo halves.
[0052] It should be understood that the foregoing description is only illustrative of the invention. Thus, various alternatives and modifications can be devised by those skilled in the art without departing from the invention.
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The customizable yo-yo system of the present invention makes available a plurality of yo-yos, e.g. two yo-yos or three or more yo-yos, which can easily be disassembled and reassembled to make a set of custom yo-yos. Each of the custom yo-yo has a unique set of performance characteristics selected by the user's preference and skill level. In addition, each of the yo-yos parts are color coded to indicate its associated skill level.
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FIELD OF THE INVENTION
[0001] This invention relates to a fabric treatment composition for use in a tumble dryer where the benefit agent(s) is/are comprised and preferably contained within a rigid outer shell.
BACKGROUND AND PRIOR ART
[0002] ‘Unit dose’ means of delivery for detergent compositions useful in home laundry have been known for many years. Early products of this type included sachets which opened in the wash. These have the disadvantage that the sachet must be recovered at the end of the wash. More recently tablets and water-soluble sachets have provided means for delivering detergents without the need for recovery of some component.
[0003] Some forms of laundry tablet use various disintegrant materials which either swell on contact with water or dissolve rapidly. It is also known to form tablets from a loosely sintered material and then coat the tablet with a dicarboxylic acid based material to provide some structural integrity. For tablets which are delivered via the drum (as opposed to drawer dispensed) it is known to use a net-like bag to prevent the tablet staying in one place and producing a prolonged contact between the tablet and the fabrics being washed.
[0004] Numerous patents describe various fabric treatments applied in the tumble dryer. One of the obvious differences between the washing environment and the drying environment is that far less water is present in the drying environment. A consequence of this is that it is difficult to ensure uniform distribution of whatever treatment agent is being applied. Several approaches have been made to this problem. The methods of delivery mentioned in the literature are: aerosol foams, structured foams, dispensers, and flexible sheets.
[0005] U.S. Pat. No. 3,796,599, U.S. Pat. No. 4,077,891, U.S. Pat. No. 3,650,816, EP 0839905, U.S. Pat. No. 3,806,359, U.S. Pat. No. 3,963,629, U.S. Pat. No. 3,822,145, U.S. Pat. No. 3,826,682, U.S. Pat. No. 4,242,377, U.S. Pat. No. 4,252,656 describe the application of various treatments in the tumble dryer dispensed as a foam. Patent WO 0024851 describes a fabric care composition applied to fabric by either spraying, soaking, dipping or during the pre-wash or rinse stage of the laundry process. The composition is preferably added as a spray in the dryer.
[0006] U.S. Pat. No. 1,357,740 and U.S. Pat. No. 1,357,739 describe the use of an aerosol spray by which agents are applied to the drum of the dryer.
[0007] Dryer sheets appear to be, in practice, the most commercially widespread vehicles for delivery. These suffer from the disadvantage that they must be recovered at the end of the dryer cycle.
[0008] U.S. Pat. No. 5,869,442 and WO 9411482 describes the use of DTI (dye-transfer inhibition) polymers (such as PVP) in the rinse stage of the washing process or the drying stage using dryer sheet form as a dryer delivery method. U.S. Pat. No. 1,571,527 describes the use of a impregnated sheet to deliver cationic softener during the drying stage. Patent WO 9840459 describes the dryer-activated laundry additive compositions with colour care agents from a dryer sheet. U.S. Pat. No. 1,571,526 describes the delivery of polyglycerol esters in the dryer from a flexible sheet. Patent WO 9812296 describes the delivery of dye fixing agents from a sheet. Patent WO 9841605 describes an improved fabric care composition comprising a pro-perfume and an amino-functional polymer delivered from a substrate, preferably a sheet.
[0009] WO94/11482 discloses a “vanishing substrate material” mentioned, but no detail is given on what this substrate is.
[0010] Many proposals have been made which relate to dispensers comprising a rigid outer shell, usually formed of a plastics material. In addition to the obvious problems of noise in the dryer, certain difficulties have also been encountered in providing plastics material dispensers which can survive the temperatures encountered in the dryer cycle without melting or other damage. WO 0015755 describes a fabric care composition comprising a amine- or amide-epichlorohydrin resin or derivative, delivered from a sheet or sponge or a dispenser such as a dosing ball. These devices have the disadvantage that they must be recovered at the end of the dryer cycle.
BRIEF DESCRIPTIONS OF THE INVENTION
[0011] We have determined that the above mentioned problems are overcome by a rigid dispenser which is shattered to a fine powder by the action of the tumble dryer.
[0012] Accordingly, a first aspect of the present invention provides a dispenser comprising a rigid and fragile outer shell and further comprising a benefit agent, together with instructions to use the same in the tumble dryer.
[0013] A second aspect of the present invention provides for a method of fabric treatment which comprises the steps of:
[0014] a) placing the fabric, together with a dispenser in a tumble-drier, and,
[0015] b) operating the tumble drier,
[0016] wherein the dispenser comprises a rigid and fragile outer shell and further comprises a benefit agent,
[0017] The benefit agent is preferably enclosed within the shell of the dispenser. The benefit agent can be can be in a powder, gel or liquid form, such that when the outer shell breaks, the agents are released to deposit onto the fabric, thus imparting the required benefit. In an alternative embodiment the benefit agent can be comprised within the material of the shell itself.
[0018] It is believed that a shell which fragments to a fine powder enables the rapid release and dispersal of the benefit agent.
[0019] The powder produced is sufficiently fine to be lost through the drum of the dryer. However it is advantageous that the powder should not give adverse effects if it remains on the articles being washed.
[0020] Advantageously, there is no need to recover any component of the dispenser (such as a net, ball or dryer sheet) at the end of the drying cycle.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Shell Materials:
[0022] In preferred forms of the invention, the outer shell comprises one or more biodegradable non-hazardous materials. It is preferable that at least one of these materials has melting points above 35° C. and has adequate mechanical robustness. Preferably the robustness is such that when melt-formed the shell can withstand a weight of at least 500 g. As noted above, at least some of the components used to form the shell may be benefit agents themselves.
[0023] Preferably the shell is a sphere. This has the advantage that the quantity of shell required material is minimised for a given internal volume.
[0024] Suitable shell materials comprise mixtures of:
[0025] a) cellulosic materials, and
[0026] b) polyol esters.
[0027] Suitable cellulosic materials include hydroxyalkyl cellulose materials and fibrous cellulose materials.
[0028] Suitable esters include glycol and glyceryl esters and in particular stearates thereof.
[0029] It is believed that quantities of both of these preferred materials may become deposited on the articles being washed without detriment.
[0030] Optionally, the shell material comprises perfume.
[0031] The shell can be moulded from a suitable material. Preferably the shell is cast. Where the shell is a sphere it is preferable to cast the shell in the form of two hemispheres which are fixed together.
[0032] Benefit Agents:
[0033] Benefit agents may be selected from the following: fabric softeners, perfumes, colour enhancers, optical brightening agents, antimicrobial agents, pill/fuzz prevention agents, dye transfer inhibitors, soil release agents, anti-redeposition agents, fibre lubricants, sequestrants, odour elimination agent.
[0034] If the composition of the present invention is in the form of a textile conditioner composition, the benefit agent will comprise a textile softening and/or conditioning compound (hereinafter referred to as “textile softening compound”), which may be a cationic or nonionic compound.
[0035] The softening and/or conditioning compounds are preferably water insoluble quaternary ammonium compounds, sugar derivatives or mixtures of the same.
[0036] Suitable cationic textile softening compounds are substantially water-insoluble quaternary ammonium materials comprising a single alkyl or alkenyl long chain having an average chain length greater than or equal to C 20 . More preferably, softening compounds comprise a polar head group and two alkyl or alkenyl chains having an average chain length greater than or equal to C 14 . Preferably the textile softening compounds have two, long-chain, alkyl or alkenyl chains each having an average chain length greater than or equal to C 16 .
[0037] Most preferably at least 50% of the long chain alkyl or alkenyl groups have a chain length of C 18 or above. It is preferred if the long chain alkyl or alkenyl groups of the textile softening compound are predominantly linear.
[0038] Quaternary ammonium compounds having two long-chain aliphatic groups, for example, distearyldimethyl ammonium chloride and di(hardened tallow alkyl) dimethyl ammonium chloride, are widely used in commercially available rinse conditioner compositions. Other examples of these cationic compounds are to be found in “Surface-Active Agents and Detergents”, Volumes I and II, by Schwartz, Perry and Berch. Any of the conventional types of such compounds may be used in the compositions of the present invention.
[0039] The textile softening compounds are preferably compounds that provide excellent softening, and are characterised by a chain melting Lβ to Lα transition temperature greater than 25° C., preferably greater than 35° C., most preferably greater than 45° C. This Lβ to Lα transition can be measured by DSC as defined in “Handbook of Lipid Bilayers”, D Marsh, CRC Press, Boca Raton, Fla., 1990 (pages 137 and 337).
[0040] Substantially water-insoluble textile softening compounds are defined as textile softening compounds having a solubility of less than 1×10 −3 wt % in demineralised water at 20° C. Preferably the textile softening compounds have a solubility of less than 1×10 −4 wt %, more preferably less than 1×10 −8 to 1×10 −6 wt %.
[0041] Especially preferred are cationic textile softening compounds that are water-insoluble quaternary ammonium materials having two C 12-22 alkyl or alkenyl groups connected to the molecule via at least one ester link, preferably two ester links. An especially preferred ester-linked quaternary ammonium material can be represented by the formula:
N + R 1 .R 1 .(R 3 -T-R 2 ).(CH 2 ) p -T-R 2
[0042] wherein each R 1 group is independently selected from C 1-4 alkyl or hydroxy-alkyl groups or C 2-4 alkenyl groups; each R 2 group is independently selected from C 8-28 alkyl or alkenyl groups; and wherein R 3 is a linear or branched alkylene group of 1 to 5 carbon atoms, T is an ester linkage in either orientation, i.e.
—O—CO— or —CO—O—;
[0043] and p is 0 or is an integer from 1 to 5.
[0044] Di(tallowoxyloxyethyl) dimethyl ammonium chloride and/or its hardened tallow analogue is especially preferred.
[0045] A second preferred type of quaternary ammonium material can be represented by the formula:
(R 1 ) 3 N + —(CH 2 ) p .CH.(TR2)(CH 2 TR 2 )
[0046] wherein R 1 , p, T and R 2 are as defined above.
[0047] It is advantageous if the quaternary ammonium material is biologically biodegradable.
[0048] Preferred materials of this class such as 1,2-bis(hardened tallowoyloxy)-3-trimethylammonium propane chloride and their methods of preparation are, for example, described in U.S. Pat. No. 4,137,180 (Lever Brothers Co). Preferably these materials comprise small amounts of the corresponding monoester as described in U.S. Pat. No. 4,137,180, for example, 1-hardened tallowoyloxy-2-hydroxy-3-trimethyl-ammonium propane chloride.
[0049] Other useful cationic softening agents are alkyl pyridinium salts and substituted imidazoline species. Also useful are primary, secondary and tertiary amines and the condensation products of fatty acids with alkylpolyamines.
[0050] The compositions may alternatively or additionally contain water-soluble cationic textile softeners, as described in GB 2 039 556B (Unilever).
[0051] The compositions may comprise a cationic textile softening compound and an oil, for example as disclosed in EP-A-0829531.
[0052] The compositions may alternatively or additionally contain nonionic textile softening agents such as lanolin and derivatives thereof.
[0053] Lecithins are also suitable softening compounds.
[0054] Nonionic softeners include Lβ phase forming sugar esters (as described in M Hato et al Langmuir 12, 1659, 1666, (1996)) and related materials such as glycerol monostearate or sorbitan esters. Often these materials are used in conjunction with cationic materials to assist deposition (see, for example, GB 2 202 244). Silicones are used in a similar way as a co-softener with a cationic softener in rinse treatments (see, for example, GB 1 549 180).
[0055] The composition can also contain fatty acids, for example C 8 to C 24 alkyl or alkenyl monocarboxylic acids or polymers thereof. Preferably saturated fatty acids are used, in particular, hardened tallow C 16 to C 18 fatty acids. Preferably the fatty acid is non-saponified, more preferably the fatty acid is free, for example oleic acid, lauric acid or tallow fatty acid. The weight ratio of quaternary ammonium material or other cationic softening agent to fatty acid material is preferably from 10:1 to 1:10.
[0056] Sugar derivatives are also suitable softening agents.
[0057] The preferred sugar derivatives are solid (at room temperature of 20 C) derivatives of a cyclic polyol or of a reduced saccharide, said derivatives resulting from at least one, and preferably two or more of the hydroxyl groups in said polyol or in said saccharide being esterified or etherified. Preferably, the derivatives have two or more ester or ether groups independently attached to a C 8 -C 22 alkyl or alkenyl chain.
[0058] Examples of suitable saccharides include xylose, arabinose, galactose, fructose, sorbose and glucose. Glucose is especially preferred. An example of a reduced saccharide is sorbitan. Examples of suitable disaccharides include maltose, lactose, cellobiose and sucrose. Sucrose is especially preferred.
[0059] In order that the invention may be further and better understood it will be described hereinafter with reference to examples.
EXAMPLES:
Example 1
[0060] A hollow sphere of 25 mm external diameter, 23 mm internal diameter, was produced from a mix of 42% Cellosize QP-100 MH (hydroxyethylcellulose, Union Carbide) and 58% Tegin G (glycol stearate SE, Goldschmidt). The ester was heated above its melting point whereupon the hydroxyethylcellulose was blended in to form a low viscosity paste. A small quantity of perfume was added. The physical properties of the shell were such that under drying conditions the shell rapidly broke up without forming sticky residues either in the dryer or in the dryer filter. No spotting was observed on the treated fabrics.
[0061] The molten material was then poured into a hemispherical mould and formed into a hemisphere of 1 mm thickness. Two identical shells were then bonded together by the application of heat to the edges.
[0062] The softening composition comprised a 2:1 mix of Sisterna SP-50C (sucrose polyester, Sisterna) and Tegin 4100 (glyceryl stearate, Goldschmidt). The two materials were mixed together, heated to above the melting point of the sucrose polyester, then allowed to solidify. The resulting material was then ground to a powder. Addition of the ester is necessary to reduce the viscosity of molten sucrose polyester so that even deposition is achieved.
[0063] The powdered material was then introduced through a hole in the shell of the sphere. When the requisite amount had been added, the hole was filled with molten material as detailed above.
[0064] The above sphere was added to a 2 kg mixed load of woven cotton sheeting, terry towelling and blue cotton interlock. After sixty minutes drying, the load was removed and panelled in comparison with an untreated load and one treated with a tumble-dryer sheet.
[0065] On completion of the drying cycle, the treated fabric was found be softer than the untreated and perfumed.
Example 2
[0066] A hollow sphere of 25 mm external diameter, 23 mm internal diameter, was produced from a mix of 40% Arbocel B600 (fibrous cellulose, 60 μm average fibre length, 20 μm average fibre thickness, J Rettenmaier) and 60% Tegin G (glyceryl stearate SE, Goldschmidt).
[0067] The ester was heated above it's melting point whereupon the hydroxyethylcellulose was blended in to form a low viscosity paste. A small quantity of perfume was added. The physical properties of the shell were such that under drying conditions the shell rapidly broke up without forming sticky residues either in the dryer or in the dryer filter. No spotting was observed on the treated fabrics.
[0068] The interior was filled with a 2:1 mix of Sisterna SP-50C (sucrose polyester, Sisterna) and Tegin 4100 (glyceryl stearate, Goldschmidt). The two materials were mixed together, heated to above the melting point of the sucrose polyester, then allowed to solidify. The resulting material was then ground to a powder. Addition of the ester is necessary to reduce the viscosity of molten sucrose polyester so that even deposition is achieved.
[0069] The above sphere was added to a 2 kg mixed load of woven cotton sheeting, terry towelling and blue cotton interlock. After sixty minutes drying, the load was removed and panelled in comparison with an untreated load and one treated with a tumble-dryer sheet.
[0070] On completion of the drying cycle, the treated fabric was found be softer than the untreated and perfumed.
Example 3
[0071] A hollow sphere of 25 mm external diameter, 23 mm internal diameter, was produced from a mix of 40% Arbocel B600 (fibrous cellulose, 60 μm average fibre length, 20 μm average fibre thickness, J Rettenmaier) and 60% Tegin G (glyceryl stearate SE, Goldschmidt).
[0072] The ester was heated above it's melting point whereupon the hydroxyethylcellulose was blended in to form a low viscosity paste. A small quantity of perfume was added. The physical properties of the shell were such that under drying conditions the shell rapidly broke up without forming sticky residues either in the dryer or in the dryer filter. No spotting was observed on the treated fabrics.
[0073] The interior was filled with a 2:1 mix of Sisterna SP-50C (sucrose polyester, Sisterna) and Tegin 4100 (glyceryl stearate, Goldschmidt). The two materials were mixed together, heated to above the melting point of the sucrose polyester, then allowed to solidify. The resulting material was then ground to a powder. Addition of the ester is necessary to reduce the viscosity of molten sucrose polyester so that even deposition is achieved. A further addition of 0.2 g of poly(vinyl pyrrolidone), molecular weight 40,000, was added to impart next-wash dye-transfer benefits.
[0074] To test the dye-transfer benefit, 1 kg of the treated woven cotton was washed at 40° C. with 35 g of Persil Original Non-Biological washing powder in a Whirlpool horizontal axis washing machine containing 80 g. of unfixed Direct Green 26 woven cotton. A similar wash was carried out using 1 kg of untreated woven cotton. The degree of dye transfer was measured using a Datacolor International Microflash 200d spectrophotometer.
[0075] Untreated cloth ΔE 14.62 (std. devn. 0.59)
[0076] Treated cloth ΔE 11.92 (std. devn. 0.21)
[0077] The cloth treated with the dryer ball has reduced dye transfer, signified by the lower AE value measured on the cloth.
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The invention relates to a fabric treatment composition for use in a tumble dryer where the benefit agent(s) is/are contained within a rigid outer shell. A first aspect of the present invention provides a dispenser comprising a rigid and fragile outer shell and containing a benefit agent, together with instructions to use the same in the tumble dryer. A second aspect of the present invention provides for a method of fabric treatment which comprises the steps of: a) placing the fabric, together with a dispenser in a tumble-drier, and, b) operating the tumble drier, wherein the dispenser comprises a rigid and fragile outer shell and contains a benefit agent. The benefit agent contained within the shell can be in a powder, gel or liquid form, such that when the outer shell breaks, the agents are released to deposit onto the fabric, thus imparting the required benefit. It is believed that a shell which fragments to a fine powder enables the rapid release and dispersal of the benefit agent. The powder produced is sufficiently fine to be lost through the drum of the dryer.
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FIELD OF THE INVENTION
[0001] The present invention relates to a handle for an angular brush having an holding tenon for the glue, to the relative brush and to the method for its construction.
[0002] Brushes consist of an elongated handle to which bristles are fixed. The bristles are firstly glued together at one end to form a pack. They are then fixed to the handle by means of a collar. The collar is fixed to the brush by two nails or clouts.
[0003] With prolonged use of the brush, these nails tend to cause cracks to open in the wood of the handle, they can rust and hence ruin the brush, to the extent of making it unserviceable.
[0004] Moreover, when they are inserted into the wood they tend to raise the collar, hence forming a slight projection on the collar which can be annoying if not dangerous to the user.
SUMMARY OF THE INVENTION
[0005] The object of the present invention is to provide a brush which is without the drawbacks of the known art, and is of simple construction.
[0006] This object is attained according to the invention by a handle for a brush of angular type, characterized in that said handle comprises, at one end of said handle, a tenon having a profile inclined to the central axis of said handle, said profile comprising at least one circular recess, said profile further comprising at least one lateral chamfer along a major side thereof.
[0007] Said object is also attained by a brush of angular type comprising a handle and bristles, characterized in that said handle comprises a tenon having a profile inclined to the central axis of said brush, said profile comprising incorporating means, said bristles being fixed to each other and also fixed to said handle by glue, said glue gripping said incorporating means and said bristles.
[0008] Said object is also attained by a method for constructing a brush of angular type including a handle having an end inclined to its central axis, a collar and bristles, comprising the steps of providing suitable recesses in said end of said handle; providing on said end of said handle at least one lateral chamfer along a major side thereof; inserting said bristles through a first opening in said collar; pouring glue into said collar through a second opening opposite said first opening; inserting said end of said handle into said collar through said second opening; said glue gripping said bristles and said recesses.
[0009] Further characteristics of the invention are described in the dependent claims.
[0010] In accordance with the present invention an angular brush can be constructed without the use any nail. The construction is simplified compared with traditional constructions. The brushes no longer present breakages or cracks in the wood.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The characteristics and advantages of the invention will be apparent from the ensuing detailed description of one embodiment thereof, illustrated by way of non-limiting example in the accompanying drawings, in which:
[0012] FIG. 1 is a front view of a brush;
[0013] FIG. 2 is a front view of a handle;
[0014] FIG. 3 is a side view of a handle;
[0015] FIG. 4 is a top view of a handle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] With reference to the accompanying figures, the brush consists of a handle 10 , bristles 12 and a collar 16 .
[0017] At one end, namely in its wider end, the handle 10 has a tenon 11 having on its outer edge a profile 13 which is inclined by an angle α of about 70° to a central axis 15 of the brush, in the direction of the brush length.
[0018] This is therefore a so-called angular brush, i.e. presenting the end of the bristles 12 inclined by the predetermined angle α. The collar 16 is also of inclined type.
[0019] The profile 13 presents a chamfer 20 , preferably on both sides (the longer sides) to enable it to more easily penetrate into the glue subsequently used for gluing.
[0020] At the point at which it engages the handle 10 , the tenon 11 has a perimeter slightly less than that of the handle along a section taken at that point. In this manner an edge 17 is obtained at which to position the collar 16 .
[0021] The bristles 12 are grouped together to form a pack suitable for the brush dimensions, and are partially inserted into the collar 16 . A glue of the type normally used for this type of application is inserted through the other opening of the collar 16 , to fix the bristles 12 together. For this operation, the bristles 12 and the collar 16 are placed in an inclined position, equal to the inclination of the angle α of the brush, so that the glue settles on the head of the bristles in a horizontal position.
[0022] The tenon 11 is then inserted through that end through which the glue has been inserted, and becomes glued to the bristles 12 .
[0023] The operation can be carried out in a single step by inserting a quantity of glue adequate both for gluing the bristles and for gluing the handle. Alternatively, but requiring an additional working step, the glue for gluing the bristles 12 can be inserted as a first step, left to dry and then a new quantity of glue be inserted followed by insertion of the handle 10 .
[0024] Hence in both cases, between the bristles 12 and the profile 13 of the handle 10 a region 14 of previously determined dimensions is created, in which the sealing glue for the brush is present.
[0025] The recesses 18 , and in particular the undercuts obtained thereby, serve to cause the glue to adhere to and securely grip the handle 10 . The recesses 18 are provided as laterally as possible to reduce any stresses undergone by them.
[0026] The recesses 18 are of circular shape as they are made by simple drill bits. They can also have other shapes (for example of dovetail type with a aperture at their tip, or two or more oblique cuts) such as to form elements having an undercut in which the glue can grip, but in that case the construction may be more complex and require more than one working step.
[0027] Brushes of the known art, in which the collar is fixed to the handle by nails, require a metal insert to bind the bristles to the handle. The insert, having suitable holes or other gripping elements for the glue, is inserted into the glue used to glue the bristles, it extending along the interior of the collar and being fixed to the handle by the nails.
[0028] According to the present invention, this insert is no longer required, so further saving production costs.
[0029] By virtue of the edge 17 the collar 16 , which is contained within it and does not project from it, cannot annoy the user. Because of the particular inclination of the profile 13 , which equals that of the bristles 12 , the size of the region 14 can be dimensioned such as to reduce as much as possible the quantity of glue used while at the same time maintaining secure fixing, so reducing glue costs and the relative weight. The collar 16 preferably presents ribs which by gripping the materials in its interior prevent it from moving or sliding along the tenon 11 .
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Handle for angular brush characterized in that said handle comprises, at one end of said handle, a tenon having a profile inclined to the central axis of said handle, said profile comprising at least one circular recess, said profile further comprising at least one lateral chamfer along a major side thereof.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 61/398,461, filed on Jun. 25, 2010, which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The field of the invention relates to roofing materials, and more particularly to methods and systems for spacing panels on roofs.
[0004] 2. Description of the Related Art
[0005] Roofs cover the uppermost part of a space or building, protecting the space or building interior from rain, snow, wind, cold, heat, sunlight, and other weather effects. Many roofs are pitched or sloped to provide additional protection against the weather, allowing rain or snow to run off the angled sides of the roof. Roofs generally include a supporting structure and an outer skin, which can be an uppermost weatherproof layer. The supporting structure of a roof typically includes beams of a strong, rigid material such as timber, cast iron, or steel. The outer layer of a roof can comprise panels or boards constructed of timber, metal, plastic, vegetation such as bamboo stems, or other suitable materials.
[0006] In some cases, a pitched roof is desired to shield a space against elements such as rain or snow, while still admitting light into the space and allowing air to freely circulate through the roof and into the space. Thus, methods and systems to efficiently and reliably attach an outer skin to the supporting structure of a roof such that the roof shields against weather elements, admits light, and allows advantageous air circulation are desired and remain a significant challenge in the design of roofing systems.
SUMMARY OF CERTAIN EMBODIMENTS
[0007] The systems, methods, and devices of the invention each have several aspects, no single one of which is solely responsible for its desirable attributes. Without limiting the scope of this invention, its more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section entitled “Detailed Description” one will understand how the features of this invention provide advantages over other roofing systems.
[0008] Methods and devices for spacing panels on a roof are provided. In one embodiment, a wedge-shaped device for spacing panels on a roof includes a bottom surface; a top surface inclined at an angle α relative to the bottom surface; and an integral support structure connecting the top surface and the bottom surface. The support structure includes a plurality of support ribs and a plurality of nail boxes.
[0009] Another embodiment provides a method of installing roof panels on roof support beams. The method includes fastening a plurality of wedge-shaped spacers to a top surface of one or more roof support beams; and fastening a bottom surface of one or more roof panels to the spacers.
[0010] In yet another embodiment, a roof panel spacer system for constructing a roof is provided. The system includes a plurality of support beams; a plurality of spacers fastened to at least some of said support beams; and a plurality of roof panels fastened to the plurality of spacers. Each spacer orients each roof panel substantially horizontal to the ground. Each spacer is positioned to create a space between adjacent roof panels allowing air and light to pass through the roof. Each spacer is also positioned to create an overlap between adjacent roof panels, inhibiting rain and other weather elements from passing through the roof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1A is a top perspective view of an embodiment of a roof panel spacer device.
[0012] FIG. 1B is a bottom perspective view of the device of FIG. 1A .
[0013] FIG. 1C is a bottom elevational view of the device of FIG. 1A .
[0014] FIGS. 2-7 illustrate the device of FIG. 1A in use on a roof.
[0015] FIG. 8 is a top elevational view of the device of FIG. 1A .
[0016] FIG. 9A is a side elevational view of the device of FIG. 1A .
[0017] FIG. 9B is a side elevational view of the device of FIG. 1A showing additional internal features.
[0018] FIG. 10A is a back elevational view of the device of FIG. 1A .
[0019] FIG. 10B is a back elevational view of the device of FIG. 1A showing additional internal features.
[0020] FIG. 11A is a bottom perspective view of another embodiment of a roof panel spacer device.
[0021] FIG. 11B is a bottom elevational view of the device of FIG. 11A .
[0022] FIG. 11C is a cross-sectional view of the device of FIG. 11A taken along line 11 C- 11 C of FIG. 11B .
[0023] FIG. 11D is a cross sectional view of the device of FIG. 11A taken along line 11 D- 11 D of FIG. 11B .
[0024] FIGS. 12-15 illustrate the device of FIG. 11A in use on a roof.
DETAILED DESCRIPTION
[0025] Any feature or combination of features described herein are included within the scope of the present invention provided that the features included in any such combination are not mutually inconsistent as will be apparent from the context, this description, and the knowledge of one skilled in the art. In addition, any feature or combination of features may be specifically excluded from any embodiment of the present invention. For purposes of summarizing the present invention, certain aspects, advantages, and novel features of the present invention are described herein. Of course, it is to be understood that not necessarily all such aspects, advantages, or features will be present in any particular embodiment of the present invention.
[0026] It is to be understood that embodiments presented herein are by way of example and not by way of limitation. The intent of the following detailed description, although discussing exemplary embodiments, is to be construed to cover all modifications, alternatives, and equivalents of the embodiments as may fall within the spirit and scope of the invention.
Roof Panel Spacer for Two-Sided Roof
[0027] FIG. 1A is a top perspective view of an embodiment of a roof panel spacer 100 according to the present invention. FIG. 1B is a bottom perspective view of the spacer 100 . FIG. 1C is a bottom elevational view of the spacer 100 . The spacer 100 generally has a width W measured along an x-axis of the spacer 100 , a length L measured along a y-axis of the spacer 100 , and a height H measured along a z-axis of the spacer 100 . The spacer 100 includes a top surface 102 ; a bottom surface 104 ; sides 106 , 108 ; a back 110 ; and a front 112 .
[0028] The height H of the spacer 100 can be measured at different locations along the spacer 100 . For example, the height of the spacer 100 at the back 110 can be H BACK , while the height of the spacer 100 at the front 112 can be H FRONT . Embodiments of the spacer 100 can be wedge-shaped. For example, the top surface 102 can be inclined at an angle α relative to the bottom surface 104 . Additionally, the bottom surface 104 can be inclined at an angle β relative to the back 110 . In some aspects, the top surface 102 is oriented at an angle of 90° or about 90° relative to the back 110 .
[0029] The spacer 100 can include an integral support structure connecting the top surface 102 and the bottom surface 104 . The support structure can include a plurality of support ribs. For example, the spacer 100 includes width ribs 130 , 132 extending along the width W of the spacer 100 between the sides 106 , 108 . The spacer 100 can also comprise a length rib 134 extending along the length L of the spacer 100 between the back 110 and the front 112 . Bottom surfaces of the ribs 130 , 132 , 134 can form all or a portion of the bottom surface 104 of the spacer 100 .
[0030] In some aspects, the support structure also includes a plurality of nail boxes. For example, the spacer 100 includes nail boxes 150 , 152 , 154 , 156 , which will be described in greater detail below with reference to FIGS. 8-10B . The nail boxes can be configured to accept nails or other fasteners. Some embodiments of the nail boxes 150 , 152 , 154 , 156 comprise a hollow tube extending from the top surface 102 and the bottom surface 104 . The nail boxes can be connected to the width ribs 130 , 132 via flanges 160 , 162 , 164 , 166 , respectively. The spacer 100 may also comprise a nail box 168 disposed in the length rib 134 . Other configurations are possible. For example, in some aspects, the spacer 100 may not comprise one or more of width ribs, length ribs, nail boxes, and/or flanges.
[0031] FIGS. 2-7 illustrate one embodiment of a spacer according to the present invention in use on a roof 268 . Referring now to FIG. 2 , a first spacer 200 according to one embodiment is positioned between a first support beam 270 and a roofing panel or board 275 . The support beam 270 includes a top surface 272 . The panel 275 comprises a top surface 276 and a bottom surface 278 . A second spacer 200 is also positioned between a second support beam 280 and the panel 275 . The support beams 270 , 280 can comprise portions of the support structure of a roofing system, and the panel 275 can comprise a portion of the outer skin of the roofing system.
[0032] A top surface 202 of the spacers 200 are adjacent to and contact the bottom surface 278 of the panel 275 , while a bottom surface 204 of the spacers 200 are adjacent to and contact the top surfaces 272 of the support beams 270 , 280 . Other configurations are possible. For example, in another embodiment, the top surface 202 of the spacers 200 may be adjacent to the support beams 270 , 280 and the bottom surface 204 of the spacers 200 may be adjacent to the panel 275 .
[0033] FIGS. 3 and 4 illustrate embodiments of the spacers 200 in use. The support beams 270 , 280 are inclined relative to a horizontal axis x of the roof 268 by an angle θ BEAM . The panel 275 is inclined relative to the horizontal axis x of the roof 268 by an angle θ PANEL . As described above, the spacers 200 are positioned between the panel 275 and the support beams 270 , 280 . Additional spacers 200 (not illustrated in FIGS. 3 and 4 , but illustrated in FIG. 5 ) are positioned between a panel 282 and the support beams 270 , 280 . An “n” number of panels can be positioned on the support beams 270 , 280 using the spacers 200 . Additionally, the panels 275 , 282 can be positioned on “n” number of support beams using the spacers 200 in order to construct the roof 268 .
[0034] In some embodiments, the spacers 200 are positioned on the support beams 270 , 280 such that the panels 275 , 282 are horizontal or substantially horizontal to the ground and θ PANEL is 0° or about 0°. The spacers 200 may be positioned on the support beams 270 , 280 such that a vertical space 284 separates the panels 275 , 282 . In the embodiment illustrated in FIG. 3 , for example, each of the adjacent panels on the roof 268 are separated by the vertical space 284 . The spacers 200 can be positioned along the support beam 270 at the same or substantially the same distance intervals, such that the vertical spaces 284 separating adjacent panels are the same or substantially the same. It will be understood, however, that the vertical space 284 separating adjacent panels of the roof 268 need not be the same or substantially the same across the entire roof 268 . The vertical spaces 284 can advantageously allow for air to enter the space underneath the roof 268 and circulate within the space. Advantageously, the vertical spaces 284 can also allow light to enter the space underneath the roof 268 .
[0035] In some aspects, the top surface 276 of the panel 275 and the bottom surface 278 of the panel 282 overlap in a region 286 . This overlap between adjacent panels 275 , 282 can advantageously restrict rain and other weather elements from passing through the vertical space 284 and entering the space underneath the roof 268 . For example, embodiments of spacers described herein can shield the interior of a building or other space below a roof from light rain and/or rain without horizontal wind.
[0036] Persons of skill in the art will understand that the spacers 200 can be used with roofs 268 of varying slope or pitch. For example, the support beams 270 , 280 may be less sloped relative to the horizontal axis x of the roof 268 (corresponding to a smaller beam angle θ BEAM than that illustrated in FIGS. 2-7 ), in which case the angle α of the spacer 200 may be decreased. Similarly, the support beams 270 , 280 may be more sloped relative to the horizontal axis x of the roof 268 (corresponding to a greater beam angle θ BEAM than that illustrated in FIGS. 2-7 ). In such cases, the angle α of the spacer 200 can be increased accordingly. Of course, it will be understood that beam angle θ BEAM may not be equal to the angle α of the spacer 200 .
[0037] FIG. 5 illustrates a plurality of spacers 200 use on adjacent panels 275 , 282 . For example, the panel 275 is spaced from the support beam 270 by a first spacer 200 , from the support beam 280 by a second spacer 200 , and from a support beam n BEAM by a third spacer 200 . The panel 282 is spaced from the support beam 270 by a fourth spacer 200 , from the support beam 280 by a fifth spacer 200 , and from the support beam n BEAM by a sixth spacer 200 . Each of the panels of the roof 268 can be spaced from the support beams in a similar manner.
[0038] FIG. 6 illustrates the vertical spaces 284 that can be provided between adjacent panels 275 , 282 according to some embodiments of the present invention. As described above with reference to FIGS. 3 and 4 , the vertical spaces 284 between adjacent panels of the roof 268 can allow air and light to enter through the roof 268 , while also preventing weather elements such as rain from entering the space below the roof 268 .
[0039] FIG. 7 illustrates a plurality of spacers 200 in use on the roof 268 . A spacer is provided at the interface between each panel and each supporting beam. As described above with reference to FIG. 3 , the top surface of a first panel and the bottom surface of a second, higher panel are horizontally overlapped such that rain and other weather elements falling in a vertical direction do not enter the vertical spaces 284 and penetrate the space below the roof 268 .
[0040] Embodiments of the spacers 200 can advantageously be used to construct two-sided roofing structures. For example, the roof 268 illustrated in FIGS. 2-9 comprises a first side 288 and a second side 290 . The spacers 200 are positioned between support beams and panels on the first side 288 , as well as between support beams and panels on the second side 290 .
[0041] FIG. 8 is a top elevational view of the spacer 100 . FIG. 9A is an elevational view of the side 106 of the spacer 100 , illustrating internal features in dashed lines. FIG. 9B is an elevational view of the side 106 showing additional internal features such as the width ribs 130 , 132 . FIG. 10A is an elevational view of the back 110 of the spacer 100 , illustrating internal features in dashed lines. FIG. 10B is an elevational view of the back 110 illustrating additional internal features, including ribs and nail box features.
[0042] As described above with reference to FIGS. 1A-1C , the spacer 100 can include nail boxes 150 , 152 , 154 , 156 , and 168 . In one embodiment, the nail box 150 comprises a recessed area 151 and the nail box 152 comprises a recessed area 153 . The recessed areas 151 , 153 can accommodate the head of a nail or other fastener disposed in nail boxes 150 , 152 , respectively. It will be understood that other nail boxes of the spacer 100 can comprise recessed areas, and that the spacer 100 need not comprise any recessed areas around the nail boxes.
[0043] Referring now to FIG. 9A , the bottom surface 104 of the spacer 100 may be inclined at an angle α relative to the top surface 102 . The angle α can be between about 10° and about 25°. In one embodiment, the angle α corresponds to the angle θ BEAM of the support beams of the roof relative to a horizontal axis x of the roof. Where α equals θ BEAM , the top surface 276 of the panels of the roof may lie substantially horizontally on the spacers, such that the angle θ PANEL of the panels relative to the horizontal axis x of the roof is 0° or about 0°.
[0044] Additionally, the bottom surface 104 can be inclined at an angle β relative to the back 110 . The angle β can be between about 80° and about 65°. In the embodiment illustrated in FIG. 9A , angle α is about 18° and the angle β is about 72°. Other configurations are possible. For example, for a roof comprising support beams disposed at an angle θ BEAM of 20°, the spacer 100 can be modified such that the angle α is 20° and the angle β is 70°.
[0045] FIGS. 10A and 10B show additional views of the spacer 100 . FIG. 10A illustrates nail boxes 150 , 152 , 154 , 156 , 168 , as well as recessed areas 151 , 153 in dashed lines. FIG. 10B illustrates rib 134 in dashed lines.
[0046] FIG. 1A illustrates advantageous dimensions of certain specific embodiments of the spacer 100 . For example, the top surface of the spacer 100 is about 6 inches by about 4 inches; and the back 110 is about 4 inches by about 2 inches. Persons of skill in the art will understand that other dimensions are possible, and embodiments of the spacer 100 are not limited to the number or configuration of nail boxes shown, or the dimensions of spacer 100 .
[0000] Roof Panel Spacer for Roof with Three or More Sides
[0047] FIG. 11A is a bottom perspective view of an embodiment of a roof panel spacer 1300 according to the present invention. FIG. 11B is a bottom elevational view of the spacer 1300 . FIG. 11C is a cross-sectional view taken along line 11 C- 11 C of FIG. 11B . FIG. 11D is a cross-sectional view taken along line 11 D- 11 D of FIG. 11B . Embodiments of the spacer 1300 can be used to construct roofing structures with three or more sides.
[0048] The spacer 1300 generally has a width W measured along an x-axis of the spacer 1300 , a length L measured along a y-axis of the spacer 1300 , and a height H measured along a z-axis of the spacer 1300 . The spacer 1300 includes a first top surface 1302 A; a second top surface 1302 B; a bottom surface 1304 ; and sides 1306 , 1308 , 1310 , 1311 , 1312 , and 1313 . In some aspects, the spacer 1300 includes a peaked top surface.
[0049] The height H of the spacer 1300 can be measured at different locations along the spacer 1300 . For example, the height of the spacer 1300 where the sides 1310 , 1311 meet can be H MAX , while the height of the spacer 1300 where the sides 1308 , 1311 meet can be H MID . Embodiments of the spacer 1300 can be wedge-shaped. For example, the top surface 1302 of the spacer 1300 may be inclined at an angle α relative to the bottom surface 1304 . The bottom surface 1304 can also be inclined by an angle β 1 relative to the intersection of the sides 1308 , 1311 . Additionally, the bottom surface 1304 can be inclined at an angle β 2 relative to the intersection of the sides 1310 , 1311 .
[0050] The spacer 1300 can include an integral support structure connecting the top surface 1302 and the bottom surface 1304 . The support structure can include a plurality of support ribs. For example, the spacer 1300 includes width ribs 1330 , 1332 extending along the width W of the spacer 1300 between the sides 1306 , 1308 . The spacer 100 can also comprise a length rib 1334 extending along the length L of the spacer 1300 between the sides 1310 , 1311 and the sides 1312 , 1313 . Bottom surfaces of the ribs 1330 , 1332 , 1334 can form a portion of the bottom surface 1304 of the spacer 1300 .
[0051] In some aspects, the support structure includes a plurality of nail boxes. For example, the spacer 1300 comprises nail boxes 1350 , 1352 , 1354 , 1355 , 1356 , and 1357 . Some embodiments of the nail boxes 1350 , 1352 , 1354 , 1355 , 1356 , and 1356 comprise a hollow tube extending from the top surface 1302 and the bottom surface 1304 . The nail boxes 1354 , 1355 can be connected to the width rib 1331 via flanges 1360 and 1362 . Other configurations are possible. For example, in some aspects, the spacer 1300 may not comprise width ribs, length ribs, nail boxes, and/or flanges.
[0052] In some aspects, the nail box 1354 comprises a recessed area 1351 and the nail box 1355 comprises a recessed area 1353 (not illustrated). The recessed areas 1351 , 1353 can accommodate the head of a nail or other fastener disposed in nail boxes 1354 , 1355 , respectively. It will be understood that other nail boxes of the spacer 1300 can comprise recessed areas, and that the spacer 1300 need not comprise any recessed areas around the nail boxes.
[0053] FIGS. 12-15 illustrate this embodiment of a spacer according to the present invention in use on a roof 1468 that has three or more sides. Referring now to FIG. 12 , a spacer 1400 according to one embodiment is positioned between a support beam 1470 and a first roofing panel or board 1475 . The roof 1468 also comprises a second spacer 1400 positioned between the support beam 1470 and a second panel 1482 . The support beam 1470 includes a top surface 1472 . The panels 1475 , 1482 each include a top surface 1476 and a bottom surface 1478 . The support beam 1470 can comprise a portion of the support structure of a roofing system, and the panels 1475 , 1482 can comprise a portion of the outer skin of the roofing system.
[0054] A top surface 1402 of the spacers 1400 are adjacent to and contact the bottom surfaces 1478 of the panels 1475 , 1482 , while a bottom surface 1404 of the spacers 1400 are adjacent to and contact the top surface 1472 of the support beam 1470 . Other configurations are possible.
[0055] In one embodiment of the present invention, the spacers 1400 are positioned on the support beam 1470 such that a vertical space 1484 separates the panels 1475 , 1482 . In some aspects, each of the adjacent panels on the roof 1468 are separated by a vertical space 1484 . As described above with reference to FIG. 3 , the vertical spaces 1484 can advantageously allow for air to enter the space underneath the roof 1468 and circulate within the space. Advantageously, the vertical spaces 1484 can also allow light to enter the space underneath the roof 1468 .
[0056] In some aspects, the top surface 1476 of the panel 1475 and the bottom surface 1478 of the panel 1482 overlap in a region 1486 . This overlap between adjacent panels 1475 , 1482 can advantageously restrict rain and other weather elements from passing through the spaces 1484 and entering the space underneath the roof 1468 .
[0057] FIGS. 13-15 illustrate a plurality of panels spaced from the support beam 1470 by the spacers 1400 . The panel 1475 and a panel 1492 are positioned on a first spacer 1400 (not illustrated), and the panel 1482 and a panel 1494 are positioned on a second spacer 1400 (not illustrated). A third spacer 1400 is also positioned on the support beam 1470 , ready to receive panels. As described above, the spacers 1400 allow the panels 1492 , 1494 to be advantageously separated by a vertical space 1484 .
Installation of Roofing Spacers
[0058] Embodiments of the roofing spacers described herein can be installed using fasteners such as nails. In one embodiment, a spacer according to the present invention is first positioned on a support beam. Nails are driven into one or more nail boxes of the spacer. The nails may be driven into nail boxes comprising recessed areas, for example. These nails may initially restrict movement of the spacer relative to the support beam until additional nails are driven into the spacer. Next, a panel is positioned over the spacer, and additional nails are driven through the panel into the spacer. In some aspects, the installer is aware of the general location of the nail boxes which remain empty, but is not able to see the precise location of the empty nail boxes through the panel. The installer can estimate the location of the empty nail boxes and aim the nails so that they enter the spacer at or near the empty nail boxes.
[0059] It will be understood by those of skill in the art that positioning nails precisely in the nail boxes is not required to install embodiments of spacers described herein. Nails and other fasteners can effectively secure the spacers to support beams, and panels to the spacers, if they are driven into the nail boxes, the ribs, and/or the flanges described herein. It will also be understood that a nail need not be driven into each nail box provided on the spacers in order to secure the spacer to a support beam, or to secure a panel to the spacer.
Materials for a Roofing Spacer
[0060] Embodiments of the spacers described herein can be made of any suitable material, including plastic or metal. In one embodiment, spacers according to the present invention are made of polypropylene copolymer. In some aspects, the comonomer of the polypropylene copolymer is ethylene. Polypropylene copolymer is characterized as having high impact resistance strength. Polypropylene copolymer also has slightly increased elongation at break, and is thus more pliable, compared to unmodified polypropylene homopolymer. Typical material properties of polypropylene copolymer are provided in Table 1 below.
[0000]
TABLE 1
Property
Yield Point
24
MPa
Elongation at Yield
10-12%
Tensile Break
33
MPa
Elongation at Break
650%
Tensile Modulus
1050
MPa
Flexural Modulus
1270
MPa
Flexural Strength
25-26
MPa
Tensile Impact
800
kJ/m2
[0061] Spacers described herein need not be made of polypropylene copolymer, and can be made of any suitable material, including but not limited to materials exhibiting material properties similar to that of polypropylene copolymer. Spacers made of polypropylene copolymer can advantageously accept fasteners without shattering or suffering other adverse structural effects which may result when a nail or other fastener is driven into the spacer.
[0062] Embodiments of the spacers described herein can be molded from one piece of injection-molded plastic, such that the spacer is monolithic. The spacers described herein can also be manufactured by connecting together separate components, such as the top surface, the bottom surface, the back, and the integral support structure, to form one spacer.
[0063] The above-described embodiments have been provided by way of example, and the present invention is not limited to these examples. Multiple variations and modifications to the disclosed embodiments will occur, to the extent not mutually exclusive, to those skilled in the art upon consideration of the foregoing description. Additionally, other combinations, omissions, substitutions and modifications will be apparent to the skilled artisan in view of the disclosure herein. Accordingly, the present invention is not intended to be limited by the disclosed embodiments.
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Devices, methods, and systems are provided herein for spacing an outer skin of a roof from the supporting structure of the roof such that the roof shields against weather elements, admits light, and allows advantageous air circulation. In one embodiment, a wedge-shaped device for spacing panels on a roof includes a bottom surface, a top surface inclined at an angle relative to the bottom surface, and an integral support structure connecting the top surface and the bottom surface, the support structure including a plurality of ribs and a plurality of nail boxes.
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BACKGROUND OF THE INVENTION
This invention relates to devices which release drugs in response to environmental stimuli. More particularly, this invention relates to delivery devices containing drug laden hydrogels which deswell and release drugs from the device, hereinafter referred to as mechanical squeezing, in response to external or internal stimuli such as temperature or pH changes, or chemical reactions.
DESCRIPTION OF PRIOR ART
There have been many approaches to meet the problems of regulating the delivering of drugs or other chemicals to biological systems in the place and at the proper time and dose to achieve the desired regulatory effect. These systems depend on the utilization of physical or chemical stimuli which are a result of changes in the surrounding environment. These changes are usually of an external nature to the drug delivery system. These mechanisms respond to such stimuli or signals which include protein binding, hydrogel expanding or swelling, polymer erosion, membrane reorganization, solubility change, energy conversion, supply of activation energy for permeation, physical property changes of the materials that comprise the system, or phase transition phenomena, and the like. Examples are presented in J. Heller, Chemically self-regulated drug delivery systems, J. Control. Rel., 8, 111-125 (1988).
Additional prior art systems are described in the following patents. Higuchi et al., U.S. Pat. No. 4,034,756 is drawn to a device that essentially has two compartments, one filled with an osmotic agent or gel that swells in the presence of water and the other filled with a bioactive drug or other material. The expanding or swelling of the osmotic agent compartment or gel forces the material contained in the second compartment through an orifice. A flexible partition between the two compartments acts as a pump forcing the material in the second compartment through the orifices. Additional patents also include modified shapes and arrangements of the components. Other exemplary art, namely Deters, et al., U.S. Pat. No. 4,627,850; Eckenhoff et al., U.S. Pat. No. 4,717,566; Wong et al, U.S. Pat. No. 4,783,337; Wong, U.S. Pat. No. 4,743,247; Eckenhoff et al., U.S. Pat. No. 4,814,180; Deters et al., U.S. Pat. No. 4,837,111; Eckenhoff, U.S. Pat. No. 4,865,598; Eckenhoff, U.S. Pat. No. 4,871,544; Eckenhoff, U.S. Pat. No. 4,883,667; and Eckenhoff, U.S. Pat. No. 4,966,767 do not have the flexible partition between the two compartments. The systems disclosed in these patents rely on the expanding or swelling of the osmotic agent compartment or gel to force the drug surrounding them out through orifices or a permeable membrane. Theeuwes, U.S. Pat. No. 4,320,759 includes additional partitioning membranes. U.S. Pat. Nos. 4,871,544 and 4,966,767 include osmotic agents to enhance the expanding or swelling of the gels. Osmotic agents are also mixed with beneficial agent formulations in the second compartment in the systems taught in U.S. Pat. Nos. 4,783,337 and 4,837,111. Some patents reveal the inclusion of a density member to keep the devices in a aqueous environment. The density member is dispersed in the expandable hydrogel compartment (U.S. Pat. Nos. 4,783,337 and 4,837,111) or in separate compartments (U.S. Pat. Nos. 4,717,566 and 4,865,598) which are placed in different locations in relation to other compartments. Edgren et al., U.S. Pat. No. 4,503,030 shows pH responsive release, that is, controlled release at low pH, but dumping of all remaining agents at high pH by disintegration of the devices. This action cannot be repeated with subsequent pH changes. Ayer et al., U.S. Pat. No. 4,948,592 demonstrates a two mode release pattern, that is a one time burst releasing the beneficial agents at the beginning followed by a controlled release. This is based on the dissolution of a coating layer covering the osmotic devices, containing beneficial agents for quick release, followed by the timed sustained release of agents from the inner compartment of the device by osmotic squeezing. U.S. Pat. Nos. 4,814,180 and 4,871,544 contain temperature responsive materials in the devices disclosed. This material delivers the agent at body temperature with no release at storage temperature. At room or storage temperature, the material remains in the solid state, preventing squeezing of agents from the devices in the presence or absence of environmental water. However, at body temperature the material becomes a liquid allowing the formulation containing the beneficial agents to flow, which can then be pushed out via a passageway(s) by osmotic force. A contracting or deswelling process of hydrogels for drug delivery purposes has been reported by Hoffman et al. J. Control. Rel., 4, 213-222 (1986). A temperature sensitive hydrogel was synthesized which deswelled at elevated temperatures and swelled at low temperatures. Vitamin B12 was entrained at a low temperature and released at a higher temperature by a squeezing action. However, the overall release rate was quick and vitamin B12 was released in two steps; a fast squeezing and subsequent slow release due to a rigid surface formation on the hydrogel. It is expected that the release of entrained drug from the unprotected hydrogel at low temperatures will be unacceptably high. Therefore, this system may not be suitable for repeated pulsatile drug release by temperature modulation. The Opposite release pattern from a monolithic device Was reported by Bae et al., Makromol. Chem Rapid Commun., 8, 481-485 (1987)in which a pulsatile release was demonstrated using N-isopropylacrylamide based thermo-sensitive hydrogels (see also Hoffman et al, J. Control. Rel., 4, 213-222 (1986)). These polymers showed immediate rigid surface formation with contracting or deswelling process when the temperature was raised. This phenomenon blocks solute release from the gel matrices at an elevated temperature while allowing solute release at a low temperature. J. Kost (Ed.), Pulsed and Self Regulated Drug Delivery, CRC Press Inc., Boca Raton, Fl., (1990), Chapter 2, Temperature Responsive Control Drug Delivery, (authored by the present inventors) discloses the formation of a gel that expands or swells and contracts or deswells according to the temperature changes. This article indicates that the gel was used to entrain drug solutions but does not disclose or suggest that the gel can be contained within or used in a structured drug delivery device.
None of the prior art suggests the concept of entraining the beneficial agent in a hydrogel confined to a structured dispensing device which, when exposed to stimuli, then forces the agent by contracting or deswelling into the space within the device previously occupied by the swollen hydrogel allowing the beneficial agent to be released from the device into the surrounding environment.
OBJECTS AND BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide a delivery system which enables the effective delivery of drugs entrained within a hydrogel, via a squeezing mechanism, in response to external or internal, physical Or chemical stimuli.
It is also an object of this invention to provide a drug delivery system from which the drug release from a hydrogel of zero or first-order kinetics is achieved in response to such stimuli.
A still further object of this invention is to provide a suitable structure for a self-regulating or externally modulated drug delivery system which gives a pulsatile release pattern from a hydrogel with a minimal lag time.
Another object of this invention is to provide a delivery system meeting the above objectives Which also results in a controlled basal release of drugs from a hydrogel in the absence of stimuli or at reduced signal strength.
Yet another object is to control the triggering stimuli for the drug release from a device with the same hydrogel by changing drug loading conditions.
An additional object of this invention is to provide a stimuli responsive drug delivery system from a hydrogel enabling relatively easy drug loading and recharging when the system is exhausted.
These and other objects may be obtained by means of a dispenser device which is composed of sponge-like porous or dense hydrogel, in solid or particulate form, contained Within the confines of a walled structure wherein the walls either contain dispensing orifice(s) or are permeable to the diffusion of the entrained biologically active agent Or drug. Depending upon the drug and the stimuli to be used, the walls of the dispenser device may be either impermeable or permeable to chemicals that are stimuli to the swelling or expanding, or contracting or deswelling of the hydrogel. The sponge-like porous hydrogel reversibly deswells, shrinks or contracts in response to stimuli, such as temperature, pH, ionic strength, glucose concentration, metabolites in the body, or other conditions that cause the hydrogel to contract. The swollen hydrogel entrains the drug solution or formulation and the system maintains a minimal release when not subjected to stimuli that causes the hydrogel to deswell or contract. Once the hydrogel deswells or contracts in response to a stimulus, the drug in an aqueous solution is freed from the hydrogel by mechanical squeezing of the sponge-like matrix and subsequently is available for diffusion from the dispenser either through the orifice(s) in the dispenser walls or by permeation, if a permeable membrane is used. Either a minimal amount or no drug at all will be released when the hydrogel expands or reswells within the walled structure upon removal of the stimuli since undiffused drug solution is reabsorbed into the (porous) hydrogel matrix. This concept provides a drug delivery system which is reversible upon the controlled contracting or deswelling and expanding or swelling of the hydrogel in response to external stimuli.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a first embodiment consisting of a walled dispenser having an interior compartment with orifices in the walls and wherein the compartment is filled with a swollen hydrogel containing an entrained drug solution.
FIG. 2 shows the dispenser of FIG. 1 wherein the hydrogel is partially deswelled or contracted in response to being contacted by some form of stimuli, thereby releasing the entrained drug into the portion of the compartment space previously occupied by the swollen gel and also diffusing through the orifices in the dispenser walls into the surrounding environment.
FIG. 3 shows a dispenser similar to that shown in FIG. 1 wherein the orifices are sealed and wherein the compartment contains dried hydrogel only prior to being swollen with a drug solution by the introduction of a solution through the orifices in the dispenser walls.
FIG. 4 shows a different embodiment consisting of a walled dispenser containing an outer permeable membrane and an inner support structure with orifices in the walls and having the dispenser compartment filled with a hydrogel swollen by an entrained drug solution.
FIG. 5 shows a still different embodiment of a dispensing device consisting of a double walled structure one being a rigid outer permeable membrane partially enclosing a continuous inner permeable rigid and porous or perforated wall that allows the drug solution to diffuse from the compartment through both walls and into the environment surrounding the device.
FIG. 6 shows a device similar to FIG. 5 except that the outer wall is not permeable and may or may not be rigid.
DETAILED DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 show one embodiment of a delivery device 10 consisting of an outer wall 11, preferably constructed a material of sufficient rigidity to be self supporting. The wall defines and encloses an interior space or compartment 12. FIG. 1 shows the compartment 12 filled with a swollen hydrogel 13 containing an entrained drug solution. Hydrogel 13 is sensitive to internal or external physical or chemical stimuli such as pH or temperature changes. The walls 11 of the device contain one or more orifices 14. FIG. 1 illustrates the device a filled and ready-to-use state. The hydrogel can be continuous or particulate, porous or dense. The hydrogel must be capable of entraining a drug solution which causes the hydrogel to swell and fill compartment 12 prior to use. The degree of expanding or swelling of the hydrogel 13 is a function of external or internal, physical or chemical stimuli as is more fully described elsewhere.
FIG. 2 demonstrates drug release from the device 10 described in FIG. 1 resulting from an applied stimulus. Although not specifically shown in FIG. 1, the soluble drug 15 dissolved in a solution 16, is entrained or absorbed into the swollen hydrogel 13. The hydrogel 13 deswells, shrinks or contracts in the presence of a stimulus to only partially fill the compartment 12 as shown in FIG. 2. thereby squeezing the drug 15 in solution 16 into the portion of compartment 12 now unoccupied by the shrunken hydrogel. The drug 15 in solution 16 released from hydrogel thus resides in the compartment 12 in the space between wall 11 and deswollen hydrogel 13. The drug 15 and solution 16 is diffused from the device 10 into the surrounding media through orifices 14 or drug 15 may diffuse through wall 11 by means of permeation if the wall 11 is permeable. The wall 11 conducts the environmental stimulus to the compartment 12. The wall materials are selected based on the stimuli used and applications of the devices and are more fully described elsewhere in this specification. The orifices 14 in the device 10 are major passageways for bulk diffusion of the drug when the hydrogel 13 is deswollen with a stimulus. The size and number of the orifices 14 determines the release rate of the drug 15 into the surrounding atmosphere. The orifices 14 in the embodiment shown in FIGS. 1 or 2 can be located anywhere in the wall. When the stimulus disappears or is weakened, the drug 15 and solution 16 are reabsorbed into the hydrogel 13 to minimize or terminate the release of the drug. Although FIGS. 1 and 2 portray the device as being in the shape of a conventional capsule, the particular shape is not critical to the functioning of the device. What is essential is that the walls be constructed to conduct the applied stimuli to the hydrogel and that the drug released from the deswollen hydrogel pass through the walls by means of orifices in the walls or permeation through the wall or both into the surrounding environment.
When the drug is unstable in an aqueous environment, the drug solution or formulation can be loaded just before use. FIG. 3 illustrates such a device. The numerals in FIG. 3 are the same as those in FIGS. 1 and 2. In FIG. 3 there is shown a dispenser device 10 containing dried hydrogel particles 13 only. The orifices 14 are sealed from the outside environment by tape or other closing means 17 on the outer surface of wall 11. The drug solution or formulation (not shown) is introduced into the compartment 12 through the one of the orifices 14, especially through the orifice shown in FIG. 3 which is located in the wall at the top after removing closing means 17 from the outer surface of wall 11. This particular orifice diameter should be large enough to allow the introduction of a drug solution or formulation into the compartment 12 using injection means. The orifice should also allow the air to be evacuated during injection. When the device 10 shown in FIG. 3 is filled with drug solution, orifice 14 should again be closed with closure means 17. However, before closing the orifice, the hydrogel should absorb the maximum amount of drug solution so as to fill compartment 12 of the device. The closure means 17 can be removed when the device is ready for use. It can be seen that the device shown in FIG. 3 will assume the same configurations and functions shown in FIGS. 1 and 2 when the hydrogel 13 is either fully swollen or is partially or fully deswollen as a result of the application of the appropriate stimuli.
FIG. 4 illustrates a different embodiment of a delivery device 20 consisting of a rigid inner porous or perforated wall 21 covered with an outer flexible and permeable membrane wall 28. The inner wall 21 provides support allowing the device 20 to retain its original shape. Orifices 14 in each wall 21 and 28 communicate to provide a channel for the dispensing of drug from the hydrogel upon contact with the desired stimuli. In this embodiment, the stimuli can be either chemical or physical. The inner and outer walls 21 and 28 can be permeable to the stimulating molecules which permeate through the walls. Depending upon the size of the drug molecules, the walls may also be permeable to the dispensing of the drug. In other words, drug may be delivered to the surrounding environment both through the communicating orifices 14 in the walls and by permeation through walls 21 and 28. FIGS. 5 and 6 illustrate a still different embodiment consisting of a delivery device 30 having inner and outer walls neither of which have orifices through which the drug is to be discharged into the environment. The device 30 illustrated in FIGS. 5 and 6 has an inner wall 31 made of a rigid porous or perforated material which is permeable to the drug 15 and drug solution 16. An Outer membrane wall 38 only partially covers the inner wall 31 and is shown in both FIGS. 5 and 6 as leaving a wall opening 34 at the top of the device. The uncovered portion of inner wall 31 defined by opening 34 in outer wall 38 can be used as a passageway for drug release in the place of orifices. When hydrogel 13 is in the form of small particles, this type of structure prevents any possible leakage of such particles from the device.
In the FIG. 5 embodiment, the outer wall 38 is permeable, either to chemical stimuli entering the device to trigger the release of drug or to the dispensing of drug through the outer wall. This embodiment is particularly adapted for use in a system for the utilization of chemical stimuli with the release of drug through the inner wall in the area of opening 34 in the outer wall. In this embodiment, the outer wall 38 can be either flexible and non-supporting or rigid and supporting.
The embodiment of FIG. 6 is similar in all respects to FIG. 5 except that the outer wall or membrane 38 is not permeable. Provided the inner wall 31 is structurally self-supporting, the outer impermeable wall 38 may be either flexible or rigid. In either event the dispensing of drug will be through the inner wall 31 in the area of the opening 34 in the outer wall. This embodiment may be more readily adaptable to physical stimuli, such as temperature, than chemical. However, inner membrane may still be permeable to chemical stimuli which penetrates the inner wall through opening 34 in the outer wall.
DETAILED DESCRIPTION OF THE INVENTION
As can be seen from the above description of the various embodiments shown in the drawings, the invention is directed to devices made up of impermeable or permeable enveloping walls having an interior space or compartment filled with sponge-like porous or dense hydrogel o hydrogel particles which entrain drug solutions or formulations. By "enveloping walls" is meant any structure having an inner compartment space surrounded by walls. These may be in the form of hollow spheres, boxes, rods or any other number of configurations. For the sake of simplicity, these will generally be referred to throughout this disclosure as "capsules". However, the term "capsule" is not to be limited to the shape of the conventional gelatin capsule utilized for the dispensing of medicines. Also, the term, "wall(s)" may be used to define a single continuous wall enclosing a compartment or a discontinuous wall, such as is found in a conventional capsule wherein there are two sections one of which is telescoped into the other to form a compartment. Further, a capsule may consist of a lower hollow section onto which is fitted a top to complete the enclosed compartment.
The devices of this invention can utilize, in the compartment thereof, any hydrogel which swells to entrain an aqueous drug solution and which deswells or contracts in response to external or internal, physical or chemical stimuli to release or squeeze out the drug solution. The invention is not drawn to any novel hydrogels or class of novel hydrogels. There are various suitable hydrogels already taught in the prior art which react appropriately to drug entrainment and deswell or contract in response to contact by appropriate chemical and/or physical stimuli. Some of these hydrogels are referenced above. However, there also may now exist, or be developed in the future, other hydrogels which can also be utilized in this invention. Therefore, the invention is to be limited only by the functionality of the hydrogels and is inclusive of all hydrogels which meet the parameters given above. For example, N-isopropylacrylamide based copolymers or interpenetrating polymer networks can be used as temperature sensitive hydrogels and crosslinked polyelectrolytes as pH sensitive hydrogels. These hydrogels deswell or contract as a result of increasing temperature or variations in the environmental pH. Typical temperature sensitive hydrogels are disclosed in Bae, et al. Temperature Dependence of Swelling of Crosslinked poly(N,N-alkyl Substituted Acrylamide) in Water, J. Polym. Sci.: Part B: Polym. Phys., 28 (1990) 923; Y. H. Bae, et al., A New Thermo-sensitive Hydrogel: Interpenetrating Polymer Networks from N-acryloylpyrrolidine and poly(oxyethylene), Makromol. Chem., Rapid Commun., 9 (1988), 185; and Ilmain, et al., Volume Transition in a Gel Driven by Hydrogen Bonding, Nature, 349 (1991) 400. pH sensitive hydrogels are disclosed in Brannon et al., The Swelling Behavior of pH Sensitive Hydrogels. Proceed. Intern. Symp. Control. Rel. Bioact. Mater., 15 (1988) 28; and Siegel et al., pH-Dependent Equilibrium Swelling Properties of Hydrophobic Polyelectrolyte Hydrogels, Macromolecules, 21 (1988) 667.Photo-sensitive hydrogels are described in Ishihara,et al., Photo Induced Swelling Control of Amphophilic Azoaromatic Polymer Membrane, J. Polym. Sci.: Polym. Chem. Ed., 22 (1984) 121; Sunamoto, et al., Liposomal Membranes, 13. Transport of an Amino Acid Across Liposomal Bilayer as Mediated by Phoresponsive Carrier, JACS, 104 (1982) 5502; Irie, et al., Photo Responsive Polymers, 8. Reversible Photo Stimulated Dilation of Polyacrylamide Gels Having Triphenylmethane Leuco Derivatives, Macromolecules, 19 (1986) 2477; Marada, et al., Photo Induced Phase Transition of Gels, Macromolecules, 23 (1990) 1517; Suzuki, et al., Phase Transition in Polymer Gels Induced by Visible Light, Nature, 346 (1990) 345. Glucose sensitive hydrogels are illustrated in Kost, et al., Glucose-Sensitive Membranes Containing Glucose Oxidase: Activity, Swelling and Permeability Study, J. Biomed. Mater. Res., 19 (1985) 1117; Albin, et al., Theoretical and Experimental Studies of Glucose Sensitive Membranes, J. Control. Rel., 6 (1987) 267; Ishihara, et al, Glucose Induced Permeation Control of Insulin Through a Complex Membrane Sensitivity of Immobilized Glucose Oxidase and a Poly(amine), Polymer J., 16 (1984) 625.
Temperature sensitive hydrogels, which are crosslinked homopolymers or copolymers, may be made from the following monomers: N-isopropylacrylamide, N,N-diethylacrylamide, acryloylpiperidine, N-ethylmethacrylamide N-n-propylacrylamide and N-(3'-methoxypropyl)acrylamide, preferably N-isopropylacrylamide, N,N'-diethylacrylamide and N-n-propylacrylamide. A crosslinking agent is required for gel formation. Typical classes of crosslinking agents include (1) di-,tri-, or tetraacrylates such as bisphenol-A diacrylate, 1,3-butanediol diacrylate, 1,4-butanediol diacrylate, 1,10-decanediol diacrylate, diethylene glycol diacrylate, 1,6-hexamethylene diacrylate, pentaerithritol tetraacrylate, pentaerithriol triacrylate, p-phenylene diacrylate, tetraethylene glycol diacrylate, triethylene glycol diacrylate, 1,1,1-trimethylolethane triacrylate, and 1,1,1-trimethylolpropane triacrylate; (2) di-, tri-, or tetramethacrylates such as bisphenol-A dimethacrylate, bisphenol-A-bis(hydroxyprophyl) methacrylate, 1,3-butanediol dimethacrylate, 1,4-butanediol dimethacrylate, crotyl methacrylate, 1,4-cyclohexanediol dimethacrylate, 1,10-decanediol dimethacrylate, diethylene glycol dimethacrylate, 2,2,-dimethylpropanediol dimethacrylate, glyceryl trimethacrylate, hydrogenated bisphenol-A dimethacrylate, pentaerithritol tetramethacrylate, tetraethylene glycol dimethacrylate, triethylene glycol dimethacrylate, and 1,1,1-trimethylolpropane trimethacrylate; (3) chemicals containing diallyl groups such as N,N-Diallylacrylamide, diallyl diglycol carbonate, diallyl fumarate, diallyl maleate, diallyl phthalate, N,N'-diallyltartardiamide, and diallylterephthalate; (4) chemicals having divinyl groups such as divinylbenzene; and, (5) others materials such as 4-methacryloxyethyl trimellitate anhydride and N,N'-methylene bisacrylamide. The resulting gel will swell at lower temperature and deswell at higher temperature. Preferred crosslinking agents are water soluble or slightly water soluble and are miscible With monomers.
pH sensitive hydrogels may be made by polymerizing the following monomeric unsaturated acids: 2-acetamidoacrylic acid, acrylic acid, cis-aconitic acid, trans-aconitic acid, allylacetic acid, 2-allylphenoxyacetic acid, β-benzoacrylic acid, 2-chloroacrylic acid, crotonic acid, N,N-di-n-butylmaleamic acid, fumaric acid, N,N-diethylmaleamic acid, dihydroxymaleic acid, itaconic acid, 3,3-dimethylacrylic acid, N-ethylmaleamic acid, trans-2-hexenoic acid, trans-3-hexenoic acid, methacrylic acid, maleic acid, 5-norbornene-2-acrylic acid, trans-2-pentenoic acid, 1,4-phenylenediacrylic acid, N-phenylmaleamic acid, vinylacetic acid, 2,4-hexadienonic acid, 4-vinylbenzoic acid, and 2-vinylpropionic acid pH sensitive hydrogels may also be made by polymerizing polymerizable bases containing amino or amine groups such as: allylamine, allycyclohexamine, allyldiethylamine, allyldimethylamine, allylethylamine 1,4-bis(diallylamino)butene-2, 1,3-bis(diallylamino)propane, bis(diallylamino)methane, t-butylaminoethyl methacrylate, diallylamine, N,N-diallylaminoacetonitrile, 2-N,N-diallylaminoethylamine, diallylmethylamine, diallyl-2-ethylhexylamine, N,N-diallylethanolamine, diallylaminopropionitrile, N,N-dimethallylamine, N,N-dimethyllallylamine, N,N-dimethylaminoethyl acrylate, N,N-dimethylaminoethyl methacrylate, N,N-dimethylaminopropyl acrylamide, N,N-dimethylaminopropyl methacrylamide, N,N-diethylaminoethylacrylate, and N,N-diethylaminoethylmethacrylate. A crosslinking agent such as is used for the formation of temperature sensitive gels is required for gel formation. The resulting gels from monomeric acids will swell at higher pH values and deswell at lower pH values. The resulting gels from monomeric bases will show an opposite swelling behavior.
Ionic sensitive hydrogels are made in the same manner as the pH sensitive hydrogels.
Glucose sensitive hydrogels are made by using glucose oxidase, an enzyme which converts glucose to gluconic acid and peroxide. As used herein glucose sensitive hydrogels are glucose oxidase immobilized pH sensitive hydrogels made from acid monomers, listed above as pH sensitive components, plus 4-carboxy styrene (see Broos et al., J. Chem. Ed. 55 (1978) 813). These gels deswell in the presence of glucose.
The walls of the impermeable capsule can be formulated from any inert material which has minimal volume change with a given stimulus. The capsule materials must have a capacity to conduct a given stimulus from outside environment to the compartment or vice versa. The capsule materials must have a minimal interaction with the entrained drug solution or formulation and should be inert to an aqueous environment. The materials required for an impermeable capsule include natural or synthetic polymers, ceramic or metallic materials. Surface modified plastics to minimize interactions with drug formulations can also be used.
When the hydrogel is reactive to chemical signals, the capsule membrane can be made of impermeable or permeable materials. With the impermeable membrane, signal molecules can only enter through the orifice(s) in the capsule walls. In this case, the response of drug release to signal changes may be delayed if the flux rate for the signal molecules through the orifice(s) is not fast enough. The flux rate can be more precisely controlled by a permeable membrane having a certain molecular cutoff, which allows permeation of signal molecules and water, but is not permeable to the drug molecules entrapped by the hydrogel. If a basal release of drug molecules is required, the permeable membrane allows entry of signal molecules and the outward diffusion or permeation of drug molecules. When the permeable material (membrane) is so flexible that the capsule can not maintain its original shape, porous or perforated rigid materials can be used as supporting structures in the construction of the capsule as is demonstrated in the devices shown in FIGS. 4, 5 and 6. Then a flexible semi-permeable membrane can be overlaid on the supporting materials as is shown in FIGS. 4 and 5.
Semi-permeable polymer membranes for use in the pH sensitive device which allow H+and OH- ions to diffuse through the membranes by osmosis and reverse osmosis are formed typically from cellulose derivatives, such as cellulose esters, cellulose ethers, cellulose ester-ethers, cellulose acrylate, cellulose diacrylate, cellulose triacrylate, cellulose acetate, cellulose diacetate, cellulose triacetate, hydroxypropyl methylcellulose, mixtures thereof. (A more detailed description of suitab)e semipermeable membranes is found in U.S. Pat. 4,966,767, col. 6, line 16 to col. 7, line 33.)
The permeable membranes, such as those useful in the glucose sensitive devices, have a certain molecular Weight cut-off. These membranes allow for free diffusion of signal molecules, such as glucose, and for basal diffusion of beneficial drugs. Such polymers are known as dialysis membranes, such as cellulose acetate, regenerated cellulose, polysulfone, and polymethylmethacrylate.
Inclusive of other polymers that allow diffusion of signal molecules and basal diffusion of beneficial drugs are (1) ultra filtration porous membranes such as made of ethylene vinylacetate, polypropylene, polyvinylidene difluoride, and polycarbonate; (2) hydrogel membranes having appropriate water content for diffusion of signal molecules and drugs, e.g. those composed of hydrophilic polymers such as polyhydroxyethyl methacrylate, polyvinylpyrrolidone, polyacrylamide, and alkyl derivatives thereof; and (3) copolymers of (a) water soluble monomers, such as vinylpyrrolidone, hydroxyethylmethacrylate, acrylamide, alkyl derivatives of acrylamide (N-ethylacrylamide, N,N-dimethylacrylamide, Nmethylacylamide, N,N-diethylacrylamide and the like), acrylic acid, methacrylic acid, and the like and (b) water insoluble monomer such as styrene, alkylmethacrylates, and alkylacrylates.
The devices of the invention can be used for rectal delivery of antipyretic drugs and other pharmacologically active agents. For the treatment of symptoms/diseases where a fever is a present, antipyretic drugs can be released from devices containing temperature sensitive hydrogels in response to the increase in body temperature (above normal body temperature >38° C.) and the fever can be controlled automatically. Other therapeutic agents can also be released in response to the change in body temperature caused by diseases, such as in malaria.
This approach can be used for insulin dependent diabetic patients by implantation of the device containing glucose sensitive gels in the peritoneal cavity. Glucose oxidase converts glucose to gluconic acid resulting in an acidic environment. This characteristic of the gel can be utilized in making glucose sensitive gels in which glucose oxidase is immobilized in polybase which swells upon contact with glucose. These devices utilize crosslinked polyacid gels containing glucose oxidase. The polyacid will then shrink in the presence of glucose, resulting in insulin release.
Similar devices for self-regulating drug delivery can be made utilizing appropriate signal molecules and hydrogels responding to the signal.
Using pH sensitive gels which deswell at physiological pH but swell in stomach pH, these devices can be fashioned to orally deliver labile agents into the acidic environment.
The compartment volume and shape of the device will depend on the actual use. The compartment volume will range from a few microliters to several hundred milliliters or larger. The shape of the device is governed by the eventual use of the device and any shape with a certain compartment volume will be acceptable as long as it can be filled with the porous hydrogel or hydrogel particles. The preferred shapes are cylindrical, disc, or slight modifications of these shapes such as bullet for pharmaceutical applications.
Devices shown in FIGS. 1, 2 and 3 are made by drilling a hole(s) on the impermeable rigid capsule wall. To make double wall devices, presented in FIGS. 4, 5, and 6, permeable or semipermeable tubing can be used. A dialysis tubing with a hole or holes is inserted into a fabricated capsule and both ends are sealed by glue or other means of closing the ends. The peripheral edge of the hole or holes is glued making tight contact with the capsule wall insuring precise control of drug flux.
The dimension of the device dependent upon a specific application. For example, the size and shape of the device is similar to suppositories in the market for the rectal delivery of antipyretic drugs. For insulin delivery, the volume ranges from 5 ml to 200 ml. The size and shape of the device can vary in response to the actual application needs (i.e., cylinder or disk types). In actual application the preferred size and configuration will be obvious to the skilled practitioner.
One or more orifices can be located anywhere on the capsule walls. The diameter of each orifice can range from a micrometer to several millimeters. The number and the diameter of the orifices determine basal release and the rate of release in relationship to a given signal strength. The orifices should be placed where they contact the inner hydrogel and do not interfere with the filling procedure.
To prevent the possibility of leaking hydrogel particles into the environment the orifices can be replaced by a passageway which communicates with a permeable membrane as illustrated in FIGS. 5 and 6. Only a single passageway 34 is shown in these figures; however, the number, location and size of these passageways can be varied according to the use of the device.
The (porous) swellable hydrogel which expands when acted upon by a given stimulus can be synthesized by solution polymerization and crosslinking. In order to generate a porous structure for the hydrogel, polymerization should be carried in a solvent which dissolves the monomer but is not a solvent for the crosslinked polymer. The resulting crosslinked polymers have a porous structure. However, the detailed synthetic conditions and procedures for the manufacturing of the (porous) hydrogel may depend upon monomer and polymer properties.
Hydrogel particles can be produced by suspension polymerization or breaking large polymer pieces into smaller pieces. The size of polymer particles in a deswollen or contracted state should be bigger than the orifice diameter of the drug delivery device to prevent the particles from leaking. The hydrogels are materials Which swell or deswell in response to pH, temperature, chemical reactions, concentration of chemical or biological substances, enzyme mediated processes and other stimuli.
The drugs used in the device should be soluble in an aqueous solution and diffusible in the aqueous media surrounding the device. The type and size of the drug is not limited. The device delivers drugs ranging in size from several angstroms to a few microns in diameter.
The invention is not limited to the use of any type or class of drug or other pharmaceutical agent as long as it is functional for use in the gels described. Acetaminophen, allopurinol, aspirin, magnesium salicylate, phenacetin, sodium salicylate, diflunisal, ibuprofen, indomethacin, naproxen, naproxen sodium, oxyphenbutazone, phenylbutazone and tolmetin sodium are examples of antipyretic drugs that can be used in connection with the temperature sensitive devices. Insulin is used with the glucose sensitive device. Other drugs suitable for use in these devices are listed in standard publications of which Remington's Pharmaceutical Sciences, The Merck Index or Physicians Desk Reference. The functionality of any given drug may be readily determined by those skilled in the art.
The conditions for loading the hydrogel with drugs may determine the triggering signal strength which causes gel contracting or deswelling, followed by drug release. When the degree of swelling of a hydrogel is a continuous function of the signal strength, the drug can be loaded into the hydrogel at a given signal strength. This signal strength is a critical point for drug release. When a stronger signal strength causes contracting or deswelling of the hydrogel in relationship to the signal strength of the loading condition, the enhanced drug release occurs, while if a weaker signal strength causes more swelling than the loading condition, the release is at a zero or a minimal level. Therefore, the critical point can be varied with the same hydrogel depending on the loading condition.
These devices can be used in a variety of applications, i.e., orally, rectally, vaginally, or implanted depending on the conditions to be treated. For example, capsules can be made for oral ingestion that release anti-ulcer drugs in response to the increase in acidity the stomach and then are dissolved by the high pH of the intestines. Additionally, suppositories can be made, to be inserted in the rectum or vagina for uniform release of a drug, without fear of excess dosage, to control fever or alleviate other symptoms. Implantable capsules can be formed, as set forth above, that are implanted under the skin or in the peritoneal cavity, which when exposed to high glucose levels release insulin as needed for the control of diabetes.
The examples which follow are representative of the invention but are not to be considered as limitations thereof.
EXAMPLE 1
A device for pulsatile release of a drug is fabricated from 1 mm thick impermeable polypropylene in capsular form to define an interior space Or compartment. The capsule is cylindrical and is 5.2 cm in height, has a 1.1 cm inside diameter and is closed at the top by a friction fitting snap top having one 1.3 mm diameter opening in the center. Instead of fabricating the capsule from polypropylene a similar device can be made using any kind of inert rigid materials which do not swell in an aqueous environment, i.e. plastics, sheet metals and ceramics. For example, plastics such as polyethylene, polystyrene, polycarbonate, polyvinyl chloride, and polyesters may be utilized.
EXAMPLE 2
Several crosslinked poly(N-isopropylacrylamides) were synthesized as temperature sensitive hydrogels suitable for use in the present invention. N-isopropylacrylamide (1 gram) with N,N'-methylenbisacrylamide (0.02 to 0.1 g) was dissolved in water to make 5 ml volume. Polymerization was initiated in the solution by ammonium persulfate (1 mg) and N,N,N',N'-tetramethylethylene diamine (10 μg). The polymerization was performed in ice water for one hour. Each gel obtained was soaked in distilled water to remove unreacted compound and sol fraction. To exemplify the degree of swelling of these gels as a function of temperature, a hydrogel formed by the polymerization of one gram of N-isopropylacrylamide and 0.1 gram of N,N'-methylenebisacrylamide was utilized. The gel was first freeze dried, broken into small pieces and was then allowed to equilibrate at various temperatures using an aqueous acetaminophen solution at a concentration of 1 mg/ml. The degree of swelling, given in Table 1, is the ratio of Vs/Vp where Vs is the absorbed water volume and Vp is the dried polymer volume:
TABLE 1______________________________________Temperature (°C.) Vs/Vp______________________________________10 13.620 11.326 9.028 8.130 6.032 5.332.6 4.133 1.934 1.740 1.5______________________________________
These data quite clearly show the shrinkage of the polymer as a function of rising temperature.
EXAMPLE 3
Freeze dried hydrogel pieces prepared as in Example 2 were equilibrated in aqueous acetaminophenol solution at 1 mg/ml concentration at room temperature. The swollen gel pieces were placed in the compartment of the device described in Example 1 and monitored for acetaminophen release over an extended period of time as a function of temperature modulation. Release data are presented in Table 2.
TABLE 2______________________________________Release Rate Temperature Elapsed Time(mg/min) (°C.) (hours)______________________________________ n.d.* 20 1.0n.d. 20 21.2n.d. 30 25.6n.d. 31 30.40.6 31 30.81.0 31 31.21.0 31 32.01.0 33 46.02.4 33 46.43.1 33 47.03.8 33 47.64.4 33 48.44.8 33 50.04.8 30 52.3n.d. 30 53.6n.d. 33 69.02.9 33 70.06.0 33 71.86.0 20 74.0n.d. 20 75.2______________________________________ *not detectable by UV
These results clearly show that release rate is responsive to temperature modulation with release rates going up as a function temperature increase and dropping as the temperature is lowered.
EXAMPLE 4
A temperature sensitive copolymer consisting of acrylic acid (12 mole %), and N-isopropylacrylamide (88 mole %) was synthesized following the same procedure as in Example 2. The added amount of N,N'-methylenebisacrylamide was 4.2 mole % of the total monomers. The hydrogel polymer was recovered and freeze dried for future use.
EXAMPLE 5
The same procedure utilized in Example 3 was repeated using the hydrogel obtained in Example 4 and was loaded at 36° C. instead of at room temperature.
As in Example 3, acetaminophen release was monitored as a function of temperature modulation over a period of time. These results are reported in Table 3.
TABLE 3______________________________________Release Rate Temperature Elapsed Time(μg/hr) (°C.) (hours)______________________________________-- 30 0.0 n.d.* -- 0.1-- 34 0.2n.d. -- 0.3-- 36 0.5140 -- 0.8-- 38 1.0120 -- 1.1-- 40 1.3120 -- 1.5-- 44 2.0110 -- 2.5-- 42 3.0110 -- 3.3-- 40 3.5 60 -- 3.8-- 38 4.0 60 -- 4.3-- 36 4.5 20 -- 4.8-- 34 5.0n.d. -- 5.3-- 36 5.5130 -- 5.8-- 40 6.0 65 -- 6.5-- 40 7.0 40 -- 7.3-- 36 7.5n.d. -- 7.8______________________________________ *not detectable by UV
These results again show that release rate is responsive to temperature modulation with release rates being maximum at about the loading temperature of 36° C.
EXAMPLE 6
Crosslinked pH sensitive poly(acrylic acid) hydrogel was prepared following the procedure essentially as described in Example 2. A mixture of 0.5 ml of acrylic acid and 0.042 gram of N,N'-methylene bisacrylamide was dissolved in 4.5 ml of carbonate buffer (pH 8). This solution was polymerized by the same amount of redox initiator as in Example 2. After purification, the freeze-dried hydrogel pieces were placed in the compartment of the device described in Example 1, followed by the addition of aqueous insulin solution at a concentration of 1 mg/ml. After equilibration the device was closed with the snap fitting top. The rate of insulin release by varying the pH is illustrated in Table 4.
TABLE 4______________________________________Release Rate Elapsed Time(mg/min) pH (hours)______________________________________ n.d.* 8.0 3.20.4 6.0 8.0n.d. 5.0 14.00.5 5.0 31.01.1 4.4 46.55.4 4.4 48.05.4 6.0 51.01.0 6.0 52.01.0 6.0 56.2______________________________________ *not detectible by UV
These results demonstrate that, at the lower pH ranges, the release rate intensifies and that, when pH is raised, the release rate is diminished.
While the invention has been described and illustrated with reference to certain preferred embodiments thereof, those skilled in the art will appreciate that various modifications, changes, omissions, and substitutions can be made without departing from the spirit of the invention. It is intended, therefore, that the invention be limited only by the scope of the following claims.
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A device for the dispensing of a biologically active material into the surrounding environment is disclosed which consists of at least one wall enclosing a compartment which contains a swollen stimuli sensitive hydrogel in which the biologically active material is entrained in solution. The hydrogel deswells or shrinks in response to contact by external physical or chemical stimuli releasing the biologically active material into the portion of the compartment previously occupied by the swollen hydrogel. The wall enclosing the compartment is rigid and contains means allowing the passage of the biologically active material from the compartment to the surrounding environment and also for transmitting the external stimuli to the swollen hydrogel in said compartment. The wall may contain orifices or be permeable to the active material and external stimuli depending upon the drug and the stimuli to be used. The hydrogel reversibly deswells, shrinks or contracts in response to stimuli, such as temperature, pH, ionic strength, glucose concentration or metabolites in the body and then reswells and reentrains active material not diffused from the compartment when the stimuli is removed. The wall may consist of one or more layers which, in combination, provide for the expeditious delivery of the active substance either through permeation through the wall or through orifices in the wall and also for the conducting of the external stimuli through the wall into the compartment to trigger the deswelling of the hydrogel.
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BACKGROUND OF THE INVENTION
1. Field of The Invention
The present invention relates generally to devices for monitoring, measuring, and evaluating internal combustion engine ignition events. The present invention relates more specifically to devices for sensing, measuring, and analyzing the combustion characteristics, including combustion pressures, of individual cylinders in an internal combustion engine. The present invention, in particular, applies to both retrofit devices that may be installed in conjunction with existing sparkplugs and to replacement sparkplug devices that incorporate the novel structures of the present invention.
2. Description of the Prior Art
Informative data regarding the operation and physical condition of internal combustion engines, especially regarding the combustion process itself, is desirable and important for a number of reasons. First, it is one goal of engine design to create an engine that possesses both high efficiency and high power output. Critical to engine efficiency and output are the characteristics of the combustion event from which derive the forces necessary for producing the rotational torque of the engine. The starting point, therefore, for any analysis of the efficient conversion of combustion energy into the torque necessary to drive a vehicle begins with an understanding of the pressures, temperatures, timing, and other variables associated with the combustion event.
A second important reason for obtaining information on the combustion characteristics within an engine derives from the need to track engine deterioration over its operational lifetime. As engine wear and mechanical fatigue progress during the life of an internal combustion engine, the efficiency of the engine changes, often in ways that can be compensated for if these changes can be identified and tracked. Once again, a primary source of information about the efficiency of an engine, in this case over its deteriorating lifetime, lies in an analysis of the specific realtime combustion characteristics and the changes in those characteristics that occur over time. In the laboratory setting, the above information is often acquired from in-cylinder pressure measurements and analysis. These laboratory techniques, however, are often impractical because of the high cost of suitable pressure transducers that can be incorporated into the internal combustion cylinders. The high temperatures and pressures that normally occur within an engine cylinder can prevent the use of more fragile, less costly pressure transducers. To get away from the direct measurement of the high pressures and temperatures, and thus the high cost of the sensor systems required, many existing engine management systems instead measure other parameters and then infer what the combustion characteristics must have been.
While efforts in the laboratory to measure engine efficiency and output by measuring and analyzing combustion pressures and characteristics have been hampered by the lack of suitable, low-cost pressure transducers, the same effort outside of the laboratory has been hampered to an even greater extent because of the difficulty converting the types of transducers and sensors utilized in the laboratory into on-board monitoring systems capable of withstanding the combustion temperatures and pressures over a more prolonged period of time. Whatever progress has been made in measuring and utilizing combustion pressures to evaluate engine performance in the laboratory has been slow to translate into similar monitoring systems in the real world.
If a reliable, low-cost, in-cylinder pressure sensor were available, much real-time information on the combustion process could be gathered and many engine control input parameters could be immediately improved. An array of individual, in-cylinder pressure sensors could be used to provide accurate information on an entire range of critical values. These values include: indicated mean effective pressure (MEP) measurements, burn pressure phasing, peak pressure determinations, engine knock sensing, engine misfire detection, power efficiency determinations, cylinder-by-cylinder control of engine firing, over all ignition process detection, and a variety of other similar combustion event characteristics.
It is well known in the art to utilize combustion pressure characteristics, however they might be measured, to analyze and improve the efficiency, output, and deterioration character of an engine or of a particular combustion cylinder within an engine. Representative applications of such pressure data are described in John B. Heywood, Internal Combustion engine Fundamentals, Section 9.2.2 Analysis of Cylinder Pressure Data (1988). What is not known in the art is a device for continuously acquiring this information in a low-cost, efficient, and accurate fashion. Even more remote in the field is the ability to translate systems for obtaining these measurements from the laboratory to the typical automotive engine on the street.
More recent sensor technologies, including some that utilize the magnetostrictive effect, have been shown in other fields to provide a sensitive means for mechanical stress wave measurement in both metallic and non-metallic structures. Some limited application of these magnetostrictive devices has been made in the field of internal combustion engines and, in particular, to gross measurements of the occurrence of combustion events. These previous efforts may be typified by the following:
U.S. Pat. No. 4,736,620, issued to Adolph on Apr. 12, 1988, entitled "Magnetostrictive Element for Measuring Knocking Engines" describes the use of a magnetostrictive element to detect self-ignition or "knocking" in the combustion cycle. A plurality of sensor devices are connected by way of mechanical wave guides or wires to each of the combustion chambers within an engine. The ability of these devices to gather information, however, is strictly limited to the detection of a knocking event within a specific cylinder and, over all, the system does not lend itself to easy installation on existing engines or, for that matter, versatility in its ability to characterize combustion characteristics other than simply the occurrence of combustion.
U.S. Pat. No. 2,534,276, issued to Lancor on Dec. 19, 1950, entitled "Vibration Pick-Up Device and System" describes an early magnetostrictive-type vibration sensor utilized to detect impact, shock, or detonation. This device functions much like an accelerometer and is mounted in an engine's cylinder wall. Here again, the vibration sensor is limited in that it gathers information relevant only to the occurrence or non-occurrence of a combustive event and little, if anything, about the pressures or other physical characteristics associated with the event.
U.S. Pat. No. 4,823,621, issued to Sobel, et al, on Apr. 25, 1989, entitled "Magneto Elastic Force Transducer" describes a transducer comprised of two cylindrical bodies with a hollow magnetic core held together by a force transmitting bolt. The device measures a force exerted on the centralized stud bolt through the magnetostrictive effect exhibited by the stresses traveling through the stud bolt.
U.S. Pat. No. 4,408,496, issued to Dahle, et al, on Oct. 11, 1983, entitled "Pressure Sensing Transducer" describes a device that utilizes magnetostrictive characteristics to measure the pressure in the cylinder of an internal combustion engine, more specifically of a diesel engine (without sparkplugs).
While the above patents represent that some effort has been made to utilize magnetostrictive effect based sensors in engine analysis, it is clear that such use has, to date, been quite limited, especially as it relates to incorporating such measurement capabilities into spark plug devices. The limitations on such use derive from the fact that the sensor structures and methods disclosed heretofore have been unable to isolate and interpret anything other than the gross occurrence of combustion events. Other previous attempts describe systems that are only able to measure pressure characteristics of combustion events under laboratory conditions for short periods of time.
Where the magnetostrictive effect has been considered for making pressure measurements of combustive events in internal combustion engines, it has been significantly limited by the inability to provide low cost and accurate mechanisms for making the necessary measurements. Prior attempts to make such pressure measurements have been limited strictly to the laboratory environment and have not translated into devices appropriate for the constant monitoring of the combustion event over the life of the engine.
It would, therefore, be advantageous to develop an apparatus for detecting, measuring, and analyzing combustion characteristics within an internal combustion engine with a sensitivity that allows a more thorough understanding of engine efficiency, output, and operational characteristics that are inherent in the engine design, or that derive from the deteriorating effects of engine use. It would be desirable to have such an apparatus that could function in an analytical setting where the then existing engine output, efficiency, and combustion characteristics could be determined. On the other hand, it would also be advantageous if such an apparatus could be implemented in a monitoring mode where information on the combustive characteristics of an engine could be gathered during the ongoing, long-term operation of the engine and either retained for later analysis or used for continuous comparison with baseline values in a manner that would allow the immediate signaling of problems. Further, it would be advantageous to have such an apparatus that would permit use of the information in a feedback compensation arrangement where engine management control systems could modify engine characteristics so as to compensate for measured changes.
BACKGROUND OF THE MAGNETOSTRICTIVE EFFECT
The magnetostrictive effect is a property peculiar to ferromagnetic materials. The magnetostrictive effect refers to the phenomena of physical, dimensional change within a material associated with variations in magnetization. The effect is widely used to make vibrating elements for such things as sonar transducers, hydrophones, and magnetostrictive delay lines for electric signals.
The magnetostrictive effect actually describes physical/magnetic interactions that can occur in two directions. The Villari effect occurs when stress waves or mechanical waves within a ferromagnetic material cause abrupt, local dimensional changes in the material which, when they occur within an established magnetic field, can generate a magnetic flux detectible by a receiving coil in the vicinity. The Joule effect, being the reverse of the Villari effect, occurs when a changing magnetic flux induces a mechanical vibrational motion in a ferromagnetic material through the generation of a mechanical wave or stress wave.
Typically, the Joule effect is achieved by passing a current of varying magnitude through a coil placed within a static magnetic field thereby modifying the magnetic field and imparting mechanical waves to a ferromagnetic material present in that field. These waves then propagate not only through the portion of the ferromagnetic material adjacent to the generating coil but also into and through any further materials in mechanical contact with the ferromagnetic material.
Application of the Villari effect typically involves placing a coil about a ferromagnetic material subjected to an established magnetic field and measuring variations in the magnetic field caused by mechanical stress waves propagating through the ferromagnetic material. As long as these stress waves communicate into the ferromagnetic core material, as from any non-ferromagnetic material in mechanical contact with the core material, the waves can be detected using the magnetostrictive sensor coil. In this way, non-ferromagnetic materials can serve as conduits for the mechanical waves or stress waves that can thereafter be measured by directing the waves through these ferromagnetic "wave guides" placed proximate to the magnetostrictive sensor element.
The advantages of magnetostrictive sensors over other types of vibrational sensors becomes quite clear when the structure of such sensors is described. All of the components typically utilized in magnetostrictive sensors can be made temperature, pressure, and environment resistant in ways that many other types of sensors, such as piezoelectric based sensors, can not. High temperature permanent magnets, magnetic coils, and ferromagnetic materials are quite easy to produce in a variety of configurations. In addition, although evidence from the previous applications of magnetostrictive sensors would imply otherwise, magnetostrictive sensors are capable of detecting low amplitude mechanical waves and translating them into signals that are subject to very free analysis and discrimination in a manner that allows very accurate and detailed information to be obtained about the combustive events in an engine that have initially generated the stress.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide an apparatus for measuring the in-cylinder pressures of an internal combustion engine for the purpose of evaluating engine operational characteristics.
It is another object of the present invention to provide an apparatus for long-term monitoring of the combustion characteristics, especially combustion pressures, of an internal combustion engine.
It is another object of the present invention to provide an apparatus for the collection and analysis of information regarding combustion characteristics within an internal combustion engine, the use of that information to detect inefficiencies in the operation of the engine, and the identification of anomalous events that indicate the deterioration of the engine, all of such information facilitating either immediate correction and/or compensation of such effects or the signaling of engine problems to an engine operator.
It is another object of the present invention to provide a means for detecting, measuring, and analyzing the in-cylinder pressures of an internal combustion engine, which means may retrofit to existing spark plug structures or may be incorporated into customized spark plug devices for use in standard internal combustion engines.
In fulfillment of these and other objectives, the present invention provides a magnetostrictive sensor positioned in mechanical contact with a standard sparkplug device for a single cylinder of an internal combustion engine. The magnetostrictive sensor is capable of translating stress from mechanical waves received through the ferromagnetic material contained in the standard sparkplug device into an electrical signal whose frequency, amplitude, and timing characteristics are indicative of combustion pressures generated within the cylinder. The present invention provides a means for accurately characterizing a stress wave so measured as being directly related to combustive pressures of particular amplitudes. The present invention permits a retrofit of the sensor to existing sparkplug structures or the incorporation of the sensor technology into a customized sparkplug device that fits into standard internal combustion engine sparkplug apertures. The present invention permits investigation of internal combustion characteristics in this manner on either a one-time "snapshot" basis or on a continuous monitoring basis. The present invention provides such a sensor in a low cost yet durable construction that is easily incorporated into existing engine system management configurations.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a sparkplug structure representative of the prior art for the present invention.
FIG. 2 is a cross-sectional view of a first preferred embodiment of the sparkplug structure of the present invention.
FIG. 3 is a cross-sectional view of a second preferred embodiment for the sparkplug structure of the present invention.
FIG. 4 is a schematic block diagram showing the primary elements of the apparatus of the present invention and their functional relationship.
FIG. 5 is a graphic representation of a typical signal produced by the sensor system of the present invention from which pressure measurements may be made.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As generally described above, the apparatus of the present invention can be implemented in a number of environments, depending upon the specific type of information to be gathered and the period of time over which the information is monitored. The apparatus of the present invention, may be arranged in a laboratory setting or in a technical engine repair shop setting wherein access to the engine while operating is possible without motion of the vehicle itself. In such a case, the elements and components of the present invention, as described in more detail below, could be positioned in temporary fashion on existing sparkplug structures, or in temporary fashion through the substitution of standard sparkplugs with customized sparkplug structures suitable for such immediate data analysis.
The same invention, however, could also be configured in a manner that allows its incorporation on board a potentially mobile vehicle with sensors placed in association with each combustion cylinder for the engine. In an on-board configuration, the information would be gathered in a monitoring mode and, with certain limited display capabilities and/or analytical capabilities, could be utilized to track the combustion characteristics of the engine over time, to report on these characteristics as necessary, and in some situations to direct corrective action to modify engine characteristics in response to the combustion pressure data gathered.
Reference is first made, therefore, to FIG. 1 for a preliminary description of the basic structure of standard sparkplug devices in anticipation of incorporating the elements of the present invention thereto. FIG. 1 shows a typical sparkplug device (10) for an internal combustion engine that is usually inserted into a threaded aperture on the cylinder head of the engine itself. Typically, sparkplug (10) provides a high voltage electrode gap (11) across which a current spark may flow at intervals appropriate for the firing of the engine cylinder. In FIG. 1, sparkplug (10) is comprised primarily of a ceramic core structure (12) surrounded by metal collar (14). Collar (14), typically constructed of zinc-plated, high-quality steel, itself is comprised of hexagonal nut section (16), center section (17), and threaded section (18). Installation of sparkplug (10) involves matching a sparkplug wrench (not shown) to hexagonal nut section (16) and threading threaded section (18) into a standard threaded aperture in the engine head.
The spark in the sparkplug occurs at spark gap (11) between electrode (20) which derives from metal collar (14) by way of threaded section (18), and electrode (24) which is coaxially centered in ceramic core structure (12) and terminates on one end of structure (12) near electrode (20) through ceramic cone section (22). The electrodes are typically nickel alloys, although precious metals are sometimes used. The ceramic material of cone section (22), typically a fired aluminum oxide composition, serves to insulate electrode (24) from the surrounding metal of threaded section (18) at all points except at gap (11) between electrode (24) and electrode (20). It is at gap (11) that the spark occurs and the air\gas mixture in the engine chamber begins to ignite. Current to the standard sparkplug is provided by way of a complete circuit between a ground voltage at metal collar (14) by way of its insertion into the metallic cylinder head, and spark plug wires (not shown) connected at the termination of electrode (24) at sparkplug post (28).
Ceramic core structure (12) is held captive within metal collar (14) by way of gas-tight seal (31), typically formed from an aluminum oxide sillment, and by formed lip (32) which extends from nut section (16) of metal collar (14). Electrode (24) is held within ceramic core (12) in a similar fashion with a sillment seal (not shown).
Reference is now made to FIG. 2 for a detailed description of a first preferred embodiment of the present invention. The configuration of a sparkplug sensor device appropriate for the replacement of a standard plug and which incorporates the elements of the present invention is shown generally as (38) in FIG. 2. The components of sparkplug (38) that carry out the spark and ignition of the gas/air mixture in the chamber are essentially the same as in the prior art shown in FIG. 1. The distinction in the implementation of the present invention lies in the replacement of metal collar (14) in FIG. 1 with magnetized metal collar (40), shown in FIG. 2. Magnetized metal collar (40) is configured so as to create a substrate base upon which coil winding (42) can be wound. Coil winding (42) in the preferred embodiment is constructed with 50 windings of 36 gauge magnetic polytheraeze insulated wire. The terminal ends of coil winding (42) are directed away from sparkplug (38) by way of conductors (44). Otherwise, the structure of sparkplug (38) remains much the same as sparkplug (10) in FIG. 1. Sparkplug post section (12) is comprised of elements nearly identical in structure, such that the same standard plug wires (not shown) might be utilized in the operation of the modified plug design.
As placed within an engine cylinder head, sparkplug (38) positions magnetized threaded section (18) in the block so as to present a generally circular face comprising electrode (20), electrode (24), and ceramic cone (22) towards the interior of the combustion chamber. The forces of combustion, therefore, are directed outward against the face of ceramic cone (22) and, to some extent, threaded section (18), and electrodes (20) and (24). Resistance to this expansive force is, of course, maintained by threaded section (18) in its adherence to the cylinder head walls as a threaded aperture. It may also be seen, however, that forces against ceramic section (12) must be resisted by the internal adherence of ceramic section (12) to magnetized metal collar (40), gas-tight seals (31), and formed lip (32).
The stresses associated with the forces from the combustion event, therefore, are transferred from ceramic section (12) into metal collar (40) where, within the static magnetic field established, they generate the typical magnetostrictive effect. This magnetic flux aspect of the magnetostrictive effect can then be detected by coil winding (42) in the standard fashion described above. Because the primary source of mechanical waves within metal collar (40) is the combustive event, much can be learned from the characteristics of these stress waves within metal collar (40) about the combustive event itself. More specifically, an accurate measure of the pressures within the combustion cylinder can be made after reference measurements for representative combustions and pressures, are taken, and a specific indexing of magnetostrictive signal levels against internal combustion pressures is established. Means for alternatively calculating the combustion pressures can be used once the sensor response has been characterized and referenced.
Implementing the embodiment shown in FIG. 2 involves the replacement of a standard sparkplug device with the device specifically configured for the present invention. This device lends itself to either a one-time "snapshot" analysis of the combustion characteristics of a particular cylinder of an engine or to the on-board monitoring of such characteristics during continuous engine operation. Terminal leads (44) would be directed, as described in more detail below with respect to FIG. 4, to appropriate circuitry for the amplification, filtering, analysis, and possible display of the received signal. Again, it is anticipated that sparkplug/sensor (38) might be individually used to analyze the combustion characteristics of each of the cylinders in an engine, one at a time, as in a sophisticated automotive repair shop, or sparkplug/sensor (38) may be implemented in conjunction with other similar sparkplug devices to form an array of magnetostrictive sensors, each of which may be separately interrogated or all of which may be interrogated in sequence in conjunction with timing information for the engine.
Reference is now made to FIG. 3 for an alternate preferred embodiment of the present invention. In some cases, it is not possible or desirable to replace the standard sparkplug device with one specifically configured to implement the elements of the present invention. FIG. 3 describes an alternative approach whereby all of the necessary components to implement the present invention are incorporated into a sparkplug connector rather than in a new sparkplug unit, in a manner that continues to allow measurement of the magnetostrictive signals generated by the stress waves present in the metallic sparkplug collar. Sparkplug (48) in FIG. 3 is, as indicated, a sparkplug of standard configuration with metal collar (14) magnetized, but with the balance of the sparkplug structure similar to that shown in FIG. 1. Again, the forces on sparkplug (48) are directed longitudinally along the length of sparkplug (48) in a manner that tends to force it from the cylinder head where it is threaded into place. These forces translate into stress waves within the ceramic components of the sparkplug and within magnetized metal collar (14).
Typically, sparkplug wires, i.e., the electrical conductors that carry the high voltage current from the distributor or from the electronic ignition system to the individual sparkplugs, are comprised of well-insulated cables with centralized high-carbon conductors that terminate with insulated plastic boots that cover and surround the post of a standard sparkplug. The electrical conductor within the wire terminates in what is typically a cylindrical press-on connector that surrounds sparkplug post (28) and, thereby, conducts current from the sparkplug wire into the sparkplug through electrode (24). Once again, completion of the electrical circuit is achieved by a ground connection through the engine block to metal collar (14). The insulating boot that typically terminates a sparkplug wire serves a number of purposes. Not only does the boot keep the sparkplug post terminal clean and in electrical contact with the sparkplug wire, but it also serves to center the connector on the sparkplug post to facilitate the insertion and removal of the sparkplug wire.
In the present invention, the necessary coil windings for the magnetostrictive sensor are incorporated into the sparkplug wire boot. As seen in FIG. 3, sparkplug wire boot (50) is comprised of post boot section (54) and metal collar boot section (51). Whereas a normal sparkplug wire boot might terminate with post boot (54), the boot of the present invention extends beyond this point so as to enclose and partially surround metal collar (14). This facilitates the positioning of coil windings (52) adjacent to magnetized metal collar (14) where they can pick up, by way of the magnetostrictive effect, the stress waves that are present in magnetized metal collar (14). Coil wire terminal ends (62) are molded into post boot (54) in a manner that directs conductors (62) away from sparkplug/sensor (58). As described above, sparkplug boot (50) is attached to sparkplug wire (58) which directs coaxial conductor (60) to a point where it contacts metal connector (56) which itself surrounds and contacts sparkplug post (28).
The magnetostrictive sensor function of the preferred embodiment shown in FIG. 3 is identical to that of the embodiment shown in FIG. 2. Stresses generated by the combustive event are communicated into magnetized metal collar (14) and may thereby be measured through the magnetostrictive effect by coil windings (52). The signal generated within coil windings (52) is carried by way of conductor (62) to the appropriate circuitry described in more detail below. The embodiment in FIG. 3 lends itself to a more permanent installation in an automotive engine where on-board monitoring of each of the cylinders can be maintained throughout the life of the engine. The embodiment in FIG. 3 also lends itself to a method of retrofitting existing engines in a manner that does not require the substitution of sparkplugs but only requires the replacement of the sparkplug cables connected to the plugs.
Reference is now made to FIG. 4 for a detailed description of the system components designed to receive and analyze the signals generated by the various sensor configurations described above. In FIG. 4, sparkplug sensors (70a-n), each configured as described above, direct magnetostrictive sensor signals out to the circuitry of the invention by way of conductors (72a-n). In a preferred embodiment, each cylinder of an engine under analysis incorporates a separate magnetostrictive sensor (70a-n) and each of the conductors (72a-n) terminates in signal multiplexer device (74). Multiplexer (74) is capable of combining the signals in timed fashion from each of sensor sparkplugs (70a-n) in a manner that can then be interpreted by the balance of the components of the invention.
The multiplexed signal is then amplified and filtered by amplifier\filter (76) and presented to microprocessor (78) for analysis. This analysis includes a measurement of the amplitude and duration of the magnetostrictive sensor signal associated with each combustive event. To facilitate the identification of a particular signal and to confirm its association with a particular engine cylinder, other sensor inputs (80) could be received by microprocessor (78) and used to accurately track the information received from the magnetostrictive sensors. Typically, these other sensor inputs (80) provide such information as the timing and firing sequence of the engine that microprocessor (78) then compares with the timing sequences presented through multiplexer (74). It is understood that multiplexer (74) maintains some identification of each discreet magnetostrictive signal as it is received from the respective magnetostrictive sensor (70a-n) and presents this identification in conjunction with the magnetostrictive signal to microprocessor (78) for analysis. Other relevant information that bears upon the interpretation of the magnetostrictive sensor signal associated with the combustion events might optionally include engine temperature, operating RPM, torque, fuel richness, and other engine operational values.
Microprocessor (78) carries out a comparison of signal amplitudes, frequencies, and patterns with similar values stored in memory (82) and previously correlated with combustion pressures, bum rates, timing, etc. Alternatively, microprocessor (78) uses algorithms previously defined to correlate signal characteristics with combustion pressure. As a pressure traducer, a simple direct correlation between a bum event signal amplitude and the combustion pressure is possible. The analysis arrives at these combustion characteristic values according to well known techniques, such as those descried in Heywood, referenced above.
After a determination of combustion pressures and bum characteristics, microprocessor (78) provides this information numerically and/or graphically to a test or vehicle operator by way of display (84). In a monitoring mode, display (84) may simply be a digital readout or even an array of indicator lights. In a more technical analysis of the combustion event, display (84) may be a video display terminal capable of providing signal graphics such as that shown in FIG. 5. The apparatus of the present invention derives a signal, such as shown in FIG. 5, of sufficient resolution to allow not only discreet amplitude measurements to be made, but also to allow sophisticated pattern recognition techniques to identify specific combustion characteristics.
In addition to providing displayed information, microprocessor (78) may, when appropriate, direct compensatory action through engine controls (86). In the preferred embodiment, this takes the form of directing a modification of the cylinder ignition timing or a modification of the fuel mixture. Various other engine controls that effect or depend upon engine timing or power output might also be affected by microprocessor (78) in similar fashion.
An accurate measure of the combustion pressure can be made simply from a measurement of the amplitude and timing of the magnetostrictive sensor signal. More refined analysis of the combustion characteristics may be achieved through the incorporation of additional information such as described above (fuel richness, engine temperature, etc.) that can then not only characterize internal combustion pressures but also completeness of burn and other factors relevant to the efficiency and output of the engine. The primary objectives in the present invention, however, are achieved simply by amplifying the sensor output and integrating the output signal over time, to produce a value that is directly proportional to the cylinder pressure. This value may then be used in traditional methods of analysis such as those described in Heywood, referenced above.
In addition to making pressure measurements of the combustion within the engine cylinder, the present invention is capable of acting as a magnetostrictive sensor component for a more complex engine analysis system. It is anticipated that the present sensor could be used as a means for identifying the occurrence and timing of engine misfire and engine knock, as well as various other events and characteristics associated specifically with the ignition and combustion of gasses within the cylinder.
Derived through multiplexer (74), amplifier\filter (76), and microprocessor (78), information regarding the firing or misfiring of a particular cylinder and the complete or incomplete combustion within that cylinder, would, for example, allow microprocessor (78) to determine that the ignition timing control system is inadequate or misadjusted with respect to a particular cylinder. This could be as a result of the deterioration of the engine over time or could derive from the failure of some component within the ignition system. Whatever the case, the sensor of the present invention can act as a monitoring sensor that controls compensatory action on the engine without the need for human intervention and analysis.
It is intended that the above description of a first and second preferred embodiment of the structure of the present invention and the description of one implementation of the present invention into an over-all engine management system for an internal combustion engine, are but one or two enabling best mode embodiments for implementing the invention. Other applications are likely to be conceived of by those skilled in the art, which applications still fall within the breadth and scope of the disclosure of the present invention. It is anticipated that other internal combustion engines such as diesel engines which do not normally require ignition sparkplugs in the same fashion as gasoline-powered internal combustion engines, could still benefit from the application of the present invention through its utilization on such devices as diesel glow plugs or any other components that project into the combustion chamber in a manner that allows the stresses associated with the force derived from the combustion event to act upon ferromagnetic material. The primary import of the present invention, however, lies again in its ability to be configured in association with standard sparkplug devices and/or slightly modified sparkplug devices. The benefits derive from the versatility of application of the present invention and its low cost and accuracy. Again, it is understood that other applications of the present invention will be apparent to those skilled in the art upon a reading of the above description of the preferred embodiments and a consideration of the appended claims and drawings.
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A pressure transducer suitable for use in measuring the pressures created by the combustive events that occur in internal combustion engines. The transducer utilizes the magnetostrictive effect to measure stress waves present in magnetized metallic components associated with sparkplug devices typically placed in apertures into internal combustion engine cylinders. The present invention includes a replacement sparkplug device that incorporates a pickup coil for measuring magnetostrictive events within the magnetized metal components of the sparkplug device and alternatively a sparkplug boot cover that separately incorporates a removable pickup coil for measuring the stress waves. In either embodiment, the present invention utilizes the magnetostrictive sensor signals measured as a basis for identifying internal combustion cylinder pressures and for identifying the characteristics of the ignition events within the cylinder. The invention incorporates electronic components appropriate for multiplexing, amplifying, and filtering signals from a number of cylinders within a engine and analyzing and processing this information in a manner that allows both the identification of problems associated with combustion in the engine and, in some cases, the correction of these problems on a realtime feedback basis.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to connections for scaffolding and, more particularly, to latchable scaffolding connections between horizontal and vertical scaffold members.
2. Background of the Invention
Many different designs have been employed to secure the ends of horizontal scaffold members to vertical scaffold members. Because of a concern for a positive locking arrangement, prior art connections employ a latch assembly, whereby the connection between a horizontal and a vertical member is held in place against an uplifting force by some type of latch. One such joint is disclosed in U.S. Pat. No. 4,445,307, which discloses a connector positioned on a horizontal scaffold member, where the connector has two vertically spaced hook sections. These hook sections couple with two vertically spaced upstanding ring members located on the vertical scaffold member. To withstand an uplifting force, the connector includes a wedge that is driven (generally by a hammer) into position below the upper ring member, thereby latching the connector hook sections against the ring member through a wedging type of action.
A second type of latching connector is disclosed in U.S. Pat. Nos. 5,078,532 and 5,028,164, hereby incorporated by reference. These patents also show a connector positioned on a horizontal scaffold member, where the connector has two vertically spaced hooked sections that couple with two vertically spaced upstanding ring members located on the vertical scaffold member. In this device, the latching of the ring members to the hooked sections is accomplished by a deploying a pivoting member, positioned on the connector, into position below the top ring member. The pivoting member cages or traps the connector to the vertical member, thereby resisting an uplifting force. The pivoting member allows for ease of assembly of a scaffold structure, and the assembled joint retains a degree of play, as this connector lacks the wedging action of the '307 patented device.
By using a two points of attachment between a horizontal and vertical member (the two hooked sections coupled to the two upstanding ring members), the '532 join and the '307 join are more resistive to torsional forces than would be a single ring/hook section embodiment, such as shown in U.S. Pat. No. 4,369,859. However, because the bottom hook of the '532 connector and '307 connector is not latched to the bottom ring member, the connector is still weak when subject to high torsional forces; for instance, it is not recommended that a worker tie onto a horizontal member that is designed only as specified in the '532 patent, as a falling worker will subject that connector to high torsional force and possible connector failure. Hence it is desired to have a scaffold join that is more resistive to torsional forces, that enables a scaffold structure to be easily and quickly erected, and can be used with existing vertical scaffold members.
SUMMARY OF THE INVENTION
Therefore, it is an object of this invention to provide an improved scaffold latch mechanism that latches at two vertically offset points, and which can be quickly and efficiently installed or dismantled without the aid of tools.
Accordingly, an improved scaffold connector is provided that has an upper side and a lower side, and an upper hook section and a lower hook section engagable with the ring members on a vertical scaffold members. The invention includes two latches to lock the connector to two ring members, where the two latches are mechanically coupled.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a side view of scaffold joint shown attached to a vertical scaffold member in a latched configuration, where the leg portion is shown cutaway.
FIG. 1B is a side cross sectional view of one embodiment of the scaffold connector in an unlatched configuration invention.
FIG. 2 is side view cross sectional view of another embodiment of the scaffold connector in an latched configuration.
DETAILED DESCRIPTION
Shown in FIG. 1A is a scaffold connector 1 , joining a vertical scaffold member 10 with a horizontal scaffold member 20 . Positioned on the vertical scaffold member 10 is a plurality of ring members 11 . In general, the vertical scaffold member 10 will have a series of ring members 11 positioned at regular intervals along the length of the vertical member. Ring members 11 are positioned in a vertically spaced apart relationship on the vertical scaffold member 10 . Shown in FIG. 1A are upper ring member 12 , and lower ring member 13 . Ring members have an upper side 14 and a lower side 15 . As shown, ring members 11 are upwardly curved cup shaped members. Alternative ring members can be seen in U.S. Pat. Nos. 4,044,523 and 4,039,264 hereby incorporated by reverence
The connector 1 is fixedly attached to the horizontal scaffold member 20 , preferably by welding. As shown, connector 1 has a connector body with a top housing 2 shaped to accept a horizontal scaffold member 20 . Protruding from the top front edged of the connector body is upper hook section 3 . Downwardly projection from the housing 2 is leg portion 6 . Leg portion has two opposing sides, a front edge 7 and a rear edge 8 , and terminates in lower hook section 4 . As shown, hook portion has a front lip and a rear lip formed by the leg portion, forming a “U” shaped channel between the two lips. A single lip or tooth can be used (e.g. terminate the back lip section of the leg portion before the hook section) but this is not preferred as the double lip results in a more stable attachment. A cavity is formed between the two opposing sides. The opposing sides of the leg portion 6 on the rear edge 8 are folded inwardly and joined at two locations 9 A and 9 B (generally by welding) on the read edge 7 . These joins provide strength and provide support for latch members and resilient bias means. Upper 3 and lower 4 hook sections are adapted to engage with the ring members, as shown, upper side 14 portion of upper ring member 12 and lower ring member 13 engage hook portions. At the lower hook section 4 , the leg portion's sides are flared outwardly (shown as region 9 C) providing for added stability when the lower hook section 4 is engaged with a ring member.
Within the cavity between the opposing sides are two latch members, upper latch member 30 and lower latch member 40 . Latch members are secured within the cavity by pins 31 A and 31 B, and pivot on these pins. Upper latch member is “Y” shaped with the leg 33 of the “Y” functioning as a handle, the upper leg of the “Y” containing the latch surface 34 , and the lower leg 35 mechanically coupled with the lower latch member 40 . The lower latch member is L” shaped with the bottom of the “L containing the latch surface 44 , and the upper leg of the “L mechanically coupled to the upper latch member 30 . As shown, the two latch members are coupled by a pin 46 on one latch (as shown, the lower latch) engaging a slot 36 on the other latch (as shown. the upper latch). Through this mechanical coupling, joint movement of the two latch members can be effectuated through manipulation of the handle 33 alone. The dual latch mechanism is biased into a “latched” or closed configuration by a resilient biasing means, here a spring 50 position above and operating on upper latch 30 .
Operation of the Latch
As shown in FIG. 1A , in a closed or latched configuration, latch surface 34 of upper latch member 30 is positioned in a first position, below the upper hook section 3 and below the lower surface 15 of the upper ring member 30 ; lower latch member 40 latch surface 44 is positioned in a first position, beneath lower hook section 4 and under lower surface 15 of lower ring member 13 , thereby securing the horizontal scaffold member 20 to the vertical scaffold member 10 and resisting upward movement of the horizontal scaffold member. To “unlatch” the connector, the operator depresses or pivots the handle 33 of upper latch member 30 downwardly, thereby compressing spring 50 . In response to this action, upper latch member 30 rotates about pin 31 A and the upper latch surface 34 rotates to a second position away from upper ring member 12 , thus unlatching the upper latch member 30 . Since the upper latch member 30 is mechanically coupled to lower latch 40 , the rotation of the upper latch member 30 results in the rotation of the lower latch member 40 about its supporting pin 31 B (as constructed, the lower latch member 40 rotates in the opposite direction from that of the upper latch member 30 ). Rotation of the lower latch member 40 moves the lower latch surface 44 away from the lower ring member 13 , thus unlatching the lower latch member 40 . In the unlatched configuration, shown in FIG. 1B , the horizontal scaffold member can be uplifted and removed from the vertical scaffold member.
To attach the connector 1 to a vertical scaffold member 10 , the operator can depress the handle 30 to rotate the two latches away from the locked or latched position, (the connector 1 is in a “normally latched” configuration by operation of the spring 50 ); however, in general, this is not necessary. The operator can simply place the hook sections 3 and 4 of the connector on the respective ring members and press down. The action of pressing down will move the latch surfaces 34 and 44 away from the latched position and compress the resilient biasing member 50 . When the hook sections 3 and 4 are engaged to the ring members, the latch members 30 and 40 will spring back into the latched position by operation of the resilient biasing means 50 . That is, the connector can be “snapped” into place on a vertical scaffold member, making for ease and rapidity in assembly of a scaffold structure.
As shown, the dual latches are mechanically coupled by a pin and slot configuration. The two latch members may be mechanically coupled simply by a suitable overlap of the latch members, such as shown in FIG. 2 . However, this arrangement is not preferred, as a second resilient biasing means 51 is needed in this configuration to bias the lower latch member 40 into an open position. Other embodiments are feasible for the design shown in FIG. 1A , such as placing the handle 33 on the lower latch member, and lifting up the handle to operate the mechanism; locating the spring or resilient biasing means in the leg portion to bias either the lower latch or upper latch member into a closed or latched configuration. Alternatively, the leg portion 6 can be extended further downward to allow the lower latch member 40 to be pivotally connected to the leg portion 6 below the lower hook section 4 , so that the lower latch member 40 would rotate in the same direction as the upper latch member 30 . In this embodiment, both lower and upper latch members can have handles, and the two latch members may be mechanically coupled by using a bar pivotally joined to both handles, such as through the pin/slot arrangement discussed above or other means.
Instead of a leg composed of two opposing sides with a cavity between, the leg portion 6 may be a single plate with the latches 30 and 40 pivotally pinned to the leg portion 6 . However, this arrangement is not preferred, as the latches are exposed and can be more readily damaged. Other embodiments of the invention will occur to those skilled in the art, and are intended to be included within the scope and spirit of the following claims.
As can be seen, an improved scaffold connection is provided which more securely locks a horizontal scaffold member to a vertical scaffold member. The improved connection is versatile in its application, and allows for continued use of existing vertical scaffold members equipped with ring members.
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An improved scaffold connection is provided, attachable to a vertical scaffold member having a plurality of ring members. The scaffold joint has an upper side and a lower side, and an upper hook section and a lower hook section engagable with the ring members on the vertical scaffold members. The invention includes two latches to lock the joint to two ring members, where the two latches are mechanically connected.
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FIELD OF THE INVENTION
[0001] The present invention is generally directed to the fields of medicine and pharmacology and is specifically related to a pharmaceutical compositions, containing Oleandrin derived from the plant Nerium Oleander L. and other cardiac glycosides, for use in the treatment of the cell-proliferative diseases including cancer, AIDS and other diseases such as diabetes and cardiac disorders.
[0002] In another aspect, the present invention provides method, preparation and use of a variety of protein microspheres, liposomal and protein stabilized liposomal formulations of Oleandrin and cardiac glycosides with reduced toxicity, high drug to lipid ratio, long-circulating time in the bloodstream and able to deliver the drug to the desired sites such as tumor sites. The present invention also provides an effective method to reduce the growth of cancers or reducing the incidence of metastases.
BACKGROUND OF THE INVENTION
[0003] [0003] Nerium Oleander is an evergreen shrub reaching four meters in height. Leaves are 10 to 22 cm long, narrow, untoothed and short-stalked, dark or grey-green in color. Some cultivars have leaves variegated with white or yellow. All leaves have a prominent mid rib, are “leathery” in texture and usually arise in groups of three from the stem. The plant produces terminal flower heads, usually pink or white, however, 400 cultivars have been bred and these display a wide variety of different flower color: deep to pale pink, lilac, carmine, purple, salmon, apricot, copper, orange and white (Huxley 1992). Each flower is about 5 cm in diameter and five-petalled. The throat of each flower is fringed with long petal-like projections. Occasionally double flowers are encountered amongst cultivars. The fruit consists of a long narrow capsule 10 to 12 cm long and 6 to 8 mm in diameter; they open to disperse fluffy seeds. Fruiting is uncommon in cultivated plants.
[0004] The plant exudes a thick white sap when a twig or branch is broken or cut (Font-Quer 1974; Schvartsman 1979; Lampe & McCann 1985; Peam 1987). Where the species grows in the wild (i.e. in the Mediterranean), it occurs along watercourses, gravely places and damp ravines. It is widely cultivated particularly in warm temperate and subtropical regions where it grows outdoors in parks, gardens and along road sides. Elsewhere, where the plant is not frost-tolerant (e.g. in central and western Europe), it may be grown as a conservatory or patio plant. N. Oleander is cultivated worldwide as an ornamental plant; it is native only in the Mediterranean region (Kingsbury 1964; Hardin & Arena 1974).
[0005] In Mediterranean region, the plant has been used extensively for medicinal purposes. For example, the macerated leaves have been used for itch and fall of hair. The fresh leaves have been applied on tumors for treatment. The decoction of leaves and bark has been used as antisyphillic. The decoction of leaves has been used as a gargle to strengthen the teeth and gum and as a nose drop for children (Dymock 1890; Chopra 1956; Dey 1984; Kirtikar 1987).
[0006] Oleander is one of the digitalis-like plants. These plants produce certain steroidal glycosides with cardiac properties, called as either digitalis glycosides or cardiac glycosides. Digitalis glycosides are one of the most useful groups of drugs in therapeutics (Melero 2000). Among the different digitalis glycosides present in Digitalis purpurea, digoxin and its derivatives (acetyl- and methyl-digoxin) are the digitalis glycosides most currently used in therapeutics.
[0007] The oleander plant has certain toxic properties due to the presence of digitalis glycosides such as Oleandrin. It is estimated that as many as 100 novel chemical substances are present in various parts of the Oleander plant (Krasso 1963; Siddiqui 1987-1995; Taylor 1956; Abe 1992; Hanada 1992). Oleandrin [C 32 H 48 O 9 ], a glycoside, is the main toxin in the plant. Its chemical name is 16b-acetoxy-3b-[(2,6-dideoxy-3-0-methyl-a2-L-arabino-hexopyranosyl) oxy]14-hydroxy-5β, 14β-card-20(22)-enolide (Reynolds 1989). Oleandrin forms colorless, odorless, acicular crystals which are very bitter (Shaw & Pearn 1979). The concentration of Oleandrin in the plant tissues is approximately 0.08% (Schvartsman 1979). Oleandrin is almost insoluble in water; it has little resistance to light but it is heat-stable (Pearn 1987; Reynolds 1989). The chemical structure of Oleandrin is provided in Formula I.
Formula I. 1. Oleandrin: R1 = OCOCH3; R2 = H 2. Neriifolin: R1 = H; R2 = OH 3. Odoroside A: R1 = H; R2 = H 4. Odoroside H: R1 = H; R2 = OH
[0008] When ingested, Oleandrin gets widely distributed in the body and high concentrations of Oleandrin have been measured in blood, liver, heart, lung, brain, spleen and kidney in a fatal case of N. Oleander extract poisoning (Blum & Rieders 1987). Oleandrin is eliminated very slowly from the body (one to two weeks) (Shaw & Pearn 1979). In 1957, the National Cancer Institute showed that three compounds in the plant, namely, Oleandrin, adynerin and ursolic acid had significant anti-cancer activities on various cancer cell lines.
[0009] Since then several new chemical compounds have been identified from the methanolic or ethanolic extracts of the plant. Oleandrin is also present other plants like Operculina turpethum which is called by the common name Nishotra in India.
[0010] The U.S. Pat. No. 5,135,745 describes a procedure for the preparation of the extract of the plant in water. The extraction of the plant Nerium Oleander involves, cooking the leaves and stems of the plant in water for 2-3 hours and filtering off the residues. The chemical constituents of the aqueous extract have been analyzed. It has been found to contain several polysaccharides with molecular weights varying from 2 KD to 30 KD, Oleandrin, Oleandrogenin and proteins (Wang 2000). It has been shown that the water extract of the plant and Oleandrin were able to induce cell killing in human cancer cells, but not in murine cancer cells and the cell-killing potency of Oleandrin was greater than that of the water extract. Canine oral cancer cells treated with water extract showed intermediate levels of response, with some abnormal metaphases and cell death resulting from the treatment (Pathak 2000)
[0011] Cardiac glycosides are used clinically to increase contractile force in patients with cardiac disorders. A list of cardiac glycosides from plants and toads are given in Table 1.
TABLE 1 Fanerogam and Toad species containing digitalis glycosides. Species Cardiotonic glycosides 1. Family Apocynaceae Nerium oleander Oleandrin, neriin, neriantin. Nerium odorum Odoroside A and B. Strophantus gratus , S. kombe , Ouabain (G-strophantin), S. his-pidus , cymarin, sarmentocymarin, S. sarmentosus , S. emini periplocymarin, K-strophantin. Acokanthera schimperi ( A. Ouabain. ouaba{umlaut over (i)}o ), A. venenata , A. abyssinica Thevetia nereifolia Thevetin, cerberin, peruvoside. Thevetia yecotli Thevetosin, thevetin A. Cerbera odollam Cerberin. Cerbera tanghin Tanghinin, deacetyltanghinin, cerberin. Adenium boehmanianum Echujin, hongheloside G. 2. Family Asclepiadaceae Periploca graeca Periplocin. Periploca nigrescens Strophantidin, strophantidol, nigrescin. Xysmalobium undulatum Uzarin. Gomphocarpus fruticosus Uzarin. Calotropis procera Calotropin. 3. Family Brassicaceae Cheiranthus cheiri Cheiroside A, cheirotoxin. 4. Family Celastraceae Euonymus europaeus , E. atropur- Eounoside, euobioside, euomonoside. Pureus 5. Family Crassulaceae Kalanchoe lanceolata Lancetoxin A and B. Kalanchoe tomentosa Kalanchoside. Kalanchoe tubiflorum Bryotoxin A-C. Kalanchoe pinnatum Bryotoxin C, bryophyllin B. Tylecodon wallichii Cotiledoside. Tylecodon grandiflorus Tyledoside A-D, F and G. Cotyledon orbiculata Orbicuside A-C. 6. Family Fabaceae Coronilla sp. Alloglaucotoxin, corotoxin, coroglaucin, glaucorin. 7. Family Iridaceae Homeria glauca Scillirosidin derivatives. Moraea polystachya , Bovogenin A derivatives. M. graminicola 8. Family Liliaceae Urginea scilla , U. maritima Scillarene A and B, scilliroside, scillarenia, scilliacinoside, scilliglaucoside, scilliglaucosidin, scil-liphaeosidin, scilliphaeoside, scillirosidin, scillirubrosidin, scillirubroside, proscillaridin A. Urginea rubella Rubelin. Convalaria majalis Convalloside, convallatoxin. Bowiea volubilis , B. kilimand- Bovoside A, glucobovoside A, Scharica bovoruboside. 9. Family Moraceae Antiaria africana , A. toxicaria Antiarin a. 10. Family Ranunculaceae Helleborus niger , H. viridis , Helleborein, helleborin, hellebrin. H. foeti Dus Adonis vernalis , A. aestivalis , A. Adonidin, adonin, cymarin, autumnalis , A. flammea adonitoxin. 11. Family Santalaceae Thesium lineatum Thesiuside. 12. Family Scrophulariaceae Digitalis purpurea , D. lanata Digitoxin, gitoxin, gitalin, digoxin, F-gitonin, digitonin, lanatoside A-C. 13. Toad Species Genins Bufo vulgaris Bufotalin, bufotalinin, bufotalidin. Bufo japonicus Gamabufagin. Bufo gargarizans Cinobufagin. Bufo marinus Marinobufagin. Bufo arenarum Arenobufagin. Bufo regularis Regularobufagin. Bufo valliceps Vallicepobufagin. Bufo quercicus Quercicobufagin. Bufo viridis Viridibufagin. Bufo sp. Pseudobufotalin.
[0012] Their mechanism of action is well established and involves inhibition of the plasma membrane Na + , K + -ATPase, leading to alterations in intracellular K + and Ca 2+ levels.
[0013] Na + , K + -ATPase (EC 3.6.1.37) or sodium pump, is a carrier enzyme present in almost every animal cell and was discovered by Skou in 1957. Its physiological function is to maintain the Na + and K + electrochemical gradients through the cell membrane, keeping low Na + and high K + intracellular concentrations. Such concentrations of ions, their gradients and the consequent membrane potential determine a broad range of cellular functions, as excitability of nerves and muscle cells, secondary active transport and cellular volume regulation. It is estimated to consume about 25% of total ATP consumed at rest.
[0014] Related to the transport activity, the enzyme takes out 3 Na + in exchange for 2 K + carried into the cell. So, it allows the restoration of the appropriate Na + :K + ratio to maintain the transmembrane difference of potential (Na + and K + concentrations at rest are: [Na + ]int.=7-20 mM, [Na + ]ext.=140 mM, [K + ]int.=110- 120 mM, [K + ]ext.=4-5 mM). It requires ATP and Mg 2+ 0 for activity. Binding of ligands to the enzyme, including a phosphorylation step, leads to conformational changes associated to Na + and K + transport. The supposed mechanism of action currently accepted was firstly proposed by Albers (1967) and Post (1969). This mechanism includes a step in which the enzyme, after leaving out 3 Na + and before taking in 2 K + , can be bound, and thus inhibited, by digitalis glycosides or their analogues, preventing K + binding and then stopping enzyme activity.
[0015] Na + , K + -ATPase is regulated by Na + and K + concentrations, as well as by several hormones, as aldosterone, thyroid hormones, catecholamines and peptide hormones (vasopresin or insulin). Hormone regulation can be carried out at different levels, from cell surface to nucleus, and it can be expressed at short or long term (Geering 1997).
[0016] Digitalis glycosides can be defined as allosteric inhibitors of Na + , K + ATPase, and are not covalently bound to the enzyme (Repke 1989). According to the still most widely accepted mechanism of action for digitalis glycosides (Thomas 1990), they act through inhibition of Na + , K + -ATPase, thus raising indirectly the intracellular Ca 2 + concentration ([Ca 2+ ]i). Therapeutic concentrations of digitalis glycosides produce a moderate enzyme inhibition (about 30%). When the cell is depolarised, there is a lower amount of enzymes available for the restoration of the Na + /K + balance. The remaining enzymes, non-inhibited, will act faster, because the high [Na + ]i and the ionic balance must be restored before the following depolarisation, although it will take longer than if every enzyme were available. This lag causes a temporary increase of [Na + ]i, reaching higher concentrations than if ATPase activity were not partially inhibited. This temporary increase of [Na + ]i, modifies [Ca 2 + ]i through a Na + /Ca 2+ exchanger which allows Na + exit from the cell in exchange for Ca 2+ , or Ca 2+ exit from the cell in exchange for Na + , depending on the prevailing Na + and Ca 2+ electrochemical gradients (Blaustein 1974). This mechanism decreases exchange rate, or even reverses exchanger ion transport, being Ca 2+ carried into the cell; anyway increasing [Ca 2+ ]i and thus increasing contractile force.
[0017] When the concentration of digitalis glycosides reaches toxic levels, enzyme inhibition is too high (>60%), thus decreasing Na + and K + transport to the extent that the restoring of normal levels during diastole is not possible before the next depolarisation. Then, a sustained increase of [Na + ]i , and thus of [Ca 2+ ]i, gives rise to toxic effects (i.e. arrhythmia) of these glycosides.
[0018] Digitalis glycosides represent a very important group of drugs for the treatment of heart failure, but display a main disadvantage, which arises from their narrow therapeutic index, so they have to be administered under a strict supervision. The proximity between effective and toxic doses is the cause of severe adverse effects to appear. Na + , K + -ATPase inhibition at therapeutic doses is the cause of their positive inotropic effect, since only little changes in [Na + ]i are required for a large effect on contractile force (Lee 1985). Apart from this activity, they can act on other physiological systems, leading to adverse effects (Gillis 1986).
[0019] Cardiac glycosides also have well known antiproliferative effects on tumor cells (Shjratori 1967; Repke 1988; Repke 1995). Some cardiac glycosides have been evaluated in short term animal models. The conclusion from these experiments is that very high doses, probably toxic, would be needed for obtaining anticancer effects in humans (Cassady 1980). In contrast, recently it has been found that non-toxic concentrations of digitoxin and digoxin inhibits growth and induce apoptosis in different human malignant cell lines, whereas highly proliferating normal cells were not affected (Haux 1999 & 2000). The capability of cardiac glycosides to induce apoptosis has recently been confirmed in other studies (Kawazoe 1999). There is a great difference in susceptibility for cardiac glycosides in different species indicating that one can not extrapolate the results from animal models into humans (Repke 1988).
[0020] In vitro experiments the apoptosis-inducing effect was more potent for digitoxin than for digoxin, and for digitoxin there was a dose response pattern; the higher concentration the more apoptosis. Another recent report on the anticancer effects of different cardiac glycosides on tumor cell lines also confirms that digitoxin seems more potent than digoxin (Johansson 2001).
[0021] It has been shown that cardiac glycosides Oleandrin, Ouabain, and Digoxin induce apoptosis in androgen-independent human prostate cancer cell lines in vitro. Cell death was associated with early release of cytochrome c from mitochondria, followed by proteolytic processing of caspases 8 and 3. Oleandrin also promoted caspase activation, detected by cleavage poly (ADP-ribose) polymerase and hydrolysis of a peptide substrate (DEVD-pNA). Comparison of the rates of apoptosis in poorly metastatic PC3 M-Pro4 and highly metastatic PC3 M-LN4 subclones demonstrated that cell death was delayed in the latter because of a delay in mitochondrial cytochrome c release. Single-cell imaging of intracellular Ca(2+) fluxes demonstrated that the proapoptotic effects of the cardiac glycosides were linked to their abilities to induce sustained Ca(2+) increases in the cells. These results show that cardiac glycosides can be used to the treatment of metastatic prostate cancer. (McConkey 2000).
[0022] Further it is known that in vitro, cardiac glycosides may inhibit fibroblast growth factor-2 (FGF-2) export through membrane interaction with the Na + , K + -ATPase pump (Yeh 2001). It has been shown that Oleandrin (0.1 ng/mL) produced a 45.7% inhibition of FGF-2 release from PC3 cells and a 49.9% inhibition from DU145 cells. The water extract of the oleander plant (100 ng/mL) produced a 51.9 and 30.8% inhibition of FGF-2 release, respectively, in the two cell lines. These results demonstrate that the water extract, like Oleandrin, inhibited FGF-2 export in vitro from PC3 and DU145 prostate cancer cells in a concentration- and time-dependent fashion and may, therefore, contribute to the antitumor activity of the treatment for cancer (Smith 2001).
[0023] U.S. Pat. No. 6,071,885 claims cardiac glycosides, specifically, digoxin and ouabain, for the treatment of FGF-mediated pathophysiological condition in a patient. The pathophysiological condition is selected from melanoma, ovarian carcinoma, teratocarcinoma and neuroblastoma. However, the patent does not address the Na + , K + -ATPase inhibiting properties of these glycosides which are indirectly responsible for the FGF export inhibition (Yeh 2001). For example, Stewart et al (2000) and Grimes et al (1995) discusses the importance of the pump inhibition of these glycosides in prostate cancer cell lines. U.S. Pat. No. 6,281,197 similarly claims cardiac glycosides, especially digoxin and ouabain, for the treatment of complaications of diabetes involving the inhibition of the export of leaderless FGF proteins. However, a literature search on the internet using PUBMED site for cardiac glycoside and diabetes produced more than 300 publications and all of these publications imply the importance of Na + , K + -ATPase in diabetes mellitus. It has been shown that streptozotocin-induced diabetes mellitus in the rat is associated with a substantial increase in ouabain-sensitive ATPase activity along most of the nephron (Wald 1986). Further, it has been found that there is decrease in Na+-K+ pump concentration in nerve cells in diabetic rats and the decrease may be due to atrophy of the axons. In skeletal muscles, myocardium, and peripheral nerves, the observed decrease in Na+-K+ pump concentration may be important for the pathophysiology of diabetes (Kjeldsen 1987). Diabetic neuropathy is a degenerative complication of diabetes accompanied by an alteration of nerve conduction velocity (NCV) and Na + , K + -ATPase activity. Na + , K + -ATPase activity was significantly lower in sciatic nerve membranes of diabetic rats and significantly restored in diabetic animals that received fish oil supplementation. Diabetes induced a specific decrease of alpha1- and alpha3-isoform activity and protein expression in sciatic nerve membranes(Gerbi 1998). It has been observed that high glucose with suppressed Na+/K+ pump activity might induce an increase of Ca2+ influx through either Ca2+ channels or reverse Na+/Ca2+-exchange, possibly leading to the elevation of Ca2+-activated voltage-dependent K+ channels. Both a decrease in inward Na+ current and an increase in K+ conductance may result in decreased nerve conduction. In addition, a possible increase of axoplasmic Ca2+ concentration may lead to axonal degeneration.
[0024] These results provide a clue for understanding the pathophysiologic mechanism of diabetic neuropathy (Takigawa 2000).
[0025] Further it has been reported that there is a reduction in activity of the ouabain-sensitive Na + , K + -ATPase pump and a reduction in membrane permeability on the diabetic erythrocyte which is most marked in Type 1 diabetics (Jennings 1986). Further it has been found that the Na+-pumping activity, estimated from both Na + , K + -ATPase and ouabain binding, was significantly decreased in IDDM and NIDDM subjects, but its insulin sensitivity was retained only in young IDDM subjects (Baldini 1989). It has been observed that VSMC grown in high glucose concentration milieu manifests a decreased Na—K, and Ca transport in conjunction with an increase in intracellular concentration of Na and [Ca]i. These results suggest that high glucose, per se, may alter membrane permeability to cations, possibly leading to changes in VSMC contractility and/or proliferation. This abnormality seen in the diabetic state may closely link to the pathogenesis of diabetic angiopathy, thus as a result risking hypertension and vascular disease (Kuriyama 1994). Sennoune et al (2000) studied in rats the effect of streptozotocin-induced diabetes on liver Na + , K + -ATPase. Diabetes mellitus induced an increased Na + , K + -ATPase activity and an enhanced expression of the betal subunit; Diabetes mellitus led to a decrease in membrane fluidity and a change in membrane lipid composition. The results suggest that the increase of Na + , K + -ATPase activity can be associated with the enhanced expression of the beta1 subunit in the diabetic state, but cannot be attributed to changes in membrane fluidity as typically this enzyme will increase in response to an enhancement of membrane fluidity.
[0026] Further, the level of Na + , K + -ATPase activity and the number of enzyme units were about 30% lower in the red blood cells of diabetic patients than in healthy Caucasian controls (Raccah 1996).
[0027] The adenosine triphosphate-binding site, investigated by anisotropy decay studies of the fluorescent probe pyrene isothiocyanate, was modified in women with IDDM and it appears that the Na + , K + -ATPase of human placenta is altered in its disposition in IDDM (Zolese 1997). The alterations in small intestinal Na + , K + -ATPase expression in the chronic diabetic state appear to involve alterations in transcriptional and posttranscriptional events and may likely represent an adaptive response that leads to increased Na+-coupled monosaccharide absorption in the context of a perceived state of nutrient depletion (Wild 1999).
[0028] U.S. Pat. No. 5,872,103 describes a method for the prevention of mammary tumors by the administration of cardiac glycoside, especially, digoxin and digitoxin.
[0029] Further agents that can suppress the activation of nuclear factor-κB (NF-κB) and activator protein-1 (AP-1) may be able to block tumorigenesis and inflammation. Oleandrin blocked tumor necrosis factor (TNF)-induced activation of NF-κB in a concentration- and time-dependent manner. This effect was mediated through inhibition of phosphorylation and degradation of IκBα, an inhibitor of NF-κB. The water extract of oleander also blocked TNF-induced NF-κB activation; subsequent fractionation of the extract revealed that this activity was attributable to Oleandrin. The effects of Oleandrin were not cell type specific, because it blocked TNF-induced NF-κB activation in a variety of cells. NF-κB-dependent reporter gene transcription activated by TNF was also suppressed by Oleandrin. The TNF-induced NF-κB activation cascade involving TNF receptor 1/TNF receptor-associated death domain/TNF receptor-associated factor 2/NF-κB-inducing kinase/IκBα kinase was interrupted at the TNF receptor-associated factor 2 and NF-κB-inducing kinase sites by Oleandrin, thus suppressing NF-κB reporter gene expression. Oleandrin blocked NF-κB activation induced by phorbol ester and lipopolysaccharide. Oleandrin also blocked AP-1 activation induced by TNF and other agents and inhibited the TNF-induced activation of c-Jun NH2terminal kinase. Overall, these results indicate that Oleandrin inhibits activation of NF-κB and AP-1 and their associated kinases. These results may provide a molecular basis for the ability of Oleandrin to suppress inflammation and perhaps tumorigenesis. (Manna 2000)
[0030] While the water extract of the Nerium Oleander leaves has shown to ameliorate the cell proliferative diseases in humans, it is rather difficult to develop the extract as a parenteral pharmaceutical product suitable for commercialization due to the presence of several compounds. Since the anti-tumor activity of the oleander extract has been shown to be due to the presence of Oleandrin and oleandrogenin in the extract it is desirable to develop Oleandrin as an anti-tumor agent. The term cell-proliferative diseases is meant here to denote malignant as well as non-malignant cell populations which often appear morphologically to differ from the surrounding tissue.
[0031] As described before, Oleandrin is extremely toxic due to its cardiac properties and it is believed that the non-toxic nature of the water extract is due to the encapsulation of the water insoluble Oleandrin and oleandrogenin molecules into the polysaccarides present in the extract. The encapsulated Oleandrin and oleandrogenin is soluble in water and Oleandrin is released slowly upon administration through injection. Also, the amount of Oleandrin encapsulated by the extraction procedure is very small (2-5 microgram per mg) and it should be possible to develop alternate delivery vehicles to reduce the toxicity of Oleandrin and thereby increase its therapeutic value. It is highly desirable to develop new procedures for the increase of the therapeutic value of Oleandrin to treat cancers such as metastatic prostate cancer.
[0032] There are many potential barriers to the effective delivery of a toxic drug in its active form to solid tumors. Most small-molecule chemotherapeutic agents have a large volume of distribution on i.v. administration. The result of this is often a narrow therapeutic index due to a high level of toxicity in healthy tissues. Through encapsulation of drugs in a macromolecular carrier, such as a liposome, the volume of distribution is significantly reduced and the concentration of drug in the tumor is increased. This results in a decrease in the amount and types of nonspecific toxicities and an increase in the amount of drug that can be effectively delivered to the. Under optimal conditions, the drug is carried within the liposomal aqueous space while in the circulation but leaks at a sufficient rate to become bioavailable on arrival at the tumor. The liposome protects the drug from metabolism and inactivation in the plasma, and due to size limitations in the transport of large molecules or carriers across healthy endothelium, the drug accumulates to a reduced extent in healthy tissues. However, discontinuities in the endothelium of the tumor vasculature have been shown to result in an increased extravasation of large carriers and, in combination with an impaired lymphatics, an increased accumulation of liposomal drug at the tumor. All of these factors have contributed to the increased therapeutic index observed with liposomal formulations of some chemotherapeutic agents (Drummond et al 1999).
[0033] Protein microspheres have also been reported in the literature as carriers of pharmacological or diagnostic agents. Microspheres of albumin have been prepared by either heat denaturation or chemical crosslinking. Heat denatured microspheres are produced from an emulsified mixture (e.g., albumin, the agent to be incorporated, and a suitable oil) at temperatures between 100° C. and 150° C. The microspheres are then washed with a suitable solvent and stored. Leucuta et al. (1988) describe the method of preparation of heat denatured microspheres. The procedure for preparing chemically crosslinked microspheres involves treating the emulsion with glutaraldehyde to crosslink the protein, followed by washing and storage. Lee et al., (1981) and U.S. Pat. No. 4,671,954 teach this method of preparation. The above techniques for the preparation of protein microspheres as carriers of pharmacologically active agents, although suitable for the delivery of water-soluble agents, are incapable of entrapping water-insoluble ones. This limitation is inherent in the technique of preparation which relies on crosslinking or heat denaturation of the protein component in the aqueous phase of a water-in-oil emulsion. Any aqueous-soluble agent dissolved in the protein-containing aqueous phase may be entrapped within the resultant crosslinked or heat-denatured protein matrix, but a poorly aqueous-soluble or oil-soluble agent cannot be incorporated into a protein matrix formed by these techniques.
[0034] U.S. Pat. Nos. 5439686 and 5916596 teach the methods for the production of particulate vehicles for the intravenous administration of pharmacologically active agents. They disclose methods for the in vivo delivery of substantially water insoluble anticancer drug taxol. The suspended particles are encased in a polymeric shell formulated from a biocompatible polymer, and have a diameter of less than about 1 micron. The polymeric shell contains particles of taxol, and optionally a biocompatible dispersing agent in which pharmacologically active agent can be either dissolved or suspended.
[0035] Liposomes are phospholipid vesicles, composing mainly naturally occurring substances that are nontoxic and biodegradable (Lasic 1993) and are made up of at least one lipid bilayer membrane containing an entrapped aqueous internal compartment. When combined with water, phospholipids immediately form a sphere because one end of each molecule is water soluble, while the opposite end is water insoluble. Water-soluble medications added to the water are trapped inside the aggregation of the hydrophobic ends; fat-soluble medications are incorporated into the phospholipid layer.
[0036] Vesiculation of natural phospholipid bilayer is not a spontaneous process. Physical and chemical methods are used to produce well-defined liposomes from hydrated lipids. Since the discovery by Bangham in 1961, many processing methods for liposome production have been developed. The majority of these methods require the input of high energy (e.g., ultrasonic treatment, high pressure, and/or elevated temperatures) to disperse low critical micelle concentration phospholipids as a metastable liposome phase (Lasic and Paphadjopoulos 1998).
[0037] Liposomes have been employed for a number of therapeutic applications, in particular, for delivering drugs to target cells following systemic administration (Drummond et al. 1999; Gibbson and Paphadjopoulos 1988; Lasic and Paphadjopoulos 1998; Olson et al. 1982; Rahman et al. 1982). Liposomal formulations of pharmaceutical agents are superior to drugs injected in the free form. When used in the delivery of certain cancer drugs, liposomes help to shield healthy cells from the drugs' toxicity and prevent their concentration in vulnerable tissues (e.g., the kidneys, and liver), lessening or eliminating the common side effects of nausea, fatigue, and hair loss. For instance, liposomal formulations of the anticancer agent vincristine exhibit greater efficacy against L1210 leukemia cells than does free vincristine and have reduced collateral toxicity. Liposomes have also been used to deliver certain vaccines, enzymes, or insulin to the body. They have also been used experimentally to carry normal genes into a cell in order to replace defective, disease-causing genes.
[0038] Commercial liposomal drug delivery is gaining attention because of the enhanced stability of the liposomes, reduced toxicity, sustained-drug release, enhanced blood circulation time, and increased accumulation of liposomes in the target sites. Reduction in toxicity may result from the ability of liposomes to decrease drug exposure, and subsequent damage, to susceptible tissues (Allen et al. 1991). In fact, the first liposomal drug oncology drug approved for medicinal use, in liposomal form, are of the anthracyclines daunorubicin (DaunoXome; Nextstar Pharmaceuticals, Boulder, CO), EVACET (The Liposome Company, Inc.) and DOX [Doxil; Alza Corporation, Palo Alto, Calif. (CAELYX in Europe)].
[0039] Phospholipid in its simplest form is composed of glycerol bonded to two fatty acids and a phosphate group. The resulting compound called phosphatidic acid contains a region (the fatty acid component) that is fat-soluble along with a region (the charged phosphate group) that is water-soluble. Most phospholipids also have an additional chemical group bound to the phosphate. For example, it may be connected with choline; the resulting phospholipid is called phosphatidylcholine, or lecithin. Other phospholipids include phosphatidylglycerol, phosphatidylinositol, phosphatidylserine, and phosphatidylethanolamine. The fat-soluble portions associate with the fat-soluble portions of other phospholipids while the water-soluble regions remain exposed to the surrounding solvent. The phospholipids of the cell membrane form into a sheet two molecules thick with the fat-soluble portions inside shielded on both sides by the water-soluble portions. This stable structure provides the cell membrane with its integrity.
[0040] Liposomes consist of amphipathic lipid molecules, with phospholipids being the major component. Most commonly, phosphatidylcholine is used as the primary constituent. Other lipids, including phosphatidylethanolamine, phosphatidylserine, sphingomyelin, glycolipids and sterols are often added. The physical characteristics of liposomes depend on pH, ionic strength and phase transition temperatures. The phase transition consists of a closely packed, ordered structure, called as the gel-state, to a loosely packed, lessordered structure, known as the fluid state. The phase transition temperature (T c ) depends on the acyl chain length, degree of saturation, and polar head group. For example, the T c of egg phosphatidylcholine with a high degree of unsaturation of the acyl chains and varying chain length is −15° C. However, in a fully saturated distearoylphosphatidylcholine (DSPC), T c is over 50° C. Most liposomal formulations contain cholesterol in order to form a more closely packed bilayer system during preparation. Cholesterol addition to phosphatidylcholine changes the melting behavior of the bilayer, as cholesterol tends to eliminate the phase transition. Cholesterol addition has a condensing effect on the fluid-state bilayer and strongly reduces bilayer permeability.
[0041] Biologically active drug molecules can be trapped either within the aqueous compartment or incorporated within the bilayer themselves depending on their hydrophilicity or lipophilicity. However, in many instances, the drug leaks from the liposomes during long-term storage, lyophilizaion and reconstitution. Protecting liposomes by polymerized protein molecules minimizes or eliminates the drug leakage from the liposome. Furthermore, as the protein uniformly coats or forms a shell around the liposome, thereby the drug is protected from any further degradation from the liposome. This method also allows for the entrapment of a high concentration of drug inside the liposome compartment.
[0042] Major advances in improving the therapeutic index of amphotericin B encapsulated in liposomes have been demonstrated in counteracting systemic fungal infections in cancer patients (Olsen et al. 1982). The liposomal entrapment of this antifungal drug causes a remarkable reduction in toxicity. Liposomes have also been found to be effective in delivering doxorubicin (Williams et al. 1993), vincristine (Woodle et al. 1992), vinblastine, actinomycin-D, arabinoside, cytosine, daunomycin (Julliano and Stamp 1978), mitoxantrone, epirubicin, daunorubicin, (Madden et al 1990) and paclitaxel (Suffness 1995). In a liposomal drug delivery system, if the drug is highly hydrophobic, it tends to associate mainly with the bilayer compartment (Sharmaetal., 1995, 1997).
[0043] However, following i.v. administration, on some occasion, the premature release and leakage of the drug from the liposome result in faster distribution of the drug in the plasma component, higher toxicity and less amount of the drug released at the tumor site. Furthermore, for pegylated liposomal doxorubicin, a novel dose-limiting form of skin toxicity known as palmar-plantar erythrodysaesthesia or hand-foot syndrome has been described (Gordon et al. 1995). This problem can be overcome by the improvement in the design of the drug carrier, by uniform coating of the protein onto the liposome. This type of coating by protein molecules on the liposome is referred here as protein stabilized liposomes (PSL).
[0044] Following parenteral administration, a drug entrapped in the PSL nanoparticles is protected from premature release and immediate dilution or degradation. PSL nanoparticles can alter the pharmacokinetics and biodistribution. This can reduce toxic side effects and increase efficacy of the therapy. The PSL nanoparticles are distributed within the body much differently than free drugs. When administered intravenously to healthy animals and humans, most of the drug from the nanoparticles accumulates in the liver, spleen, lungs, bone marrow and lymph nodes. These nanoparticles also accumulate at sites of inflammation and infection and in some solid tumors.
[0045] PSL nanoparticle formulations, with protein stabilized liposomes have a reduced uptake by the RES, and, consequently, show a longer circulation time, increased biological and chemical stability, and increased accumulation in tumor-sites. The PSL nanoparticle formulations with components such as phosphatidyl insitol, monosialogangolioside, spingosomes, poly(ethylene glycol)-derivatized distearoylphosphatidylethanolamine (PEG-DSPE), poly(ethylene glycol)-derivatized ceramides (PEG-CER) show prolonged circulation time in blood. Most importantly, PSL nanoparticle formulations produce a marked enhancement of anti-tumor activity in mice against different carcinomas with a concomitant decrease in toxicity.
[0046] The PSL nanoparticle formulation protects the drug from metabolism and inactivation in the plasma, and due to size limitations in the transport of large molecules or carriers across healthy endothelium, the drug accumulates to a reduced extent in healthy tissues (Working et al., 1994; Mayer et al., 1989). However, discontinuities in the endothelium of vasculature provide an increased accumulation of PSL nanoparticles at the tumor. These PSL nanoparticles have sizes below 400 nm, preferably below 200 nm, and more preferably below 120 nm having hydrophilic proteins coated onto the surface of the nanoparticles.
SUMMARY OF THE INVENTION
[0047] The present invention relates to the liposomal formulation of digitalis glycosides. In particular embodiments, the invention relates to the use of the digitalis glycosides, as anti-tumor agents. The inventors have demonstrated that the liposomal formulations of the digitalis glycosides disclosed herein, for example, exerts cytotoxic effects in human cancer cell lines and in animals transplanted with these cancer cells.
[0048] The present invention is also directed to the use of PSL nanoparticle formulations containing digitalis glycosides in the treatment of cell-proliferate disease cancer in humans. More particularly, the invention is directed to the use of novel PSL nanoparticle formulations with reduced toxicity, long-circulating time in the bloodstream and able to deliver the drug to the target sites such as tumor sites. These PSL nanoparticle formulations are higher than or substantially equivalent in efficacy to each one of the pharmaceutical agents in its free form, yet generally have low toxicity. The pharmaceutical compositions of PSL nanoparticle formulations comprising a mixture of egg phosphatidylcholine (EPC), hydrogenated soy phosphatidylcholine (HSPC), phosphatidylethanolamine (PE), phosphatidylglycerol(PG), phosphatidylinsitol (PI), monosialogangolioside and spingomyelin (SPM); the derivatized vesicle forming lipids such as poly(ethylene glycol)-derivatized distearoylphosphatidylethanolamine (PEG-DSPE), poly(ethylene glycol)-derivatized ceramides (PEG-CER), distearoylphosphatidylcholine (DSPC), dimyristoyl-phosphatidylcholine (DMPC), dimyristoylphosphatidylglycerol (DMPG), and dipalmitoylphosphatidylcholine (DPPC), cholesterol, and proteins.
[0049] In a preferred embodiment the liposomal or PSL composition comprises at least one digitalis glycosides. It will, of course, be understood that the composition may further comprise a second digitalis glycosides, or one or more other pharmacologically-active compounds, and particularly one or more anti-tumor compounds. The methods of the invention may thus entail the administration of one, two, three, or more, of digitalis glycosides. The maximum number of species that may be administered is limited only by practical considerations, such as the particular effects of each compound.
[0050] The present invention also provides the preparation and use of a variety of PSL nanoparticle formulations. In another aspect, the present invenstion provides novel PSL nanoparticle formulations of digitalis glycosides with reduced toxicity, high drug to lipid ratio, long-circulating time in the bloodstream and able to deliver the drug to the target sites, including tumor sites. In another aspect, the present invention provides an effective method to reduce the growth of cancers or reducing the incidence of metastases.
[0051] In yet another aspect, the present invention provides an effective method for treating diseases such as anti-inflammation, cancer and arthritis in a warm-blooded animal.
[0052] In yet another embodiment, a PSL nanoparticle formulation is prepared by solvent evaporation of an oil-in-water emulsion consisting of an digitalis glycosides, cholesterol, protein, and lipids. A homogenozer or a microfluidizer with a pressure in the range of about 3000 to 40,000 psi or a sonicator and an evaporator are used to prepare the fine emulsion and nanoparticles. Lipophilic therapeutic compounds are dissolved in the oil phase.
[0053] This invention also provides a method for producing PSL nanoparticles having size less than 220 nm, preferably 10-220 nm and most preferably between about 30-220 nm. These PSL nanoparticles can be sterile filtered through a 0.22 μm filter.
[0054] In yet another embodiment of the method, the sterile-filtered PSL nanoparticles can be lyophilized in the form of a cake in vials using cryoprotectants such as sucrose, mannitol, trehalose or the like. The lyophized cake can be reconstituted to the original liposomes, without modifying the particle size of the PSL nanoparticles. These nanoparticles are administered by a variety of routes, preferably by intravenous, parenteral, intratumoral and oral or routes. The invention also includes a method of treating cancer with digitalis glycosides. This method comprises administration of an effective amount of a suitable liposomal composition or PSL formulation containing the digitalis glycosides to a subject in need thereof. Administration is preferably by either intramuscular or intravenous injections. The treatment may be maintained as long as necessary and may be used in conjunction with other forms of treatment.
[0055] It is a further object of the present invention to deliver the highly toxic compound Oleandrin and other digitalis glycosides in a composition of microparticles or nanoparticles, optionally suspended in a suitable biocompatible liquid.
[0056] It is yet another object of the present invention to provide a method for the formation of submicron particles (nanoparticles) of digitalis glycosides by a solvent evaporation technique from an oil-in-water emulsion using proteins as stabilizing agents in the absence of any conventional surfactants, and in the absence of any polymeric core material.
[0057] In accordance with the present invention, we have discovered that digitalis glycosides can be delivered in the form of microparticles or nanoparticles that are suitable for parenteral administration in aqueous suspension. This mode of delivery obviates the necessity for administration of substantially water insoluble compound Oleandrin through the aqueous extract formulation as described in U.S. patent.
[0058] Thus, in accordance with the present invention, there are provided methods for the formation of nanoparticles of digitalis glycosides by a solvent evaporation technique from an oil-in-water emulsion prepared under conditions of high shear forces (e.g., sonication, high pressure homogenization, or the like) without the use of any conventional surfactants, and without the use of any polymeric core material to form the matrix of the nanoparticle. Instead, proteins (e.g., human serum albumin) are employed as a stabilizing agent.
[0059] The invention further provides a method for the reproducible formation of unusually small nanoparticles (less than 200 nm diameter), which can be sterile-filtered through a 0.22 micron filter. This is achieved by addition of a water soluble solvent (e.g. ethanol) to the organic phase and by carefully selecting the type of organic phase, the phase fraction and the drug concentration in the organic phase. The ability to form nanoparticles of a size that is filterable by 0.22 micron filters is of great importance and significance, since formulations which contain a significant amount of any protein (e.g., albumin), cannot be sterilized by conventional methods such as autoclaving, due to the heat coagulation of the protein.
[0060] In accordance with another embodiment of the present invention, we have developed compositions useful for in vivo delivery of substantially water insoluble digitalis glycosides. Invention compositions comprise substantially water insoluble digitalis glycosides (as a solid or liquid) contained within a polymeric shell. The polymeric shell is a crosslinked biocompatible polymer. The polymeric shell, containing substantially water insoluble pharmacologically active agents therein, can then be suspended in a biocompatible aqueous liquid for administration.
[0061] The invention further provides a drug delivery system in which part of the molecules of digitalis glycosides are bound to the protein (e.g., human serum albumin), and are therefore immediately bioavailable upon administration to a mammal. The other portion of the pharmacologically active agent is contained within nanoparticles coated by protein. The nanoparticles containing the pharmacologically active agent are present as a pure active component, without dilution by any polymeric matrix.
[0062] In accordance with the present invention, there are also provided submicron particles in powder form, which can easily be reconstituted in water or saline. The powder is obtained after removal of water by lyophilization. Human serum albumin serves as the structural component of invention nanoparticles, and also as a cryoprotectant and reconstitution aid. The preparation of particles filterable through a 0.22 micron filter according to the invention method as described herein, followed by drying or lyophilization, produces a sterile solid formulation useful for intravenous injection.
[0063] The invention provides, in a particular aspect, a composition of anti-cancer drug Oleandrin in the form of nanoparticles in a liquid dispersion or as a solid which can be easily reconstituted for administration. While it is recognized that particles produced according to the invention can be either crystalline, amorphous, or a mixture thereof, it is generally preferred that the drug be present in the formulation in an amorphous form. This would lead to greater ease of dissolution and absorption, resulting in better bioavailability.
DETAILED DESCRIPTION OF THE INVENTION
[0064] It is understood as “digitalis activity” the ability to inhibit Na + , K + -ATPase through acting onto the digitalis receptor, along with the ability to display a positive inotropic effect. Such an action is performed by several natural, semisynthetic and synthetic compounds (Thomas 1992). Among the natural compounds, there are three groups: steroidal butenolides and pentadienolides, known as “cardiotonic steroids” or “digitalic compounds” and Erythrophleum alkaloids. The word “digitalis” is often used as a generic word for all cardiotonic steroids; similarly, the receptor for these compounds is generally known as “digitalis receptor”. Digitalis glycosides or also called as digitalis-type glycosides or also called as cardiac glycosides are compounds bearing a steroidal genin or aglycone with one or several sugar molecules attached to position C-3. In the case of toad venom, sugar is replaced by suberylarginine.
[0065] As used herein, the term “micron” refers to a unit of measure of one one-thousandth of a millimeter.
[0066] As used herein, the term “nm” or the term “nanometers” refers to a unit of measure of one one-billionth of a meter.
[0067] As used herein, the term “biocompatible” describes a substance that does not appreciably alter or affect in any adverse way, the biological system into which it is introduced.
[0068] As used herein, the term “substantially water insoluble pharmaceutical agent” means biologically active chemical compounds which are poorly soluble or almost insoluble in water. Examples of such compounds are paclitaxel, oleandrin, cyclosporine, digitoxin and the like.
[0069] As used herein, the term “cell-proliferative diseases” is meant here to denote malignant as well as non-malignant cell populations which often appear morphologically to differ from the surrounding tissue.
[0070] As discussed above, the present invention provides liposomal and PSL nanoparticle formulations of digitalis glycosides and methods of preparing and employing such formulations. The advantages of these PSL nanoparticle formulations are that a drug is entrapped in either dissolved or precipitated form. These compositions have been observed to provide a very low toxicity form of the pharmacologically active agent that can be delivered in the form of nanoparticles or suspensions by slow infusions or by bolus injection or by other parenteral or oral delivery routes. These PSL nanoparticles have sizes below 400 nm, preferably below 200 nm, and more preferably below 120 nm having hydrophilic proteins coated onto the surface of the nanoparticles.
[0071] The vesicle forming lipids such as, egg phosphatidylcholine (EPC), hydrogenated soy phosphatidylcholine (HSPC), phosphatidylethanolamine (PE), phosphatidylglycerol(PG), phosphatidylinsitol (PI), monosialogangolioside and spingomyelin (SPM); the derivatized vesicle forming lipids such as poly(ethylene glycol)-derivatized distearoylphosphatidylethanolamine (PEG-DSPE) and poly(ethylene glycol)-derivatized cerarmides (PEG-CER); and cholesterol are dissolved in organic solvents along with one or more digitalis glycoside. The phospholipids can be either synthetic or derived from natural sources such as egg or soy. The phospholipids can be distearoylphosphatidylcholine (DSPC), dimyristoylphosphatidylcholine (DMPC), dimyristoylphosphatidylglycerol (DMPG), and dipalmitoylphosphatidylcholine (DPPC).
[0072] These lipids are dissolved in the organic solvent along with the digitalis glycoside, and the protein is dissolved in the aqueous phase. The organic phase is added to the aqueous phase and subjected to high shear stress. This results in a fine oil-in-water emulsion. Evaporation of the solvent from the emulsion leads to the formation PSL nanoparticles with a high digitalis glycoside to lipid-protein ratio (wt/wt). The drug to lipid-protein weight ratio varies between 0.01 and 1, preferably between 0.05 and 1.
[0073] In order to make the protein stabilized liposomal nanoparticles, digitalis glycoside, lipid and other agents are dissolved in a suitable solvent (e.g., chloroform, methylene chloride, ethyl acetate, ethanol, tetrahydrofuran, dioxane, acetonitrile, acetone, dimethyl sulfoxide, dimethyl formamide, methyl pyrrolidinone, or the like, as well as mixtures of any two or more thereof). Additional solvents contemplated for use in the practice of the present invention include soybean oil, coconut oil, olive oil, safflower oil, cotton seed oil, sesame oil, orange oil, limonene oil, C1-C20 alcohols, C2-C20 esters, C3-C20 ketones, polyethylene glycols, aliphatic hydrocarbons, aromatic hydrocarbons, halogenated hydrocarbons and combinations thereof.
[0074] In the next stage, in order to make the protein stabilized liposomal nanoparticles, a protein (e.g., human serum albumin) is added (into the aqueous phase) to act as a stabilizing agent for the formation of stable nanodroplets. Protein is added at a concentration in the range of about 0.05 to 25% (w/v), more preferably in the range of about 0.5%-5% (w/v).
[0075] In the next stage, in order to make the protein stabilized liposomal nanoparticles, an emulsion is formed by homogenization under high pressure and high shear forces. Such homogenization is conveniently carried out in a high pressure homogenizer, typically operated at pressures in the range of about 3,000 up to 30,000 psi. Preferably, such processes are carried out at pressures in the range of about 6,000 up to 25,000 psi. The resulting emulsion comprises very small nanodroplets of the nonaqueous solvent containing the digitalis glycoside, lipid and other agents. Acceptable methods of homogenization include processes imparting high shear and cavitation such as high pressure homogenization, high shear mixers, sonication, high shear impellers, and the like.
[0076] Finally, in order to make the protein stabilized liposomal nanoparticles, the solvent is evaporated under reduced pressure to yield a colloidal system composed of protein stabilized liposomal nanoparticles of digitalis glycoside in liposome and protein. Acceptable methods of evaporation include the use of rotary evaporators, falling film evaporators, spray driers, freeze driers, and the like. Following evaporation of solvent, the liquid suspension may be dried to obtain a powder containing the pharmacologically active agent and protein. The resulting powder can be redispersed at any convenient time into a suitable aqueous medium such as saline, buffered saline, water, buffered aqueous media, solutions of amino acids, solutions of vitamins, solutions of carbohydrates, or the like, as well as combinations of any two or more thereof, to obtain a suspension that can be administered to mammals. Methods contemplated for obtaining this powder include freeze-drying, spray drying, and the like.
[0077] In accordance with a specific embodiment of the present invention, there is provided a method for the formation of unusually small submicron liposomal particles containing digitalis gfycoside, i.e., particles which are less than 200 nanometers in diameter. Such particles are capable of being sterile-filtered before use in the form of a liquid suspension. The ability to sterile-filter the end product of the invention formulation process (i.e., the drug particles) is of great importance since it is impossible to sterilize dispersions which contain high concentrations of protein (e.g., serum albumin) by conventional means such as autoclaving.
[0078] In order to obtain sterile-filterable protein stabilized liposomal particles of digitalis glycosides (i.e., particles<200 nm), the digitalis glycoside, lipids and other agents are initially dissolved in a substantially water immiscible organic solvent (e.g., a solvent having less than about 5% solubility in water, such as, for example, chloroform) at high concentration, thereby forming an oil phase containing the digitalis glycoside, lipids and other agents. Suitable solvents are set forth above. Next, a water miscible organic solvent (e.g., a solvent having greater than about 10% solubility in water, such as, for example, ethanol) is added to the oil phase at a final concentration in the range of about 1%-99% v/v, more preferably in the range of about 5%-25% v/v of the total organic phase. The water miscible organic solvent can be selected from such solvents as ethyl acetate, ethanol, tetrahydrofuran, dioxane, acetonitrile, acetone, dimethyl sulfoxide, dimethyl formamide, methyl pyrrolidinone, and the like. Alternatively, the mixture of water immiscible solvent with the water miscible solvent is prepared first, followed by dissolution of the digitalis glycoside, lipids and other agents in the mixture.
[0079] In the next stage, in order to make the protein stabilized liposomal nanoparticles of digitalis glycosides, human serum albumin or any other suitable stabilizing agent as described above is dissolved in aqueous media. This component acts as a stabilizing agent for the formation of stable nanodroplets. Optionally, a sufficient amount of the first organic solvent (e.g. chloroform) is dissolved in the aqueous phase to bring it close to the saturation concentration. A separate, measured amount of the organic phase (which now contains the digitalis glycosides, the first organic solvent and the second organic solvent) is added to the saturated aqueous phase, so that the phase fraction of the organic phase is between about 0.5%-015% v/v, and more preferably between 1% and 8% v/v. Next, a mixture composed of micro and nanodroplets is formed by homogenization at low shear forces. This can be accomplished in a variety of ways, as can readily be identified by those of skill in the art, employing, for example, a conventional laboratory homogenizer operated in the range of about 2,000 up to about 15,000 rpm. This is followed by homogenization under high pressure (i.e., in the range of about 3,000 up to 30,000 psi). The resulting mixture comprises an aqueous protein solution (e.g., human serum albumin), the digitalis glycoside, lipids, other agents, the first solvent and the second solvent. Finally, solvent is rapidly evaporated under vacuum to yield a colloidal dispersion system (liposomal digitalis glycoside and protein) in the form of extremely small nanoparticles (i.e., particles in the range of about 50 nm-200 nm diameter), and thus can be sterile-filtered. The preferred size range of the particles is between about 50 nm-170 nm, depending on the formulation and operational parameters.
[0080] The protein stabilized liposomal nanoparticles prepared in accordance with the present invention may be further converted into powder form by removal of the water therefrom, e.g., by lyophilization at a suitable temperature-time profile. The protein (e.g., human serum albumin) itself acts as a cryoprotectant, and the powder is easily reconstituted by addition of water, saline or buffer, without the need to use such conventional cryoprotectants as mannitol, sucrose, glycine, and the like. While not required, it is of course understood that conventional cryoprotectants may be added to invention formulations if so desired. The liposomal shell containing digitalis glycoside allows for the delivery of high doses of the pharmacologically active agent in relatively small volumes.
[0081] According to this embodiment of the present invention, the liposome containing digitalis glycoside has a cross-sectional diameter of no greater than about 10 microns. A cross-sectional diameter of less than 5 microns is more preferred, while a cross-sectional diameter of less than 1 micron is presently the most preferred for the intravenous route of administration.
[0082] Proteins contemplated for use as stabilizing agents in accordance with the present invention include albumins (which contain 35 cysteine residues), immunoglobulins, caseins, insulins (which contain 6 cysteines), hemoglobins (which contain 6 cysteine residues per α2 β2 unit), lysozymes (which contain 8 cysteine residues), immunoglobulins, α-2-macroglobulin, fibronectins, vitronectins, fibrinogens, lipases, and the like. Proteins, peptides, enzymes, antibodies and combinations thereof, are general classes of stabilizers contemplated for use in the present invention. A presently preferred protein for use is albumin. Specific antibodies may also be utilized to target the nanoparticles to specific locations.
[0083] In the preparation of invention compositions, a wide variety of organic media can be employed to suspend or dissolve the substantially water insoluble digitalis glycosides. Organic media contemplated for use in the practice of the present invention include any nonaqueous liquid that is capable of suspending or dissolving the pharmacologically active agent, but does not chemically react with either the polymer employed to produce the shell, or the pharmacologically active agent itself. Examples include vegetable oils (e.g., soybean oil, olive oil, and the like), coconut oil, safflower oil, cotton seed oil, sesame oil, orange oil, limonene oil, aliphatic, cycloaliphatic, or aromatic hydrocarbons having 4-30 carbon atoms (e.g., n-dodecane, n-decane, n-hexane, cyclohexane, toluene, benzene, and the like), aliphatic or aromatic alcohols having 2-30 carbon atoms (e.g., octanol, and the like), aliphatic or aromatic esters having 2-30 carbon atoms (e.g., ethyl caprylate (octanoate), and the like), alkyl, aryl, or cyclic ethers having 2-30 carbon atoms (e.g., diethyl ether, tetrahydrofuran, and the like), alkyl or aryl halides having 1-30 carbon atoms (and optionally more than one halogen substituent, e.g., CH 3 Cl, CH 2 Cl 2 , CH 2 Cl—CH 2 Cl, and the like), ketones having 3-30 carbon atoms (e.g., acetone, methyl ethyl ketone, and the like), polyalkylene glycols (e.g., polyethylene glycol, and the like), or combinations of any two or more thereof.
[0084] Especially preferred combinations of organic media contemplated for use in the practice of the present invention typically have a boiling point of no greater than about 200° C., and include volatile liquids such as dichloromethane, chloroform, ethyl acetate, benzene, and the like (i.e., solvents that have a high degree of solubility for the pharmacologically active agent, and are soluble in the other organic medium employed), along with a higher molecular weight (less volatile) organic medium. When added to the other organic medium, these volatile additives help to drive the solubility of the pharmacologically active agent into the organic medium. This is desirable since this step is usually time consuming. Following dissolution, the volatile component may be removed by evaporation (optionally under vacuum).
[0085] The liposomes containing digitalis glycoside stabilized with protein, prepared as described above, are delivered as a suspension in a biocompatible aqueous liquid. This liquid may be selected from water, saline, a solution containing appropriate buffers, a solution containing nutritional agents such as amino acids, sugars, proteins, carbohydrates, vitamins or fat, and the like.
[0086] For increasing the long-term storage stability, the PSL nanoparticle formulations may be frozen and lyophilized in the presence of one or more protective agents such as sucrose, mannitol, trehalose or the like. Upon rehydration of the lyophilized PSL nanoparticle formulations, the suspension retains essentially all the drug previously loaded and the particle size. The rehydration is accomplished by simply adding purified or sterile water or 0.9% sodium chloride injection or 5% dextrose solution followed by gentle swirling of the suspension. The potency of the drug in a PSL nanoparticle formulation is not lost after lyophilization and reconstitution.
[0087] The PSL nanoparticle formulation of the present invention is shown to be less toxic than the drug administered in its free form. Determination of toxicity in mice has shown about 1- to 20-fold decrease in acute LD 50 values for PSL oleandrin nanoparticle formulations as compared to the free oleandrin. The LD 50 values are dependent on the lipid and protein compositions. Furthermore, PSL nanoparticle formulations containing Oleandrin exhibit 1 to 100-fold decrease in toxicity as compared to the drug in its free form. PSL nanoparticle formulations with low LD 50 values show low drug accumulation levels in heart, lung and kidney tissues. Although administration PSL nanoparticle formulations lead to their uptake by liver, acute liver damage is not observed.
[0088] In order to make the protein stabilized nanoparticles without the lipids, digitalis glycoside is dissolved in a suitable solvent (e.g., chloroform, methylene chloride, ethyl acetate, ethanol, tetrahydrofuran, dioxane, acetonitrile, acetone, dimethyl sulfoxide, dimethyl formamide, methyl pyrrolidinone, or the like, as well as mixtures of any two or more thereof). Additional solvents contemplated for use in the practice of the present invention include soybean oil, coconut oil, olive oil, safflower oil, cotton seed oil, sesame oil, orange oil, limonene oil, C1-C20 alcohols, C2-C20 esters, C3-C20 ketones, polyethylene glycols, aliphatic hydrocarbons, aromatic hydrocarbons, halogenated hydrocarbons and combinations thereof. Unlike conventional methods for nanoparticle formation, a polymer (e.g. polylactic acid) is not dissolved in the solvent. The oil phase employed in the preparation of invention compositions contains only the digitalis like molecules dissolved in solvent.
[0089] Next, in order to make the protein stabilized nanoparticles, a protein (e.g., human serum albumin) is added (into the aqueous phase) to act as a stabilizing agent for the formation of stable nanodroplets. Protein is added at a concentration in the range of about 0.05 to 25% (w/v), more preferably in the range of about 0.5%-5% (w/v). Unlike conventional methods for nanoparticle formation, no surfactant (e.g. sodium lauryl sulfate, lecithin, tween 80, pluronic F-68 and the like) is added to the mixture.
[0090] Next, in order to make the protein stabilized nanoparticles, an emulsion is formed by homogenization under high pressure and high shear forces. Such homogenization is conveniently carried out in a high pressure homogenizer, typically operated at pressures in the range of about 3,000 up to 30,000 psi. Preferably, such processes are carried out at pressures in the range of about 6,000 up to 25,000 psi. The resulting emulsion comprises very small nanodroplets of the nonaqueous solvent (containing the dissolved pharmacologically active agent) and very small nanodroplets of the protein stabilizing agent. Acceptable methods of homogenization include processes imparting high shear and cavitation such as high pressure homogenization, high shear mixers, sonication, high shear impellers, and the like.
[0091] Finally, in order to make the protein stabilized nanoparticles, the solvent is evaporated under reduced pressure to yield a colloidal system composed of protein stabilized nanoparticles of pharmacologically active agent and protein. Acceptable methods of evaporation include the use of rotary evaporators, falling film evaporators, spray driers, freeze driers, and the like. Following evaporation of solvent, the liquid suspension may be dried to obtain a powder containing the pharmacologically active agent and protein. The resulting powder can be redispersed at any convenient time into a suitable aqueous medium such as saline, buffered saline, water, buffered aqueous media, solutions of amino acids, solutions of vitamins, solutions of carbohydrates, or the like, as well as combinations of any two or more thereof, to obtain a suspension that can be administered to mammals. Methods contemplated for obtaining this powder include freeze-drying, spray drying, and the like.
[0092] In accordance with a specific embodiment of the present invention, there is provided a method for the formation of unusually small submicron particles of digitalis glycosides (nanoparticles), i.e., particles which are less than 200 nanometers in diameter. Such particles are capable of being sterile-filtered before use in the form of a liquid suspension. The ability to sterile-filter the end product of the invention formulation process (i.e., the drug particles) is of great importance since it is impossible to sterilize dispersions which contain high concentrations of protein (e.g., serum albumin) by conventional means such as autoclaving.
[0093] In order to obtain sterile-filterable particles of digitalis glycosides (i.e., particles<200 nm), the pharmacologically active agent is initially dissolved in a substantially water immiscible organic solvent (e.g., a solvent having less than about 5% solubility in water, such as, for example, chloroform) at high concentration, thereby forming an oil phase containing the pharmacologically active agent. Suitable solvents are set forth above. Unlike conventional methods for nanoparticle formation, a polymer (e.g. polylactic acid) is not dissolved in the solvent. The oil phase employed in the process of the present invention contains only the pharmacologically active agent dissolved in solvent.
[0094] Next, a water miscible organic solvent (e.g., a solvent having greater than about 10% solubility in water, such as, for example, ethanol) is added to the oil phase at a final concentration in the range of about 1%-99% v/v, more preferably in the range of about 5%-25% v/v of the total organic phase. The water miscible organic solvent can be selected from such solvents as ethyl acetate, ethanol, tetrahydrofuran, dioxane, acetonitrile, acetone, dimethyl sulfoxide, dimethyl formamide, methyl pyrrolidinone, and the like. alternatively, the mixture of water immiscible solvent with the water miscible solvent is prepared first, followed by dissolution of the pharmaceutically active agent in the mixture.
[0095] Next, in order to make the nanoparticles of digitalis glycosides, human serum albumin or any other suitable stabilizing agent as described above is dissolved in aqueous media. This component acts as a stabilizing agent for the formation of stable nanodroplets. Optionally, a sufficient amount of the first organic solvent (e.g. chloroform) is dissolved in the aqueous phase to bring it close to the saturation concentration. A separate, measured amount of the organic phase (which now contains the digitalis glycosides, the first organic solvent and the second organic solvent) is added to the saturated aqueous phase, so that the phase fraction of the organic phase is between about 0.5%-015% v/v, and more preferably between 1% and 8% v/v. Next, a mixture composed of micro and nanodroplets is formed by homogenization at low shear forces. This can be accomplished in a variety of ways, as can readily be identified by those of skill in the art, employing, for example, a conventional laboratory homogenizer operated in the range of about 2,000 up to about 15,000 rpm. This is followed by homogenization under high pressure (i.e., in the range of about 3,000 up to 30,000 psi). The resulting mixture comprises an aqueous protein solution (e.g., human serum albumin), the water insoluble digitalis glycosides, the first solvent and the second solvent. Finally, solvent is rapidly evaporated under vacuum to yield a colloidal dispersion system (digitalis glycosides and protein) in the form of extremely small nanoparticles (i.e., particles in the range of about 10 nm-200 nm diameter), and thus can be sterile-filtered. The preferred size range of the particles is between about 50 nm-170 nm, depending on the formulation and operational parameters.
[0096] Colloidal systems prepared in accordance with the present invention may be further converted into powder form by removal of the water therefrom, e.g., by lyophilization at a suitable temperature-time profile. The protein (e.g., human serum albumin) itself acts as a cryoprotectant, and the powder is easily reconstituted by addition of water, saline or buffer, without the need to use such conventional cryoprotectants as mannitol, sucrose, glycine, and the like. While not required, it is of course understood that conventional cryoprotectants may be added to invention formulations if so desired.
[0097] The polymeric shell containing solid or liquid cores of digitalis glycosides allows for the delivery of high doses of the pharmacologically active agent in relatively small volumes. In addition, the walls of the polymeric shell or coating are generally completely degradable in vivo by proteolytic enzymes (e.g., when the polymer is a protein), resulting in no side effects from the delivery system as is the case with current formulations.
[0098] According to this embodiment of the present invention, particles of substantially water insoluble digitalis glycosides have a cross-sectional diameter of no greater than about 10 microns. A cross-sectional diameter of less than 5 microns is more preferred, while a cross-sectional diameter of less than 1 micron is presently the most preferred for the intravenous route of administration.
[0099] Proteins contemplated for use as stabilizing agents in accordance with the present invention include albumins (which contain 35 cysteine residues), immunoglobulins, caseins, insulins (which contain 6 cysteines), hemoglobins (which contain 6 cysteine residues per α2 β2 unit), lysozymes (which contain 8 cysteine residues), immunoglobulins, α-2-macroglobulin, fibronectins, vitronectins, fibrinogens, lipases, and the like. Proteins, peptides, enzymes, antibodies and combinations thereof, are general classes of stabilizers contemplated for use in the present invention.
[0100] A presently preferred protein for use in the formation of a polymeric shell is albumin. Optionally, proteins such as α-2-macroglobulin, a known opsonin, could be used to enhance uptake of the shell encased particles of substantially water insoluble pharmacologically active agents by macrophage-like cells, or to enhance the uptake of the shell encased particles into the liver and spleen.
[0101] Specific antibodies may also be utilized to target the nanoparticles to specific locations.
[0102] In the preparation of invention compositions, a wide variety of organic media can be employed to suspend or dissolve the substantially water insoluble digitalis glycosides. Organic media contemplated for use in the practice of the present invention include any nonaqueous liquid that is capable of suspending or dissolving the pharmacologically active agent, but does not chemically react with either the polymer employed to produce the shell, or the pharmacologically active agent itself. Examples include vegetable oils (e.g., soybean oil, olive oil, and the like), coconut oil, safflower oil, cotton seed oil, sesame oil, orange oil, limonene oil, aliphatic, cycloaliphatic, or aromatic hydrocarbons having 4-30 carbon atoms (e.g., n-dodecane, n-decane, n-hexane, cyclohexane, toluene, benzene, and the like), aliphatic or aromatic alcohols having 2-30 carbon atoms (e.g., octanol, and the like), aliphatic or aromatic esters having 2-30 carbon atoms (e.g., ethyl caprylate (octanoate), and the like), alkyl, aryl, or cyclic ethers having 2-30 carbon atoms (e.g., diethyl ether, tetrahydrofuran, and the like), alkyl or aryl halides having 1-30 carbon atoms (and optionally more than one halogen substituent, e.g., CH 3 Cl, CH 2 Cl 2 , CH 2 Cl—CH 2 Cl, and the like), ketones having 3-30 carbon atoms (e.g., acetone, methyl ethyl ketone, and the like), polyalkylene glycols (e.g., polyethylene glycol, and the like), or combinations of any two or more thereof.
[0103] Especially preferred combinations of organic media contemplated for use in the practice of the present invention typically have a boiling point of no greater than about 200° C., and include volatile liquids such as dichloromethane, chloroform, ethyl acetate, benzene, and the like (i.e., solvents that have a high degree of solubility for the pharmacologically active agent, and are soluble in the other organic medium employed), along with a higher molecular weight (less volatile) organic medium. When added to the other organic medium, these volatile additives help to drive the solubility of the pharmacologically active agent into the organic medium. This is desirable since this step is usually time consuming. Following dissolution, the volatile component may be removed by evaporation (optionally under vacuum).
[0104] Particles of pharmacologically active agent associated with a polymeric shell, prepared as described above, are delivered as a suspension in a biocompatible aqueous liquid. This liquid may be selected from water, saline, a solution containing appropriate buffers, a solution containing nutritional agents such as amino acids, sugars, proteins, carbohydrates, vitamins or fat, and the like.
[0105] In the present invention, efficacy of PSL nanoparticle formulations of the present invention with varying lipid compositions, particle size, and drug to lipid-protein ratio have been investigated on various systems such as human cell lines and animal models for cell proliferative activities. Furthermore, effects of PSL nanoparticle formulations and various drugs in their free form on the body weight of mice with different sarcomas and healthy mice without tumor have been investigated. Effects of PSL nanoparticle formulations and various drugs in their free form on the DNA fragmentation in different normal and tumor cells are investigated. These examples are not intended, however, to limit or restrict the scope of the present invention in any way and should not be construed as providing conditions, parameters, reagents, or starting materials which must be utilized exclusively in order to practice the art of the present invention.
[0106] It is known that certain anionic polysaccharides( Baba, 1988), such as dextran sulphate, pustulan sulphate stimulate cell-mediated T-cell dependent immune responses without stimulating anti-body mediated immune responses that are B-cell dependent. On the other hand, unmodified polysaccharides stimulate only B-cells and certain other polysaccharides are known to stimulate both T-cell and B-cell responses under certain conditions. The polysaccharides present in water extract of the plant Nerium Oleander has been shown to contain galacturonic acids similar to pectin. These polysaccharides are claimed to be immune stimulants. Thus the formulations of the present inventions can contain suitable polysaccharides such as pectin to provide the stimulant effect.
[0107] Compositions employing the novel compounds will contain a biologically effective amount of the compounds. As used herein a biologically effective amount of a compound or composition refers to an amount effective to alter, modulate or reduce tumor growth or related conditions. For intravenous administration, a satisfactory result may be obtained employing the compounds in an amount within the range of from about 0.001 mg/kg to about 5 mg/kg, preferably from about 0.002 mg/kg to about 2 mg/kg and more preferably from about 0.004 mg/kg to about 0.5 mg/kg alone or in combination with one or more additional anti-tumor compounds in an amount within the range from about 0.01 mg/kg to about 50 mg/kg, preferably from about 0.05 mg/kg to about 20 mg/kg and more preferably from about 0.1 mg/kg to about 10 mg/kg both being employed together in the same intravenous dosage form or in separate oral or intramuscular or intravenous dosage forms taken at the same time. The percentage of the compositions and preparations may, of course, be varied and may conveniently be between about 0.1 to about 50% of the weight of the unit. The amount of active compounds in such therapeutically useful compositions is such that a suitable dosage will be obtained.
[0108] The pharmaceutical formulations of oleandrin according to the present invention offer several advantages over the existing formulation of Nerium Oleander Extract administered parenterally. They can be intravenously administered and relatively high concentrations of oleandrin can be loaded into patients. Thus the frequency of dosage can be reduced. Thus within the spirit, the invention is related to improved formulations and methods of using the same when administering such formulations to patients. As mentioned herein above a number of excipients may be appropriate for use in the formulation which comprise the composition according to the present invention. The inclusion of excipients and the optimization of their concentration for their characteristics such as for example ease of handling or carrier agents will be understood by those ordinarily skilled in the art not to depart from the spirit of the invention as described herein and claimed herein below.
[0109] The invention will now be further described with reference to the following examples. These examples are intended to be merely illustrative of the invention and are not intended to be limiting.
EXAMPLE 1
Preparation of Liposome-Digitalis Glycoside Formulation
[0110] A lipid mixture containing HSPC:cholesterol:PEG2000-DSPE in a molar ratio of 55:40:5 was dissolved in a chloroform: ethanol (8.5.:1.5 vol/vol) mixture. For example, 3.55 g of HSPC, 1.39 g cholesterol and 1.33 g PEG2000-DSPE were dissolved in 30 mL of chloroform: ethanol (8.5:1.5 vol/vol) mixture. A chloroform-ethanol solution of oleandrin, in the range of 50-150 mg/mL was added to the above solution, resulting in a drug to lipid ratio of 1:10 (wt/wt). The above organic solution was added to the aqueous phase, with a pH of 8.0- 8.5, while mixing from 3000 to 10000 rpm. The mixture was subjected to either high-pressure microfluidization or homogenization. The pressure was varied between 20,000 and 30,000 psi. This resulted in a homogeneous and extremely fine oil-in-water emulsion. The emulsion was rapidly evaporated in an evaporator to a nanoparticle suspension. The evaporator pressure and the bath temperature during evaporation were 10-50 mm Hg and 30-70° C., respectively.
[0111] The particle size of the suspension was determined by photon correlation spectroscopy with the Malvern Zetasizer. The suspension was sterile-filtered through a 0.22 μm filter. The particle size of the suspension was between 30 and 220 nm. The suspension was frozen below −40° C. and lyophilized. The lyophilized cake was reconstituted prior to further use. The particle size did not change appreciably following lyophilization and reconstitution. In a similar manner, the liposomal formulations of neriifolin, odoroside A, odoroside H and proscillaridin A were prepared.
EXAMPLE 2
Preparation of PSL-Digitalis Glycoside Formulation
[0112] A lipid mixture containing HSPC:cholesterol:PEG2000-DSPE in a molar ratio of 55:40:5 was dissolved in a chloroform: ethanol (8.5.:1.5 vol/vol) mixture. For example, 3.55 g of HSPC, 1.39 g cholesterol and 1.33 g PEG2000-DSPE were dissolved in 30 mL of chloroform: ethanol (8.5:1.5 vol/vol) mixture. A chloroform-ethanol solution of oleandrin, in the range of 100-200 mg/mL was added to the above solution, resulting in a drug to lipid-protein ratio of 1:10 (wt/wt). A 1-10% human albumin solution was prepared. The pH of the solution was adjusted to 7.4. The above organic solution was added to the albumin phase while mixing from 3000 to 10000 rpm. The mixture was subjected to either high-pressure microfluidization or homogenization. The pressure was varied between 20,000 and 30,000 psi. This resulted in a homogeneous and extremely fine oil-in- water emulsion. The emulsion was rapidly evaporated in an evaporator to a nanoparticle suspension. The evaporator pressure and the bath temperature during evaporation were 10-50 mm Hg and 30-70° C., respectively.
[0113] The particle size of the suspension was determined by photon correlation spectroscopy with the Malvern Zetasizer. The suspension was sterile-filtered through a 0.22 μm filter. The particle size of the suspension was between 30 and 220 nm. The suspension was frozen below −40° C. and lyophilized. The lyophilized cake was reconstituted prior to further use. The particle size did not change appreciably following lyophilization and reconstitution.
[0114] In a similar manner, the PSL formulations ofneriifolin, odoroside A, odoroside H and proscillaridin A were prepared.
EXAMPLE 3
Preparation of PSL-Oleandrin Formulation
[0115] Lipid mixtures (Egg sphingomyelin:Phosphatidylcholine:cholesterol:PEG2000-DSPE=1:1:1:0.02 molar ratio) were dissolved in a chloroform:ethanol (9.5:0.05 vol/vol) mixture. A chloroform-ethanol solution of oleandrin, in the range of 100-200 mg/mL was added to the above solution, resulting in a drug to lipid ratio of 1:10 (wt/wt).
[0116] The above procedure described in Example 2 was employed to prepare PSL-Oleandrin. The particle size of the suspension before lyophilization and after reconstitution was between 50 and 220 nm.
EXAMPLE 4
Preparation of PSL-Oleandrin Formulation
[0117] The above procedure described in Example 2 was employed to prepare PSL-oleandrin formulation. However, instead of the lipid, PEG2000-DSPE, PEG2000-ceramide was used. The particle size of the suspension before lyophilization and after reconstitution was between 50 and 220 nm.
EXAMPLE 5
Preparation of PSL-Oleandrin Formulation
[0118] The above procedure described in Example 2 was employed to prepare PSL-Oleandrin. Lipid mixtures (Distearylphosphatidylcholine:cholesterol:PEG2000-ceramide=1.5:1:0.02 molar ratio) were dissolved in a chloroform:ethanol (8:2 vol/vol) mixture. The particle size of the suspension before lyophilization and after reconstitution was between 50 and 220 nm.
EXAMPLE 6
Preparation of PSL-Oleandrin Formulation
[0119] The above procedure described in Example 2 was employed to prepare PSL-Oleandrin. Lipid mixtures (egg phosphatidylcholine:cholesterol=55:45 molar ratio) were dissolved in a chloroform:ethanol (8:2 vol/vol) mixture or in chloroform or dicloromethane. The particle size of the suspension before lyophilization and after reconstitution was between 50 and 220 nm.
EXAMPLE 7
Preparation of PSL-Oleandrin Formulation
[0120] The above procedure described in Example 2 was employed to prepare PSL-Oleandrin formulation. Lipid mixtures (1,2-di(2,4-Tetradecadienoyl)-3-phosphatidylcholine:cholesterol=2:1 molar ratio) were dissolved in a chloroform:ethanol (8:2 vol/vol) mixture or in chloroform or dicloromethane. The particle size of the suspension before lyophilization and after reconstitution was between 50 and 220 nm.
EXAMPLE 8
Preparation of Nanoparticles of Oleandrin by High Pressure Homogenization
[0121] 100 mg Oleandrin is dissolved in 10 ml methylene chloride. The solution was added to 81 ml of human serum abumin solution (1% w/v). The mixture was homogenized for 5 minutes at low RPM (Vitris homogenizer) in order to form a crude emulsion, and then transferred into a high pressure homogenizer (Avestin). The emulsification was performed at 9000-18,000 psi while recycling the emulsion for at least 5 cycles. The resulting system was transferred into a Rotary evaporator, and methylene chloride was rapidly removed at 40° C., at reduced pressure (30 mm Hg), for 20-30 minutes. The resulting dispersion was translucent, and the typical diameter of the resulting Oleandrin particles was 160-220 (Z-average, Malvern Zetasizer).
[0122] The dispersion was further lyophilized for 48 hrs. without adding any cryoprotectant. The resulting cake could be easily reconstituted to the original dispersion by addition of sterile water or saline. The particle size after reconstitution was the same as before lyophilization.
EXAMPLE 9
Preparation of Nanoparticles by Sonication
[0123] 20 mg of Oleandrin is dissolved in 1.0 ml methylene chloride. The solution is added to 4.0 ml of human serum abumin solution (5% w/v). The mixture is homogenized for 5 minutes at low RPM (Vitris homogenizer, model:Tempest I.Q.) in order to form a crude emulsion, and then transferred into a 40 kHz sonicator cell. The sonicator is performed at 60-90% power at 0 degree for 1 min (550 Sonic Dismembrator). The mixture is transferred into a Rotary evaporator, and methylene chloride is rapidly removed at 40° C., at reduced pressure (30 mm Hg), for 20-30 minutes. The typical diameter of the resulting Oleandrin particles was 350-420 nm (Z-average, Malvern Zetasizer). The dispersion was further lyophilized for 48 hrs. without adding any cryoprotectant. The resulting cake could be easily reconstituted to the original dispersion by addition of sterile water or saline. The particle size after reconstitution was the same as before lyophilization.
EXAMPLE 10
Preparation of Less than 200 nm Sterile-Filterable Nanoparticles
[0124] 10 mg of Oleandrin is dissolved in 0.55 ml chloroform and 0.05 ml ethanol. The solution is added to 29.4 ml of human serum abumin solution (1% w/v), which is presaturated with 1% chloroform. The mixture is homogenized for 5 minutes at low RPM in order to form a crude emulsion, and then transferred into a high pressure homogenizer (Avestin). The emulsification is performed at 9000-18,000 psi while recycling the emulsion for at least 6 cycles. The resulting system is transferred into a Rotary evaporator, and the chloroform is rapidly removed at 40° C., at reduced pressure (30 mm Hg), for 15-30 minutes.
[0125] The resulting dispersion is translucent, and the typical diameter of the resulting Oleandrin particles is 140-160 nm (Z-average, Malvern Zeta Sizer). The dispersion is filtered through a 0.22 micron filter (Millipore), without any significant change in turbidity, or particle size. HPLC analysis of the Oleandrin content revealed that more than 97% of the Oleandrin was recovered after filtration, thus providing a sterile Oleandrin dispersion. The sterile dispersion was further lyophilized for 48 hrs. without adding any cryoprotectant. The resulting cake could be easily reconstituted to the original dispersion by addition of sterile water or saline. The particle size after reconstitution was the same as before lyophilization.
EXAMPLE 11
Preparation of Less than 200 nm Sterile-Filterable Nanoparticles
[0126] 225 mg Oleandrin is dissolved in 2.7 ml chloroform and 0.3 ml ethanol. The solution is added to 97 ml of human serum abumin solution (3% w/v). The mixture is homogenized for 5 minutes at low RPM (Vitris homogenizer) in order to form a crude emulsion, and then transferred into a high pressure homogenizer (Avestin). The emulsification is performed at 9000-18,000 psi while recycling the emulsion for at least 6 cycles. The resulting system is transferred into a Rotary evaporator, and the chloroform is rapidly removed at 40° C., at reduced pressure (30 mm Hg), for 15-30 minutes. The resulting dispersion is translucent, and the typical diameter of the resulting Oleandrin particles is 140-160 nm (Z-average, Malvern Zeta Sizer). The dispersion is filtered through a 0.22 micron filter (Sartorius, sartobran 300), without any significant change in turbidity, or particle size. HPLC analysis of the Oleandrin content typically revealed that 70-100% of the Oleandrin could be recovered after filtration, depending on the conditions employed. Thus, a sterile Oleandrin dispersion was obtained. The sterile dispersion was aseptically filled into sterile glass vials and lyophilized without adding any cryoprotectant. The resulting cake could be easily reconstituted to the original dispersion by addition of sterile water or saline. The particle size after reconstitution was the same as before lyophilization.
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The present invention provides methods, preparations, and uses of a variety of liposomal-digitalis glycoside compositions. The present invention also provides protein-stabilized nanoparticle formulations containing liposomal-digitalis glycosides such as Oleandrin, digitoxin, and digoxin with reduced toxicity, high drug to lipid ratio, long circulating time in the bloodstream and the ability to deliver the drug to tumor sites. In another aspect, the present invention provides an effective method to reduce the growth of cancers or reduce the incidence of metastases.
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FIELD OF THE INVENTION
The invention relates generally to the art of devices and methods for testing purge flow rates from an evaporative charcoal canister in a motor vehicle. More specifically, the invention pertains to a non-intrusive instrument specifically adapted to measure the rate of vapor flow in the purge line leading from the canister to the engine's fuel intake system. By non-intrusive, it is meant that measurement of the vapor flow rate during purging can be made without disconnecting any portion of the fuel vapor purge line or its associated hardware.
BACKGROUND OF THE INVENTION
Motor vehicles are subjected to wide variations in temperature and air pressure, both while in use and when parked. Elevated temperatures and reduced air pressures, in particular, result in the generation of hydrocarbon vapors within the vapor space of the vehicle's fuel tank. Modern motor vehicles include a gas cap adapted to seal the open end of the tank filler neck, to prevent atmospheric venting of these polluting vapors. Such vehicles also are equipped with a charcoal canister, having an inlet interconnected to the vapor space in the upper portion of the fuel tank, by means of a vapor vent line. The outlet of the canister is interconnected to the engine's air/fuel intake system, such as the intake manifold, or the like.
The function of the charcoal canister is to absorb excessive gasoline vapors generated during high temperature and/or low ambient pressure conditions, while simultaneously avoiding a dangerous vapor pressure buildup in the fuel tank. Thus, in a proper functioning evaporative system, when pressure in the vapor space exceeds atmospheric pressure, fuel vapors migrate through the vapor vent line into the vehicle's canister, where the hydrocarbons are absorbed by the charcoal. If vapor pressure is sufficient, the filtered vapor is safely exhausted to the atmosphere through an air vent in bottom of the canister.
Then, during driving, the vacuum existing in the intake manifold draws fresh air in through the same vent, vaporizing the hydrocarbons. The gas vapor is drawn by vacuum through the purge line, and introduced into the intake manifold for combustion. In this manner, the gasoline is fully utilized, and the charcoal canister is fully purged of vapors, restoring its hydrocarbon storage capacity for the next cycle.
If the charcoal canister is not regularly purged while the vehicle is driven, the charcoal will eventually become saturated and the trapped hydrocarbons will escape directly into the atmosphere through the canister's air vent. When this occurs, the major advantages provided by the evaporative system are defeated. The negative environmental impact of uncontrolled vapor discharge through the canister rivals that of the vehicle's exhaust emissions. Moreover, this vapor emission also decreases the overall fuel economy of the vehicle, by venting hydrocarbons which would otherwise be burned in the engine. Consequently, proper purging of the canister has significance both for the environment and for the conservation of energy.
In recognition of these facts, the Federal Environmental Agency (EPA), has mandated the testing of this canister purging function, in the context of a more comprehensive vehicle inspection and maintenance testing procedure, known as the "I/M 240" test. In the course of this 240 second test, a vehicle is put through a predetermined driving cycle on a dynamometer, simulating vehicle performance at various speeds and during acceleration/deceleration conditions. While being so tested, the purge line leading from the canister to the engine is constantly monitored, using a sensor and a recording instrument. This confirms that at some point during the predetermined driving test cycle, an adequate purging event has occurred.
The prior art includes an intrusive testing technique, requiring the temporary, mechanical connection of a flow transducer in series with the purge line leading from the canister to the intake manifold. Typically, this involves locating the canister, and disconnecting the purge line from the canister. After installing the transducer, flow measurements are monitored by a display and recording unit to determine operational effectiveness of the purge cycle. After the test is completed, the process is reversed, removing the transducer and restoring the purge line to its original connection.
This intrusive approach has a number of significant drawbacks. Some vehicles have inaccessible canisters, and cannot be tested with this method. Locating the canister, removing the purge line, installing the transducer, removing the transducer, and finally reconnecting the purge line, all take a significant amount of time for the testing personnel to complete. Lastly, removing purge lines and fittings on older vehicles and on vehicles having nearly inaccessible canister locations, can result in damage to these components.
The prior art also includes a non-intrusive testing method, employing a tracer gas. This system contemplates the removal of the fuel tank filler cap and the connection of a gas pressurization and metering device to the filler neck opening. For example, U.S. Pat. No. 5,239,858, issued to Rogers et al., shows the connection of a helium cylinder and a flow meter to a motor vehicle fuel evaporative system, using a connector cap on the filler neck.
SUMMARY OF THE INVENTION
The present invention includes a detector, or sensor housing, provided with a clamping structure for temporarily engaging the canister purge line of a motor vehicle under test. The clamping structure has an accessible recess or opening, configured and sized generally to correspond to the exterior shape and dimensions of the purge line. A snug and secure attachment between the housing and the exterior wall of the purge line are thereby assured.
In a preferred embodiment, the housing includes clamshell-like upper and lower halves, hingeably attached to each other and spring biased into a closed position. Abutting faces of these halves include adjacent, complementary cutouts or grooves which together surround and accommodate a selected section of the purge line. Such a construction allows the housing to be quickly and easily clamp-installed, along any accessible portion of the purge line.
The grooved portion of the housing includes a sensing system, designed to detect the passage of gaseous vapors through the purge line. Two different sensing systems are disclosed herein. The first system uses at least one heating element and a temperature sensor, to measure temperature variations in the exterior sidewall of the purge line, attributable to passing vapors. The second relies upon a pair of transducers to detect a phase shift in audio frequency waves, impressed upon and reflected by the passing vapors.
Each sensor system also includes associated control, measurement, and recording components to monitor and store collected data regarding vapor flow rates. These components are preferably housed in a separate console, located adjacent the vehicle under test, and are connected to the sensor housing by means of cable. This console may also include digital memory components, storing predetermined flow rate values which are appropriate for the vehicle under test. In this manner, canister purge pass/fail determinations may be made while the vehicle is subjected to a driving test on a dynamometer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a vehicle under test, showing the evaporative canister, the fuel tank, the engine, the sensor housing, and the test console;
FIG. 2 is an enlarged view of a typical sensor housing, shown clamped upon a fragmentary section of purge line;
FIG. 3 is a schematic representation of a thermal loss sensor system, including a cross-sectional view of the associated sensor housing;
FIG. 4 is a graph depicting the calculation of the total flow of vapor through the purge line over a period of time, by integrating the function of current flowing through a heating element in the sensor housing;
FIG. 5 is a schematic representation of an acoustic, or sonic phase sensor system, including a cross-sectional view of the associated sensor housing;
FIG. 6 is a graph depicting the phase shift in the detected sound wave, induced by a fixed vapor flow rate;
FIG. 7 is a graph showing the calculation of the total flow of vapor through the purge line over a period of time, by integrating the function of phase shift in the sound wave detected in the sensor housing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to FIG. 1, the outline of a motor vehicle 11 under test, is shown in broken line. Vehicle 11 includes a fuel tank 12, having a filler neck 13 and a neck sealing cap 14. A main fuel line 16 leads from the bottom of tank 12, through a pump 17, to the intake manifold 18 of engine 19. A vapor vent line 21 extends from the top portion of tank 12, to the inlet side of charcoal canister 22. A canister purge line 23 leads from the outlet side of the canister 22 to intake manifold 18.
The canister purge testing apparatus of the present invention is generally designated by the numeral 24, and includes a detector or sensor housing 26 and an operator's console 27. FIG. 2 shows a typical sensor housing 26 in more detail, installed on a section of purge line 23. In the preferred embodiment disclosed herein, housing 26 includes a purge line clamp 30 with clamshell-like upper half 28 and lower half 29. Abutting faces of halves 28 and 29 include complementary, elongated arcuate cutouts 31 and 32 defining an opening or recess 33 extending through clamp 30. Recess 33 is sized and configured so as to accommodate in tight relation, a selected segment of the purge line.
Clamp extension 34 includes a pair of plates 36 and 37, projecting, respectively, from half 28 and half 29. Plates 36 and 37 also include diverging finger grips 38 and 39. As is best shown in FIG. 2, a pin 41 hingeably interconnects proximate sides of the clamp 30; also, a spring 42 extends substantially the length of pin 41, and biases the distal sides of clamp 30 together.
It will be appreciated, then, that by squeezing grips 38 and 39 together, the distal sides of the clamp will temporarily be spread apart, facilitating installation of clamp 30 over purge line 23. Then, by releasing grips 38 and 39, clamp is spring biased into a closed position, with recess 33 snugly surrounding line 23. One of the major advantages provided by the present invention is that the clamp may be installed in a non-intrusive manner, over any accessible section of the purge line between the canister and the engine. No disassembly whatsoever of the purge line is required.
It is contemplated that housing 26 could alternatively include an appropriately configured elongated recess in an exterior sidewall, for accommodating the purge line. For example, if the material of the housing around the recess were rubber or another resilient material, the purge line could merely be press fitted into the recess, without the necessity of a clamshell-like clamping arrangement. Another alternative to the clamshell clamp would involve the use of VELCRO strapping material, or the like, which would temporarily secure the purge line against the detection components within the sensor housing.
In FIG. 3, a first vapor flow sensor system 40 is disclosed, based upon principles of thermal loss induced by vapor flow. This system employs at least one heating element and at least one temperature sensing element, typically a thermistor. In the preferred embodiment, a number of electrical heaters 43 are strategically located completely around and along the recess 33 within the housing 26. This arrangement is preferred because it effectively raises the temperature of the purge line to a control temperature well above ambient temperature, approximately 200 degrees Fahrenheit. To that end, a microprocessor 44, a heater driver 46, a current detector 47, an analog-to-digital converter 48, and a thermistor 49 are provided. The dashed line identified by numeral 27 indicates which of these components are located on the console.
Under preliminary start-up conditions, when there is no vapor flow, the heaters 43 are servo-controlled by the interaction of the just recited components to raise the hose temperature to the control temperature. The microprocessor 44 continuously samples the output of the thermistor 49 to determine the temperature in the near vicinity of the hose. When the control temperature is reached, the microprocessor appropriately controls the heaters to maintain that temperature.
Upon initiation of the vehicle test, the engine is started and the operator may be called upon to perform a specified driving cycle, for a predetermined period of time. During this cycle, the vehicle may be accelerated to a certain speed, held at a constant speed, or decelerated to a stop, all at specified rates and for predetermined periods of time, selected to simulate actual driving conditions. It is during this test cycle, that the invention herein is to monitor vapor flow within the purge line and confirm that the canister is adequately purged of hydrocarbons.
As the engine is put through this cycle, fuel vapor will begin to flow from the canister 22 to the intake manifold 18, if the vehicle's purge system is working properly. When this occurs, the fuel vapor carries heat away from the inner surface of the purge line 23, and this changed condition is detected by the thermistor 49. This information is delivered to the microprocessor 44, which increases the amount of power passed on to the heaters 43 to maintain the control point temperature.
FIG. 4 shows the current ("I") delivered to the heaters as a function of time, during an actual purge cycle. During a "no flow" condition, the heater current is substantially constant, as the control point is maintained. With increasing vapor flow, the current necessary to maintain the control point temperature increases proportionately. By integrating the difference between the current required to maintain a constant temperature during "no flow", and the instantaneous current provided during flow conditions, a value ("A"), which is proportional to the total purge flow ("F") during the test, can be determined. This value may then be compared to predetermined values for the vehicle under test, to make a pass/fail determination.
Turning now to FIG. 5, a second vapor flow sensing system 51 is disclosed. The operating principle of system 51 depends upon a phase shift induced in acoustical waves, passing through the purge line. For that purpose, a high frequency acoustic transducer, or transmitter 52 is located within the upstream portion of sensor housing 26, directed generally toward the sidewall of purge line 23. Similarly, a high frequency transducer, or receiver 53 is located within the downstream portion of housing 26, also directed toward line 23. Conventional acoustic wave directive components (not shown) may be used on both transmitter 52 and receiver 53, to focus the transmission and reception of the sonic wave path 54, improving the overall signal to noise ratio of the system.
Under "no flow" conditions, transmitter 52 radiates a sine wave, produced by signal generator 55, preferably operating at an audio frequency. The acoustical wave readily passes through the line 23 before it encounters the relatively rigid wall of recess 33, at reflection point 56. Bouncing off point 56, the wave is redirected toward the receiver 53, passing again through the line 23. The wave is detected by receiver 53, and the output signal is fed to a microprocessor 57. The output of generator 55 is also delivered to microprocessor 57, which notes the phase relationship between the two signals. This step initially establishes a "no flow" reference signal 58, depicting the phase relationship between the transmitted and received signals (see FIG. 6).
Under vapor flow conditions, the acoustical wave is physically displaced downstream by the passing vapor, both before and after bouncing off reflection point 56. This displaced wave 61, arrives at receiver 53 later than the no signal wave 54. The resultant electrical signal 59 is shown in FIG. 6, showing the phase shift or offset existing between the "no flow" and flow conditions.
The microprocessor 57 integrates the difference between the phase shift under "no flow" conditions and the instantaneous phase shift over the driving test cycle to determine a value ("A"). And, as with the thermal loss system described above, the value A is proportional to the total flow ("F"), so as to provide a useful measure of the total flow. This measured quantity, in turn, is compared to predetermined values for acceptable purge flow during the course of the driving cycle, and a pass/fail determination is made and displayed by console 27.
It will be appreciated, then, that I have disclosed an apparatus and a method for testing the canister purge system of a motor vehicle during the course of a driving cycle, without physically having to disassemble and reassemble the components of that system.
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An apparatus and method for non-intrusive testing of the rate and total amount of vapor flow through the canister purge line in a motor vehicle. The apparatus includes a clamping structure, adapted for temporary attachment to the purge line leading from the evaporative canister to the engine's intake manifold. A vapor flow sensing system is provided within the structure. Both thermal loss and acoustical phase shift detection based sensing systems are disclosed herein. An operator secures the clamp over any portion of the purge line, and the vehicle's engine is put through a driving test cycle. The output of the sensing system is displayed, recorded, and integrated, for a subsequent pass/fail determination using predetermined vapor flow values.
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This application is a continuation of application Ser. No. 06/738,269 filed 05/28/85 and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to a system for ballasting an array of mutually parallel-oriented fluorescent lamps.
2. Prior Art
Presently when ballasting a plurality of fluorescent lamps, such as in a sun tanning bed that typically comprises between 20 and 40 fluorescent lamps, with each lamp being 72' long and requiring about 100 Watt of power input for effective operation, these lamps are powered by way of a plurality of individual power-line-operated ballasts, with each ballast powering one or two lamps.
The fluorescent lamps most often used in these applications are of the so-called rapid-start type; which implies that each lamp requires four separate supply wires for proper operation. As a result, the number of wires required for powering 20-to-40 fluorescent lamps gets to be very high.
SUMMARY OF THE INVENTION
Brief Description
In its preferred embodiment, subject invention constitutes a ballasting system for an array of several series-connected pairs of mutually parallel-oriented fluorescent lamps. Each lamp has a first pair and a second pair of cathode terminals; and the lamps are positioned such that all the first pairs of cathode terminals are aligned along a first straight line, and all the second pairs of cathode terminals are aligned along a second straight line. The ballasting system is adapted to be powered from an ordinary electric utility power line and comprises:
(a) a relatively low-power first frequency converter means connected with the power line and controllably operable to provide a first AC voltage for heating the cathodes of all the fluorescent lamps, thereby conditioning them for easy starting;
(b) a relatively high-power second frequency converter means connected with the power line and controllably operable to provide a second AC voltage (30kHz/240Volt) for providing operating power to all the pairs of fluorescent lamps;
(c) a first cathode transformer connected with said AC voltage and operable to provide cathode heating power to said first pairs of cathode terminals, this first transformer being located near said first pairs of cathode terminals;
(d) a second cathode transformer connected with said first output and operable to provide cathode heating power to said second pairs of cathode terminals, this second transformer being located near said second pairs of cathode terminals;
(e) for each pair of fluorescent lamps, a high-Q series-resonant L-C ballast circuit operable to power the pair of lamps from the second AC voltage, with each of the L-C ballast circuits: i) being connected with this second AC voltage, (ii) having voltage-limiting means and circuit-protection means operative to prevent over-voltage and excessive power dissipation in case a lamp is inoperative or disconnected, and iii) being located near said first pairs of cathode terminals; and
(f) delay means operable to prevent the second AC voltage from being applied to the L-C ballast circuits until after the first AC voltage has had an opportunity to heat the lamp cathodes to incandescence.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 provides a schematic illustration of the central frequency-converting power supply.
FIGS. 2a and 2b diagramatically describes the preferred embodiment of the overall ballasting system.
FIG. 3 provides schematic details of the voltage-limiting and circuit-protection means.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Details of Construction
FIG. 1 shows an AC voltage source S, which is a 240Volt/60Hz electric utility power line.
Connected to S is a full-wave rectifier FWR that rectifies the AC voltage from S to provide an unfiltered DC voltage between a positive power bus B+ and a negative power bus B-.
A first pair of transistors Qla and Qlb are connected in series between the B+ bus and the B- bus in such a way that the collector of Q1a is connected to the B+ bus, the emitter of Q1a is connected with the collector of Q1b at a junction J1, and the emitter of Q1b is connected with the B- bus.
A second pair of transistors Q2a and Q2b are connected in series between the B+bus and the B- bus in such a way that the collector of Q2a is connected to the B+ bus, the emitter of Q2a is connected with the collector of Q2b at a junction J2, and the emitter of Q2b is connected with the B- bus.
Primary winding FTlap of saturable feedback transformer FTla and primary winding FTlbp of saturable feedback transformer FTlb are connected in series between junction Jl and inverter output terminal OTlx. The other inverter output terminal OTly is connected with junction JC between capacitors Ca and Cb; which capacitors are connected in series between the B+bus and the B- bus.
Primary winding FT2ap of saturable feedback transformer FT2a and primary winding FT2bp of saturable feedback transformer FT2b are connected in series between junction J2 and inverter output terminal OT2y. The other inverter output terminal OT2x is also connected with junction JC.
Secondary winding FTlas of feedback transformer FTla is connected between the base and the emitter of transistor Qla; and secondary winding FTlbs of feedback transformer FTlb is connected between the base and the emitter of transistor Qlb.
Secondary winding FT2as of feedback transformer FT2a is connected between the base and the emitter of transistor Q2a; and secondary winding FT2bs of feedback transformer FT2b is connected between the base and the emitter of transistor Q2b.
A resistor R1 is connected between the B+bus and a junction DJl; and a capacitor Cl is connected between junction DJl and the B- bus. A Diac Dl is connected between junction DJl and the base of transistor Qlb. A control transistor Qcl is connected with its collector to junction DJl and with its emitter to the B-bus. Its base is connected with a control terminal CT1.
A resistor R2 is connected between the B+bus and a junction DJ2. A capacitor C2 is connected between junction DJ2 and the B- bus. A Diac D2 is connected between junction DJ2 and the base of transistor Q2b. A control transistor Qc2 is connected with its collector to junction DJ2 and with its emitter to the B-bus. Its base is connected with a control terminal CT2.
The assembly consisting of transistors Qla and Qlb, feedback transformers FTla and FTlb, and output terminals OTlx and OTly is referred to as low power inverter LPI. The output from this low power inverter LPI is provided between overall output terminals OOTla and OOTlb, as well as between overall output terminals OOT2a and OOT2b.
The assembly consisting of transistors Q2a and Q2b, feedback transformers FT2a and FT2b, and output terminals OT2x and OT2y is referred to as high power inverter HPI. The output from this high power inverter HPI is provided between overall output terminals OOT2b and OOT2c.
The overall power supply of FIG. 1 is referred to as central power supply CPS.
FIGS. 2a and 2b illustrate the preferred overall system for operating an array FLA of a plurality of fluorescent lamps.
With reference to FIG. 2a, overall output terminals OOTla and OOTlb of central power supply CPS are connected respectively with input terminals ITla and ITlb of a power distribution means PDMl; which power distribution means is mounted next to one end El of fluorescent lamp array FLA. Overall output terminals OOT2a, OOT2b and OOT2c of central power supply CPS are connected respectively with input terminals IT2a, IT2b and IT2c of a power distributing means PDM2; which power distributing means is mounted adjacent the other end E2 of fluorescent lamp array FLA.
Still with reference to FIG. 2a, control terminals CTl and CT2 of central power supply CPS are respectively connected with control output terminals COTl and COT2 of programmer P.
With reference to FIG. 2b, fluorescent lamp array FLA comprises a plurality of pairs of fluorescent lamps: FLla/FLlb, FL2a/FL2b ---- FLna/FLnb.
Power distribution means PDM2 comprises a corresponding plurality of L-C ballasting means: Ll/Cl, L2/C2 ---- Ln/Cn; all of which are connected between input terminals IT2b and IT2c. Lamp pairs FLla/FLlb, FL2a/FL2b ---- FLna/FLnb, by way of their upper cathodes (i.e., those cathodes located at or near end E2 of fluorescent lamp array FLA), are respectively connected across capacitors Cl, C2 ---- Cn. Also connected across capacitors Cl, C2 ---- Cn are circuit protectors CPl, CP2 ---- CPn, respectively.
Power distribution means PDM2 additionally comprises a transformer T2, which has its primary winding connected between input terminals IT2a and IT2b. This transformer has one special secondary winding T2sx, the output of which is connected with the parallel combination of all the upper cathodes of fluorescent lamps FLla, FL2a ---- FLna. Transformer T2 also has a plurality of ordinary secondary windings, one connected with each of the upper cathodes of fluorescent lamps FLlb, FL2b ---- FLnb.
Power distribution means PDMl comprises a transformer Tl, which has its primary winding connected between input terminals ITla and ITlb. This transformer has a plurality of secondary windings, with one such secondary winding being connected with the series-connection of the lower cathodes (i.e., the cathodes located at or near end El of fluorescent lamp array FLA) of each fluorescent lamp pair FLla/FLlb, FL2a/FL2b ---- FLna/FLnb. Starting aid capacitors SACl and SACn are connected from input terminal ITla to the lower cathodes of lamps FLla and FLnb, respectively. A starting aid capacitor is similarly connected with the lower cathode of lamp FL2a as well, but is not shown.
FIG. 3 provides details of a circuit protector CPx; which circuit protector is like those identified in FIG. 2b as CP1, CP2 ---- CPn. This circuit protector has two terminals CPT1 and CPT2. Connected in series across these two terminals is a Varistor V and the primary winding CTp of a current transformer CT. Connected in parallel with Varistor V is a first bridge rectifier BRl, across the output of which is connected a filter capacitor FCx and a thyristor SCR -- the anode of the SCR being connected with the positive terminal of the output of BRl, the cathode being connected with the negative terminal. Across the secondary winding CTs of current transformer CT is connected a second bridge rectifier BR2, the negative output terminal of which is connected with the negative output terminal of BRl. The positive output terminal of BR2 is connected through a resistor Rxl to a junction Jx. An energy-storing capacitor Cx is connected between junction Jx and the negative terminal of BR2. A series-combination of a Diac Dx and a resistor Rx2 is connected between junction Jx and the gate of thyristor SCR. A resistor Rx3 is connected between the gate and the cathode of thyristor SCR; and a resistor Rx4 is connected directly across the output of BR2.
Details of Operation
The operation of the central power supply CPS of FIG. 1 may be explained as follows.
FIG. 1 shows two half-bridge inverters: a low power inverter LPI consisting of transistors Qla and Qlb with their respective saturable positive feedback transformers FTla and FTlb; and a high power inverter HPI consisting of transistors Q2a and Q2b with their respective saturable positive feedback transformers FT2a and FT2b.
Both inverters are capable of self-oscillation by way of positive feedback. When they do oscillate, the frequency of oscillation is about 30 kHz. For further explanation of the operation of this type of inverter, reference is made to U.S. Pat. Nos. 4,184,128 and 4,506,318, both issued to Nilssen.
Each of these inverters has to be triggered into oscillation; but they will only oscillate as long as the magnitude of the voltage between the B- bus and the B+ bus exceeds about 20 Volt. Thus, if one of the inverters is triggered into oscillation at the beginning of one of the sinusoidally-shaped DC voltage pulses existing between the B- bus and the B+bus (as resulting from the unfiltered full-wave rectification of the voltage from the 240Volt/60Hz power line), that inverter will cease oscillating at the end of that DC voltage pulse.
Thus, to keep either one of the inverters operating on a continuous basis, it is necessary that it be re-triggered 120 times per second: once in the beginning of each half-cycle of the full-wave-rectified 240Volt/60Hz power line voltage.
Both the half-bridge inverters use capacitors Ca and Cb to provide for an effective center-tap between the B- bus and the B+ bus--this center-tap being junction JC.
In normal operation, both inverters will provide a relatively high-frequency (30 kHz) squarewave AC voltage 100% amplitude-modulated at a frequency of 120 Hz.
Absent any control signals at control terminals CTl and CT2, when power line voltage is applied to the arrangement of FIG. 1, inverters LPI and HPI will both commence operation, receiving the requisite trigger pulses by way of trigger assemblies Rl/Cl/Dl and R2/C2/D2, respectively. The time-constants associated with Rl/Cl and R2/C2 are such as to cause the voltages on Cl and C2 to reach levels high enough for Diacs D1 and D2 to break down within about one milli-second after the beginning of each sinusoidally-shaped DC pulse provided by the full wave rectifier.
As a result of the relatively short time-constants, repeated triggering will occur during each complete DC pulse. While most often such repeated triggering is of little consequence, it is sometimes desirable to avoid it altogether; which may be accomplished by adding a first diode between junction DJl and the collector of transistor Qlb and a second diode between junction DJ2 and the collector of transistor Q2b--in both cases with the anodes of the diodes being connected with the junctions.
On the other hand, with a positive control signal provided to each of control terminals CTl and CT2, inverters LPI and HPI are both prevented from being triggered and thereby prevented from entering operation. Thus, by providing and/or removing such control signals from control terminals CTl and/or CT2, either inverter can be selectively switched between operation and non-operation--in complete independence of the other inverter.
With reference to FIG. 2a, programmer P--which is of conventional design--provides programmed positive control signals to the two control terminals, thereby providing for such selective and individual control of the operation of the two inverters--causing them to operate or non-operate, selectively and individually, in accordance with any desired program. In the preferred embodiment, starting from a situation where both inverters were non-operating on account of being both provided with a positive control signal, the desired program provides for a sequence of signals and results as follows.
(i) Initially, the positive control signal provided to CTl is removed, thereby causing inverter LPI to..initiate operation. As a result, cathode heating power is provided to all the cathodes of the fluorescent lamp array.
(ii) About 1.5 seconds later, the positive control signal provided to CT2 is removed, thereby, causing inverter HPI to initiate operation. As a result, the 30 kHzoutput voltage from the HPI inverter is now applied to all the L-C ballasting circuits, thereby--since the cathodes by now have become completely incandescent--easily starting the fluorescent lamps.
(iii) After the lamps have started, which--with preheated cathodes--is apt to take only a few milli-seconds, the positive control signal is re-applied to control the terminal CT1, thereby stopping inverter LPI from operation; which, in turn, reduces the overall power required for operating the fluorescent lamps.
(iv) After a more extended period, which in a sun tanning application might typically be 30 minutes, the positive control signal is re-applied to control terminal CT2, thereby stopping inverter HPI from operation and turning off the light from the fluorescent lamps.
With reference to FIG. 2b, it is indeed seen that the first 30 kHz voltage provided from the output of inverter LPI is applied, by way of transformers Tl and T2, to the cathodes of the fluorescent lamps in the array FLA. And, it is also seen that the second 30 kHz voltage from inverter HPI is applied across all the series-connected L-C circuits, such as the constituted by Ll/Cl; which L-C circuits are resonant at or near the frequency of the applied 30 kHz voltage.
In each of these L-C circuits, both the capacitor and the inductor have. relatively high Q-factors; which implies that there will be a substantial Q-multiplication effect. That is, absent any loading, the magnitude of the voltage developing across the capacitor will be larger by a factor of Q in comparison to the magnitude of the voltage applied to the series-resonant L-C circuit. Since the net unloaded Q-factor of the L-C circuit in the preferred embodiment is over 100, the magnitude of the voltage developing across the capacitor--assuming linear operation and no break-down -- would reach 12,000 Volt with an input of 120 Volt.
However, each L-C circuit is loaded both by two series-connected fluorescent lamps and a circuit protector; which circuit protector acts to limit the maximum voltage that can develop across the capacitor to a level that is appropriate for proper lamp starting.
With additional reference to FIG. 3, it is seen that the Varistor is in effect connected in parallel with the capacitor of the L-C circuit, and thereby in parallel with the two associated series-connected lamps. The voltage drop across the primary winding of current transformer CT is so small as to be negligible in comparison with the voltage present across the Varistor when it is performing voltage-clamping.
The clamping voltage of the Varistor is so chosen that--in the absence of the fluorescent lamps--the magnitude of the voltage developing across the capacitor is just right for proper rapid-starting of the two series-connected lamps.
With the Varistor chosen so as to clamp the voltage across the capacitor to a magnitude just right for rapid-starting of the two series-connected lamps, substantially no current will flow through the Varistor after the lamps have started. Moreover, the lamps will not start if the cathodes are non-incandescent.
When the lamps' cathodes are fully incandescent, the lamps will rapid-start in a matter of a few milli-seconds. However, due to the voltage-magnitude-limiting provided by the Varistor, with cold cathodes the lamps won't start at all.
If for some reason the lamps should not start--perhaps because they were damaged, worn out, or otherwise inoperative, or perhaps because they were disconnected--Varistor V will conduct; and current will then flow through primary winding CTp of current transformer CT. As a result, a 30 kHz voltage is developed across resistor Rx4; which voltage is rectified by bridge-rectifier BR2 and applied by way of resistor Rxl to capacitor Cx. The time-constant associated with charging capacitor Cx is so chosen that, after about 100 milli-seconds, the voltage on capacitor Cx reaches a magnitude high enough to cause Diac Dx to break down; which then results in a current being applied to the gate of thyristor SCR.
With current applied to its gate, thyristor SCR will trigger into its conductive state; which implies that it will cause an effective short circuit to be applied across the Varistor. This short circuit will continue to provide current for the primary winding of current transformer CT; which will therefore cause the short circuit to perpetuate itself in positive feedback fashion.
Thus, if a given pair of fluorescent lamps do not start within about 100 milli-seconds after having been provided with operating voltage, a short circuit will be applied across the lamps, thereby preventing excess power drain from inverter HPI as well as damage to the Varistor.
With the capacitor effectively shorted, the associated inductor will be subjected to the full voltage from inverter HPI. However, this will only give rise to a modest amount of inductively reactive load current and will case no significant ill effect.
Additional Comments
(a) During the few milli-seconds after power has been applied from inverter HPI, but before the lamps have started, the L-C series-resonant ballasting circuits are each loaded with a Varistor, thereby preventing destructive over-voltages. During this brief period, the Varistor absorbs power at a rate of nearly twice that of the two associated lamps when they are operating. That is, during these initial few milli-seconds, each Varistor absorbs power at a rate of about 400 Watt in the typical situation where each lamp draws about 100 Watt during normal operation.
However, the Varistor--although it can absorb a very large amount of power for a brief period of time--can only absorb a miniscule) amount of power on an average basis: a large-capacity Varistor is typically rated at about 1 Watt average power, although it may have a rating of perhaps 80 Joule in terms of energy-absorbing capacity. Thus, in subject system, a Varistor will indeed be able for 100 milli-second or so to safely absorb the approximately 400 Watt or power dissipation it is subjected to in case a pair of lamps fails to start--thereby absorbing a total amount of energy of about 40 Joule. However, it would not be able to absorb that level of power for longer than about 200 milli-seconds.
(b) Due to the resonant nature of the ballasting circuit, the current flowing into each lamp-ballast combination will be substantially sinusoidal in waveshape even though the driving voltage is a squarewave.
(c) The fundamental nature of a high-Q resonant series-excited L-C circuit that is parallel-loaded with a gas discharge lamp, is one of providing this lamp with current from the near-equivalent of an ideal current source, with the magnitude of the current provided to the lamp being roughly proportional to the magnitude of the driving voltage,
As an overall result, the RMS magnitude of the current drawn from central power supply CPS by the plurality of lamp-ballast assemblies will be roughly proportional to the RMS magnitude of the squarewave voltage provided by this central power supply; which, since this squarewave voltage-is amplitude-modulated in direct proportion to the instantaneous magnitude of the DC voltage provided from the full wave rectifier, implies that the magnitude of the instantaneous current drawn by the central power supply from the power line will be roughly proportional to the instantaneous magnitude of the voltage provided therefrom. Thus, the power factor by which the central power supply draws power from the power line will be high--approaching 100%.
(d) The amount of power that has to be provided by the low-power inverter LPI is less than 10% of the amount of power that has to be provided by high-power inverter HPI.
(e) The fluorescent lamps are started in a particularly gentle rapid-start fashion: the cathodes are allowed to reach full incandescence before lamp operating voltage is applied; and lamp starting aid is provided both by way of a starting capacitor (ex: CAPl in FIG. 2b) and by way of providing a ground-plane next to each lamp. (The ground-plane is not shown, but is present in the form of a grounded reflector mounted behind the lamps.)
(f) Capacitors Ca and Cb of FIG. 1 are sized such as not to store a significant amount of energy in comparison to the amount of energy drawn by the central power supply during one complete half-cycle of the 240Volt/60Hz power line voltage, while at the same time to store an amount of energy that is several times as large as the amount of energy used by the inverters during one half-cycle of the 30 kHz inverter output voltage.
(g) The power supplied to the fluorescent lamps depends on the timing or phasing of the trigger pulses provided to high-power inverter HPI. In turn, the timing of these trigger pulses depend on the delay associated with the process of charging capacitor C2 to a voltage high enough to cause breakdown of Diac D2. The length of this delay can be adjusted over a wide range by adjusting the time-constant associated with R2/C2.
(h) It is noted that inverter LPI and transformers Tl and T2 may be completely removed, yet the system would still be operable, albeit that the fluorescent lamps would then operate in an instant-start manner. However, the peak power levels then required for lamp starting would be substantially higher, which would result in substantially more costly components.
(i) It is believed that the present invention and its attendant advantages and features will be understood from the preceeding description. However, without departing from the spirit of the invention, changes may be made in its form and in the construction and interrelationships of its component parts, the form herein presented merely representing the presently preferred embodiment.
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A lighting arrangement comprises;
(i) a plurality of pairs of mutually parallel-oriented fluorescent lamps, each pair of lamps adapted to be powered from 30 kHz/240 Volt by way of a high-Q series-resonant L-C ballasting circuit;
(ii) a relatively low-power frequency converter connected with the power line and operable to provide power for heating the cathodes in these fluorescent lamps, thereby conditioning the lamps for easy starting;
(iii) a relatively high-power frequency converter also connected with a power line and operable to provide the 30 kHz/240 Volt required for operating the plurality of pairs of fluorescent lamps by way of the high-Q series-resonant L-C ballasting circuit; and
(iv) delay means operable to prevent the 30 kHz/240 Volt provided by the high-power frequence converter from being applied to the fluorescent lamps until after power has been applied to heat the lamp cathodes for at least one second.
Each high-Q series-resonant L-C ballast circuit is protected from over-voltages by a Varistor, which acts as a substitute load in case a lamp is removed or fails to operate properly. If current should flow through the Varistor for more than about 100 milli-seconds, however, a protection circuit operates to place a short circuit across the Varistor, thereby preventing excessive long term poower dissipation and/or damage to the Varistor.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. Patent Application No. 12/511,387 filed Jul. 29, 2009 and claims priority to provisional patent application 61/034,450 which was filed on Jul. 29, 2008, which applications are incorporated by reference herein.
BACKGROUND
Dr. Ignacio Ponseti is an internationally famous physician and surgeon specializing in the treatment and management of a childhood deformity commonly know as a club foot. Dr. Ponseti has for many decades promoted the use of a foot and ankle abduction device, or orthosis, that is used to correct and prevent relapses of the club foot deformity. These abduction devices typically consist of a rigid bar connected between, shoes worn by the child which bar separates the feet of the child and holds the feet in an outward rotation or abduction. Typically, if the condition is diagnosed early enough, this device is worn full-time for a period of months, but during the period of treatment, the angle of outward rotation, is periodically adjusted.
The Ponseti technique, as it has become known throughout the world, has been highly successful in treating club feet without the necessity of corrective surgery. Many devices have been designed and used for many, many years in applying the Ponseti technique. Currently used devices that apply the Ponseti technique are shown in U.S. Pat. No. 7,267,657. In this patent, there are disclosed improvements in such devices which provide for quick release of the shoes from the abduction bar and which also provide a method for varying the abduction angle and locking it in place at a selected angle. Devices of this type have been extremely successful and are widely used by those who treat patients using the Ponseti technique. However, the devices allow the user limited movement in the horizontal and vertical planes. Typically the user must pivot on his or her feet to move forward or backward. Additionally, the rigid current foot abduction apparatuses make any movement difficult for the user. There is; therefore, a need for an improved orthosis that allows greater mobility in the horizontal and vertical planes for use in treating club feet and other gait issues using the Ponseti technique.
SUMMARY OF THE INVENTION
The improved abduction apparatus system for correcting gait issues allows the user, typically a patient with a club foot, greater mobility while wearing the brace. The at least two pivot points allow a greater range of movement in at least one of the horizontal and vertical planes. Several embodiments of the invention are possible to obtain the preferred result.
A first embodiment consists of a metal or plastic bar with connection means on the far sides of the bar. One coupling device is attached to each side of the metal bar and the coupling devices are pivotable in a vertical plane. Each coupling device is then attached to either a left footplate or a right footplate. The footplates are attached to the coupling device such that the angle of outward rotation may be periodically adjusted. The selected angle of outward rotation, may be maintained once the footplate is firmly secured to the coupling device. The user of the foot abduction apparatus can lift up each foot in the vertical plane via the pivot point while maintaining the corrective angle of outward rotation. The user may achieve horizontal movement by manipulating the device in a “waddling” motion. The same embodiment also allows a user to more easily crawl if the user is unable to walk.
A second embodiment of the invention allows a user to manipulate the device in a horizontal plane. This embodiment consists of two rigid bars connected to coupling devices on both ends of the bars. The coupling device maintains the rigid members in parallel. Also attached to the coupling device are footplates which can receive a shoe. The rigid bars are attached to the coupling devices such that they are selectively pivotable at the point of connection. A user of the second embodiment attaches the shoes to the footplates. The user then manipulates the device by pushing one foot forward. The force causes the rigid bars to pivot allowing horizontal movement of the user's feet.
A third embodiment of the invention is similar to the first two and contains at least a second pivot point and an additional metal or plastic bar. The two bars are substantially in parallel and contain a means for attachment at each end. A connecting device is attached to each side of the bars. The bars may pivot about the coupling device in a horizontal direction while maintaining the bars in parallel. Each coupling device contains a third pivot point which may be attached to either a left footplate or a right footplate. The third pivot point allows movement in the vertical plane. Again the footplate contains a means to adjust and maintain the angle of outward rotation. A left shoe may then be attached to the left footplate and a right shoe attached to the right footplate. The user of this embodiment of the invention may simultaneously manipulate the device in a vertical and horizontal direction without the “waddling” motion associated with the first embodiment.
The coupling devices of the embodiments are preferably a one-piece plastic made from rotomolding or injection molding techniques. The attachments means may be of any of several know techniques for attachment but preferably the means is a standard screw. Additionally, the preferred embodiment contains a metal or rigid plastic base with means for attachment to the left or right footplate. The base is contained within a soft substance on all sides. The soft substance is preferably silicone rubber which allows greater comfort and reduces the potential of an allergic reaction to the wearer of the invention as it cushions the foot.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view generally from the top-rear of the invention showing the single bar embodiment;
FIG. 2 is a perspective view of possible connecting devices for the invention;
FIG. 3 is a top view of the double bar design without vertical movement;
FIG. 4 is a side view of the double bar design without vertical movement;
FIG. 5 is a top view of the double bar design with vertical movement;
FIG. 6 is a rear view of the double bar design with vertical movement;
FIG. 7 is a right side view of the shoe;
FIG. 8 is a cross-sectional view of the shoe taken at line 8 ;
FIG. 9 is a bottom perspective of the boot in which the rigid sole is inserted on the top of the silicone rubber;
FIG. 10 is a right side view of the shoe;
FIG. 11 is a cross-sectional view of the shoe taken at line 11 ; and
FIG. 12 is a bottom perspective of the boot in which the rigid sole is placed within the silicone.
DETAILED DESCRIPTION
Now referring to the drawings, FIG. 1 shows a single bar foot abduction system 2 comprising a rigid member 4 , a first coupling device 6 , a left shoe receiving member 8 , a left plate 12 , a second coupling device 14 , a right shoe receiving member 16 and a right plate 18 . The system 2 allows the user of the device to lift and lower each foot independently through a first pivot point 20 and a second pivot point 22 .
The rigid member 4 may be comprised of a left rigid member 24 and a right rigid member 26 . The left rigid member 24 and the right rigid member 26 substantially overlap one another and are housed in the bar adjuster device (not shown). The bar adjuster device allows the length of the overlap of the left rigid member 24 and the right rigid member 26 to be varied; thus, controlling the overall length of the rigid member 4 . The greater the overlap of the left rigid member 24 and the right rigid member 26 , the shorter the overall length of the rigid member 4 .
The rigid member 4 further comprises a first end 28 and a second end 30 . The first end 28 may be selectively attachable to the first coupling device 6 by several known methods; however, the preferred mode of attachment is by a nut and bolt (not shown in order to demonstrate shape of coupling device 6 ). The first coupling device 6 may then be selectively attachable to the left plate 12 by the preferred means of a nut 9 and bolt 11 . The left plate 12 may then be attached to the left receiving shoe member 8 . The angle of the left shoe receiving member 8 in relation to the rigid member 4 may be adjusted by loosening the attachment mechanism securing the first coupling device 6 to the left plate 12 , manipulating the left plate 12 to the desired angle, and then retightening the attachment mechanism.
The second end 30 may be selectively attachable to the second coupling device 14 in the same manner as the first end 28 is attached to the first coupling device 6 . Similarly to the left plate 12 and its attachment to the first coupling device 6 and its attachment to the left shoe receiving member 8 , the right plate 18 is selectively attachable to the second coupling device 14 and the angle between the right shoe receiving member 16 in relation to the rigid member 4 may be adjusted. Referring additionally to FIG. 2 , the first coupling device 6 and the second coupling device 14 may be of a variety of configurations that allow movement in a vertical plane.
After the angle between the left shoe receiving member 8 and the rigid member 4 , and the angle between the right shoe receiving member 16 and the rigid member 4 are set; the user inserts his left shoe and right shoe (neither shown) into the appropriate shoe receiving member 8 or 16 . Once inserted, the shoes are held in place by any of several known attachment means including a snap-on means. As the user elevates or lowers his right foot, the rigid member 4 pivots about a first pivot point 20 located at the point where the rigid member 4 and the first coupling device 6 selectively attach. As the user elevates or lowers his left foot, the rigid member 4 pivots about a second pivot point 22 located at the point where the rigid member 4 and the second coupling device 14 selectively attach. The user may move in a horizontal direction by pivoting on the bottom of the left plate 12 or the right plate 18 in a shuffling type motion.
Now referring to FIG. 3 and FIG. 4 , a second embodiment of a foot abduction system 202 is detailed. The system 202 comprises a first rigid member 204 , a second rigid member 206 , a first coupling device 208 , a second coupling device 210 , a left plate 212 , a right plate 214 , a left shoe receiving member 216 , and a right shoe receiving member 218 . The first rigid member 204 and the second rigid member 206 lie within the same horizontal plane and are spaced such that they are substantially parallel with one another. Each rigid member 204 , 206 are preferably made of metal or a rigid plastic and further comprise a first end 220 , 222 respectively and a second end 224 , 226 respectively. The first ends 220 , 222 are selectively attachable to the first coupling device 208 , while the second ends 224 and 226 are selectively attachable to the second coupling device 210 .
The first coupling device 208 and the second coupling device 210 are preferably made of plastic and each further comprise three segments 230 , 231 , 232 . The coupling devices are preferably made by rotomolding or injection molding techniques. The segment 232 is preferably substantially perpendicular to segments 230 , 231 . The segment 230 of the first coupling device 208 is selectively attachable to the first end 220 of the first rigid member 204 ; and the segment 230 of the second coupling device 210 is selectively attachable to the second end 224 of the first rigid member 204 . The segment 231 of the first coupling device 208 is selectively attachable to the first end 222 of the second rigid member 206 ; and the segment 231 of the second coupling device 210 is selectively attachable to the second end 226 of the second rigid member 206 .
Again referring to FIG. 3 and FIG. 4 , the segment 232 of the first coupling device 208 is selectively attachable to the left plate 212 . The means for attachment is preferably two standard screws. The segment 232 of the second coupling device 210 is selectively attachable to the right plate 214 , again with a two screw attachment. Once each of the segments 230 , 231 , 232 of each coupling device 208 , 210 are selectively attached, the preferred embodiment has the rigid members 204 , 206 , the left plate 212 and the right plate 214 in a position such that they remain in a fixed angle position. The first coupling device 208 and the second coupling device 210 may be located on an underside 250 of the rigid members 204 , 206 or on an upper surface 252 of the rigid members 204 , 206 , although the preferred embodiment is on the underside 250 of the rigid member.
The left shoe receiving member 216 may be attached to the left plate 212 by a variety of known techniques including a screw. Similarly, the right shoe receiving member 218 is attached to the right plate 214 . The left shoe receiving member 216 and the left plate 212 define an angle which may be adjusted and selectively fixed. The right shoe receiving member 218 and the right plate 214 define an angle which may be adjusted and selectively fixed. A shoe (not shown) may be of any of those well known in the art which have the capability of attaching to the left shoe receiving member 216 or right shoe receiving member 218 . Additionally, the left plate 212 is preferably angled downward such that the bottom of the left shoe receiving member 218 is the same elevation as the bottom of the first coupling device 208 when the left plate 212 is attached to the left shoe receiving member 216 and the first coupling device 208 . Similarly, the right plate 214 is preferably angled such that the bottom of the right shoe receiving member 218 is the same elevation as the bottom of the second coupling device 210 when the right plate 214 is attached to the right shoe receiving member 218 and the second coupling device 210 .
The points at which the rigid members 204 , 206 attach to the first coupling device 208 and second coupling device 210 define pivot points 260 . The rigid members 204 , 206 are pivotable upon the first coupling device 208 and the second coupling device 210 . A user can then manipulate the device 202 in a first plane which would typically be the horizontal plane. As the user moves the right shoe receiving member 218 or the left shoe receiving member 216 in the horizontal plane, the rigid members 204 , 206 pivot allowing horizontal movement. As the rigid members 204 , 206 are substantially in parallel and there are at least four pivot points 260 , the rigid members 204 , 206 remain substantially in parallel with one another during operation. The horizontal movement is depicted by the first position of the device 202 evidenced by the dashed lines and the second position, indicated by solid lines. Additionally, the fixed positions of the left plate 212 and the right plate 214 ensure the angle defined by the left plate 212 and the left shoe receiving member 216 remain constant as well as the angle defined by the right plate 214 and the right shoe receiving member 218 remain constant during operation of the system 202 .
Now referring to FIG. 5 and FIG. 6 , a third embodiment of a foot abduction system 302 is detailed. The system 302 comprises a first rigid member 304 , a second rigid member 306 , a first coupling device 308 , a second coupling device 310 , a left plate 312 , a right plate 314 , a left shoe receiving member 316 , and a right shoe receiving member 318 . The first rigid member 304 and the second rigid member 306 lie within the same horizontal plane and are spaced such that they are substantially parallel with one another. Each rigid member 304 , 306 are preferably made of metal or a rigid plastic and further comprise a first end 320 , 322 respectively and a second end 324 , 326 respectively. The first ends 320 , 322 are selectively attachable to the first coupling device 308 , while the second ends 324 and 326 are selectively attachable to the second coupling device 310 .
The first coupling device 308 and the second coupling device 310 are preferably made of plastic or metal alloy and each further comprise three segments 330 , 331 , 332 . The coupling devices are preferably made by machining or injection molding techniques. The segment 332 is preferably substantially perpendicular to segments 330 , 331 . The segment 330 of the first coupling device 308 is selectively attachable to the first end 320 of the first rigid member 304 ; and the segment 330 of the second coupling device 310 is selectively attachable to the second end 324 of the first rigid member 304 . The segment 331 of the first coupling device 308 is selectively attachable to the first end 322 of the second rigid member 306 ; and the segment 331 of the second coupling device 310 is selectively attachable to the second end 326 of the second rigid member 306 .
Again referring to FIG. 5 and FIG. 6 , the segment 332 of the first coupling device 308 is selectively attachable to the left plate 312 . The segment 332 further comprises a slot 340 . The slot 340 is of a size and shape which allows left plate 312 to slide within the confines of the slot 340 . The segment 332 of the second coupling device 310 is selectively attachable to the right plate 314 . The segment 332 further comprises a slot 342 which is a size and shape which allow right plate 314 to slide within the confines of the slot 342 . The attachment means for connecting left plate 312 to the first coupling device 308 or the right plate 314 to the second coupling device 310 is preferably a bolt 350 and a nut 352 or a screw pin. (not shown). Once each of the segments 330 , 331 , 332 of each coupling device 308 , 310 are selectively attached the preferred embodiment has the rigid members 304 , 306 , the left plate 312 and the right plate 314 in a position such that they remain in a fixed position to one another. The first coupling device 308 and the second coupling device 310 may be located on an underside 370 of the rigid members 304 , 306 or on an upper surface 372 of the rigid members 304 , 306 , although the preferred embodiment has the coupling devices on the upper surface 372 of the rigid members 304 , 306 .
The left shoe receiving member 316 may be attached to the left plate 312 by a variety of known techniques including a screw. Similarly, the right shoe receiving member 318 is attached to the right plate 314 . The left shoe receiving member 316 and the left plate 312 define an angle which may be adjusted and selectively fixed. The right shoe receiving member 318 and the right plate 314 define an angle which may be adjusted and selectively fixed. A shoe (not shown) may be of any of those well known in the art which have the capability of attaching to the left shoe receiving member 316 or right shoe receiving member 318 . Additionally, the left plate 312 and the right plate 314 are preferably angled downward such that the bottom of the left shoe receiving member 316 and the right shoe receiving member 318 are the lowest elevation points of the device 302 .
The points at which the rigid members 304 , 306 attach to the first coupling device and second coupling device define pivot points 380 . The rigid members 304 , 306 are pivotable upon the first coupling device 308 and 310 . A user can then manipulate the device 302 in a first plane which would typically be the horizontal plane. As the user moves the right shoe receiving member 318 or the left shoe receiving member 316 in the horizontal plane, the rigid members 304 , 306 pivot allowing horizontal movement. As the rigid members 304 , 306 are substantially in parallel and there are at least four pivot points 360 , the rigid members 304 , 306 remain substantially in parallel with one another during operation. Additionally, the fixed positions of the left plate 312 and the right plate 314 ensure the angle defined by the left plate 312 and the left shoe receiving member 316 remain constant as well as the angle defined by the right plate 314 and the right shoe receiving member 318 remain constant. The dashed lines of FIG. 5 indicate a first horizontal position while the solid lines indicate a second position.
In addition to movement in a horizontal plane, unique pivot points 362 , 364 allow vertical movement as well. As a user lifts the left shoe receiving member 316 , the right plate 314 pivots about pivot point 362 allowing vertical movement. Similarly, when the user lifts the right shoe receiving member 318 , the left plate 312 pivots about pivot point 364 which allows vertical movement. The vertical movement is depicted in FIG. 6 in which a first position is shown by solid lines and a second position is shown by dashed lines. A user may manipulate the device in both the horizontal and vertical planes simultaneously.
Now referring to FIG. 7 , FIG. 8 and FIG. 9 , a boot 400 which may be attached to the foot abduction apparatuses 2 , 202 , 302 detailed above is shown. The boot 400 comprises a flexible portion 402 and a rigid sole 404 . Specifically referring to FIG. 8 , a cross-sectional portion of the boot 400 is shown. A cavity 406 is formed within the flexible portion 402 . The shape of the cavity 406 corresponds to the shape of the rigid sole 404 . The rigid sole 404 is inserted into the cavity 406 . Once in place, the flexible portion 402 surrounds a bottom surface 408 of the rigid sole 404 . The flexible portion 402 is preferably made of silicone which possesses a cushioning characteristic. The cushioning characteristic allows the user of the boot 400 more comfort and greater shock absorption.
Again referring to FIG. 7 , the rigid sole 404 is substantially planar. Once the rigid sole 404 is inserted into the cavity 406 , attachment means 410 may be used to connect the boot 400 to the shoe receiving members described in the embodiments described above. Preferably, the attachment means 410 are standard screws that may be counter sunk in the rigid sole 404 . Any number of attachment means 410 may be utilized, but the preferred embodiment has three attachment means 410 .
The flexible portion 402 comprises a heel extension 412 which is at a substantial perpendicular in relation to the rigid sole 404 . The heel extension 412 is shaped such that it conforms to a user's bank ankle, heel and lower back calf. The heel extension 412 also allows straps (not shown) to be connected to stabilize and support a user's foot and ankle. A heel hole 414 in the flexible portion 404 allows a doctor or parent to observe the placement of a user's ankle and heel to verify the correct positioning of the user's foot. Additionally, the flexible portion 402 comprises two flaps 414 which substantially cover the user's foot. The flaps 415 also allow straps to span the width of the shoe while protecting the user from the friction created by such straps.
Now referring to FIG. 10 , FIG. 11 and FIG. 12 another embodiment of a shoe 500 for a foot abduction apparatus is detailed. The boot 500 comprises a flexible portion 502 and a rigid sole 504 . Specifically referring to FIG. 8 , a cross-sectional portion of the boot 500 is shown. A cavity 506 is formed within the flexible portion 502 . The shape of the cavity 506 corresponds to the shape of the rigid sole 504 . The rigid sole 504 is inserted into the cavity 506 . The flexible portion 502 further comprises an edge 522 which is flexible. The cavity 506 and the edge 522 may be manipulated in such a way that the rigid sole 504 can be placed in the cavity 506 . The flexible portion comprising a groove, the groove extending in an oblong elliptical shape. The rigid sole comprising a first segment and a second segment, the first segment extending a greater distance than the second segment thereby creating a lip, the lip positioned within the groove whereby the rigid sole is secured in the flexible portion. The silicone is located under the first segment providing additional cushioning. The edge 522 maintains the rigid sole 504 in the flexible portion 502 . The flexible portion 502 is preferably made of silicone which possesses a cushioning characteristic. The cushioning characteristic allows the user of the boot 500 more comfort and greater shock absorption.
Again referring to FIG. 10 , the rigid sole 504 is substantially planar. Once the rigid sole 504 is inserted into the cavity 506 , attachment means 510 may be used to connect the boot 500 to the shoe receiving members described in the embodiments described above. Preferably, the attachment means 510 are standard screws that may be counter sunk in the rigid sole 504 . Any number of attachment means 510 may be utilized, but the preferred embodiment has three attachment means 510 .
The flexible portion 504 comprises a heel extension 512 which is at a substantial perpendicular in relation to the rigid sole 504 . The heel extension 512 is shaped such that it conforms to a user's bank ankle, heel and lower back calf. The heel extension 512 also allows straps (not shown) to be connected to stabilize and support a user's foot and ankle. A heel hole 514 in the flexible portion 504 allows a doctor or parent to observe the placement of a user's ankle and heel to verify the correct positioning of the user's foot. Additionally, the flexible portion 502 comprises two flaps 514 which substantially cover the user's foot. The flaps 515 also allow straps to span the width of the shoe while protecting the user from the friction created by such straps.
Having thus described the invention in connection with the preferred embodiments thereof, it will be evident to those skilled in the art that various revisions can be made to the preferred embodiments described herein with out departing from the spirit and scope of the invention. It is my intention, however, that all such revisions and modifications that are evident to those skilled in the art will be included with in the scope of the following claims.
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An improved foot abduction apparatus allowing movement in a horizontal and vertical plane. The embodiments allow a user to more easily manipulate the apparatus in one or both planes through the use of strategically placed pivot points. The device utilizes at least one rigid member attached to coupling devices which contain at least one pivot point. The specialized coupling devices may be selectively attached to shoe receiving member or plates which are well known in the art. Additionally the shoe receiving members are able to receive an improved shoe containing a sole member contained with a silicone boot.
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CROSS REFERENCE TO RELATED APPLICATIONS
This is a Continuation application of U.S. patent application Ser. No. 14/840,336 filed on Aug. 31, 2015 which claims priority from and the benefit under 35 U.S.C. §119(a) of Korean Patent Application No. 10-2014-0115394, filed on Sep. 1, 2014, which is hereby incorporated by reference for all purposes as if fully set forth herein.
BACKGROUND
1. Field of the Disclosure
The present disclosure relates to electronic devices, and more particularly to a method and apparatus for managing audio signals.
2. Description of the Prior Art
Recently, the electronic device has provided a function to record another party's voice at the usual time or during a phone call, as well as basic functions, such as telephony or sending messages, to a user.
The electronic device includes a microphone for voice recording. The electronic device includes a plurality of microphones in order to thoroughly record audio signals. The plurality of microphones recognizes the direction of a speaker, and implements beams in the direction to thereby thoroughly record a voice that comes from the direction of the speaker. The beams may be implemented by applying a weight value to the microphones in order to increase the amplitude of the audio signal.
SUMMARY
According to one aspect of the disclosure, a method is provided comprising: detecting a first acoustic signal by using a microphone array; detecting a first angle associated with a first incident direction of the first acoustic signal; and storing, in a memory, a representation of the first acoustic signal and a representation of the first angle.
According to another aspect of the disclosure, an electronic device is provided comprising: a microphone array; a memory; a speaker; and at least one processor configured to: detect a first acoustic signal by using a microphone array; detect a first angle associated with a first incident direction of the first acoustic signal; and store, in a memory, a representation of the first acoustic signal and a representation of the first angle.
BRIEF DESCRIPTION OF THE DRAWINGS
The above features and advantages of the present disclosure will be more apparent from the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 is a block diagram of an example of an electronic device, according to various embodiments of the present disclosure;
FIG. 2 is a flowchart of an example of a process, according to embodiments of the present disclosure;
FIG. 3 is a flowchart of an example of a process, according to various embodiments of the present disclosure;
FIG. 4 is a diagram of an example of a system implementing the process of FIG. 3 , according to various embodiments of the present disclosure;
FIG. 5 is a diagram of an example of a stored audio signal, according to various embodiments of the present disclosure;
FIG. 6 is a diagram of an example of a system for rendering audio, according to various embodiments of the present disclosure;
FIG. 7 is a diagram illustrating an example of a rendered audio signal, according to various embodiments of the present disclosure;
FIG. 8 is a flowchart of an example of a process, according to various embodiments of the present disclosure;
FIG. 9 is a diagram of an example of a system implementing the process of FIG. 8 , according to various embodiments of the present disclosure;
FIG. 10 is a diagram of an example of a stored audio signal according to various embodiments of the present disclosure;
FIG. 11 is a diagram of a system for rendering recorded audio signals, according to various embodiments of the present disclosure;
FIG. 12 is a flowchart of an example of a process, according to various embodiments of the present disclosure;
FIG. 13 is a diagram of an example of a system implementing the process of FIG. 12 , according to various embodiments of the present disclosure;
FIG. 14 is a diagram of a stored audio signal, according to various embodiments of the present disclosure;
FIG. 15 is a diagram of an example of a system for rendering a stored audio signal, according to various embodiments of the present disclosure;
FIG. 16 is a diagram illustrating an example a process for recording audio, according to various embodiments of the present disclosure;
FIG. 17 is a diagram of an example of a user interface for rendering audio, according to various embodiments of the present disclosure;
FIG. 18 is a diagram of an example of a user interface for rendering audio, according to various embodiments of the present disclosure;
FIG. 19 is a diagram of an example of a user interface for rendering audio, according to various embodiments of the present disclosure;
FIG. 20 is a diagram illustrating an example of a process for recording audio, according to various embodiments of the present disclosure; and
FIG. 21 is a diagram of an example of a user interface for rendering audio, according to various embodiments of the present disclosure.
DETAILED DESCRIPTION
Hereinafter, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. It will be easily appreciated by those skilled in the art that various modifications, additions and substitutions are possible in the embodiments disclosed herein, and that the scope of the disclosure should not be limited to the following embodiments. The embodiments of the present disclosure are provided such that those skilled in the art completely understand the disclosure. In the drawings, the same or similar elements are denoted by the same reference numerals even though they are depicted in different drawings.
The expressions such as “include” and “may include” which may be used in the present disclosure denote the presence of the disclosed functions, operations, and constituent elements and do not limit one or more additional functions, operations, and constituent elements. In the present disclosure, the terms such as “include” and/or “have” may be construed to denote a certain characteristic, number, step, operation, constituent element, component or a combination thereof, but may not be construed to exclude the existence of or a possibility of the addition of one or more other characteristics, numbers, steps, operations, constituent elements, components or combinations thereof.
In the present disclosure, the expression “and/or” includes any and all combinations of the associated listed words. For example, the expression “A and/or B” may include A, may include B, or may include both A and B.
In the present disclosure, expressions including ordinal numbers, such as “first” and “second,” etc., and/or the like, may modify various elements. However, such elements are not limited by the above expressions. For example, the above expressions do not limit the sequence and/or importance of the elements. The above expressions are used merely for the purpose of distinguishing an element from the other elements. For example, a first user device and a second user device indicate different user devices although for both of them the first user device and the second user device are user devices. For example, a first element could be termed a second element, and similarly, a second element could be also termed a first element without departing from the scope of the present disclosure.
When a component is referred to as being “connected to” or “accessed by” another component, it should be understood that not only the component is directly connected or accessed to the other component, but also another component may exist between the component and the other component. Meanwhile, when a component is referred to as being “directly connected” or “directly accessed” to other component, it should be understood that there is no component therebetween.
The terms used in the present disclosure are only used to describe specific various embodiments, and are not intended to limit the present disclosure. Singular forms are intended to include plural forms unless the context clearly indicates otherwise.
Unless otherwise defined, all terms including technical and/or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the disclosure pertains. In addition, unless otherwise defined, all terms defined in generally used dictionaries may not be overly interpreted.
For example, the electronic device corresponds to a combination of at least one of the followings: a smartphone, a tablet Personal Computer (PC), a mobile phone, a video phone, an e-book reader, a desktop PC, a laptop PC, a netbook computer, a Personal Digital Assistant (PDA), a Portable Multimedia Player (PMP), a digital audio player (e.g., MP3 player), a mobile medic device, a camera, or a wearable device. Examples of the wearable device are a head-mounted-device (HMD) (e.g., electronic eyeglasses), electronic clothing, an electronic bracelet, an electronic necklace, an appcessory, an electronic tattoo, a smart watch, etc.
The electronic device according to the embodiments of the present disclosure may be smart home appliances. Examples of the smart home appliances are a television (TV), a Digital Video Disk (DVD) player, an audio system, a refrigerator, an air-conditioner, a cleaning device, an oven, a microwave oven, a washing machine, an air cleaner, a set-top box, a TV box (e.g., Samsung HomeSync™, Apple TV™, or Google TV™, a game console, an electronic dictionary, an electronic key, a camcorder, an electronic album, or the like.
The electronic device according to the embodiments of the present disclosure may include at least one of the following: medical devices (e.g., Magnetic Resonance Angiography (MRA), Magnetic Resonance Imaging (MRI), Computed Tomography (CT), a scanning machine, an ultrasonic scanning device, etc.), a navigation device, a Global Positioning System (GPS) receiver, an Event Data Recorder (EDR), a Flight Data Recorder (FDR), a vehicle infotainment device, an electronic equipment for ships (e.g., navigation equipment, gyrocompass, etc.), avionics, a security device, a head unit for vehicles, an industrial or home robot, an automatic teller's machine (ATM), a point of sales (POS) system, etc.
The electronic device according to the embodiments of the present disclosure may include at least one of the following: furniture or a portion of a building/structure, an electronic board, an electronic signature receiving device, a projector, various measuring instruments (e.g., a water meter, an electric meter, a gas meter and a wave meter), etc. respectively. The electronic device according to the embodiments of the present disclosure may also include a combination of the devices listed above. In addition, the electronic device according to the embodiments of the present disclosure may be a flexible device. It is obvious to those skilled in the art that the electronic device according to the embodiments of the present disclosure is not limited to the aforementioned devices.
Hereinafter, electronic devices according the embodiments of the present disclosure are described in detail with reference to the accompanying drawings. In the description, the term a ‘user’ may be referred to as a person or a device that uses an electronic device, e.g., an artificial intelligent electronic device.
FIG. 1 is a block diagram of an example of an electronic device, according to various embodiments of the present disclosure. Referring to FIG. 1 , the electronic device 100 may include a controller 110 , a microphone unit 130 , a speaker 140 , a memory 160 , and a communication unit 180 . The controller 110 may control overall operations of the electronic device 100 and the signal traffic between internal elements of the electronic device 100 , and may perform a data processing function. For example, the controller 110 may be formed of a central processing unit (CPU), or an application processor (AP). In addition, the controller 110 may be formed of a single-core processor, or a multi-core processor.
The controller 110 may include at least one processor. Each of the processors may include any combination of: one or more general-purpose processors (e.g., ARM-based processors, multi-core processors, etc.), a Field-Programmable Gate Array (FPGA), an Application-Specific Integrated Circuit (ASIC), a Digital Signal Processor (DSP), a Programmable Logic Device (PLD), and/or any other suitable type of processing circuitry. Additionally or alternatively, the controller 110 , may include a speaker position detecting unit 111 , a beamformer 113 , a pulse-code-modulation (PCM) file creating unit 117 , a coder 121 , a decoder 123 , and a user angle selecting unit 127 .
The speaker position detecting unit 111 may find the direction of an audio signal that has the highest level of energy from among audio signals received from a plurality of microphones 130 . Here, the direction may be angle information. The speaker position detecting unit 111 may recognize the direction to which the speaker currently speaks, using energy information, phase information, or correlation information between the microphones. When a plurality of speakers simultaneously speak, the speaker position detecting unit 111 may recognize the angle information in order of the intensity of energy of the audio signals created by the speakers.
The beamformer 113 may give weight values to the microphones to increase the amplitude of the audio signal so that beams, which are able to spatially reduce the related noise when the direction of the audio signal and the direction of the noise are different from each other.
With regard to the formation of the beams, a sound wave created in the sound source travels a different distance to each microphone. Since the sound wave has a limited speed, the sound wave will reach each microphone at a different time instant. However, apart from the time difference, the sound waves created from the same sound source may be recognized as the same wave at each microphone. Therefore, if the position of the sound source is given, the arriving time difference of the sound wave may be calculated for the correction thereof to thereby make the waves match each other.
The PCM file creating unit 117 may convert the audio signals input from a plurality of microphones 130 into PCM files. Here, the PCM file refers to the file that is stored as a digital signal converted from an analog signal, i.e., the audio signal. If the analog signal is stored without the conversion, it may be affected by the noise, so the analog signal is to be converted into the digital signal to then be stored. The created PCM file may be transmitted to a D/A converter. The D/A converter may convert the digital signal into the analog signal. The PCM file may be converted into the analog file through the D/A converter, and the converted audio signal may be finally transmitted to the speaker 140 to be thereby output to the user.
The coder 121 may store the recorded audio signal as a compressed file using a codec in order to reduce the storage capacity of the audio signal that has been converted into the digital signal. The coder 121 may receive the angle information corresponding to the speaker from the speaker position detecting unit 111 , and may store the same together with the recorded audio signal corresponding thereto.
The decoder 123 may decompress the file compressed through the coder 121 . The user angle selecting unit 127 may recognize the angle selection of the user. The user angle selecting unit 127 may recognize the speaker selection of the user as well as the angle selection. If the user wishes to hear the audio signal of the speaker “B,” or the audio signal of 90° that is mapped with the speaker “B,” the user angle selecting unit 127 may select the speaker “B,” or 90°. The user may select the same in a list or through a specific user interface (UI).
The microphone unit 130 may include a plurality of microphones. One or more microphones may receive the audio signals. The received audio signal may be recorded by the controller 110 , and may be used in calculating the position of the speaker.
The speaker 140 may reproduce the audio signal received through at least one microphone. The audio signal may be reproduced by the instruction of the controller 110 according to the user's selection.
A touch screen 150 may receive the angle information from the user angle selecting unit 127 of the controller 110 , and may display the same. Here, the angle information is stored as a file in the memory 160 together with the audio signal corresponding thereto. The touch screen 150 may detect the user's selection for one or more of the displayed angles, and may transfer the selected angle to the user angle selecting unit 127 .
In addition, the touch screen 150 may receive a recorded audio signal list from the controller 110 . The touch screen 150 may display the received recorded audio signal list. The touch screen 150 may receive text which is generated based on the audio signal associated with a specific speaker. The text may be generated by using a text-to-speech (TTS) by the controller 110 . The recorded audio signal list may permit the user to the content of each audio signal.
The memory 160 may include at least one of an internal memory or an external memory. The internal memory, for example, may include at least one of a volatile memory {e.g., a DRAM (dynamic random access memory), an SRAM (static random access memory), an SDRAM (synchronous dynamic random access memory, or the like}, a non-volatile memory {e.g., an OTPROM (one time programmable read-only memory), a PROM (programmable read-only memory), an EPROM (erasable and programmable read-only memory), an EEPROM (electrically erasable and programmable read-only memory), a mask read-only memory, a flash read-only memory, or the like}, an HDD (hard disk drive), or a solid-state drive (SSD). The external memory may include at least one of a CF (compact flash), SD (secure digital), Micro-SD (micro secure digital), Mini-SD (mini secure digital), xD (extreme digital), a memory stick, a network-accessible storage (NAS), a cloud storage or the like. The memory 160 may store the audio file compressed by the coder 121 .
The communication unit 180 may connect the electronic device 100 with external electronic devices. For example, the communication unit 180 may be connected to a network through wireless or wired communication to thereby communicate with the external electronic devices. The wireless communication may include Wi-Fi, BT (Bluetooth), NFC (near field communication), or the like. In addition, the wireless communication may include at least one selected from among the cellular communication networks (e.g., LTE, LTE-A, CDMA, WCDMA, UMTS, WiBro, GSM, or the like). For example, the wired communication may include at least one of a USB (universal serial bus), an HDMI (high definition multimedia interface), RS-232 (recommended standard 232), or a POTS (plain old telephone service).
FIG. 2 is a flowchart of an example of a process, according to embodiments of the present disclosure. Referring to FIG. 2 , the controller 110 may recognize a user's request to begin the audio recording. In operation 203 , the controller 110 may identify a plurality of angles. For example, the plurality of angles may be the angles of audio signals to be received. In some implementations, the controller 110 may map each of the received audio signals to a different one of a plurality of angles at an interval of 90 degrees, i.e., at the angles of 0°, 90°, 180°, and 270°, to thereby store the same. For example, the controller 110 may receive the audio signals from four microphones to detect the position of the speaker using energy information, phase information, or correlation information between the microphones. In instances in which the controller 110 recognizes that the position of the speaker is 80°, the controller 110 may configure the position of the speaker as 90°, which is the relatively approximate value compared with other angles.
In operation 205 , the controller 110 may receive a plurality of audio signals through a plurality of microphones of the microphone unit 130 .
In operation 207 , the controller 110 may extract the audio signal that has the highest level of energy from the plurality of audio signals received from the plurality of microphones to thereby detect the angle of the audio signal. In operation 207 , the controller 110 may map the detected angle to one of the plurality of angles identified in operation 203 . For example, if the controller 110 determines that the audio signal having the highest level of energy is received at an angle of 160°, the controller 110 may map the audio signal with 180°, which is the approximate value compared to other angles.
In operation 209 , the controller 110 may determine whether angles in the plurality identified in operation 203 have not been processed yet. For example, since the controller 110 configures that four audio signals are to be received at an interval of 90° in operation 203 , the controller 110 , which has received one audio signal in operation 207 , may determine that there are three audio signals that have not yet been detected. If it is determined that there are angles that have not yet been processed, the controller 110 may proceed to operation 211 . In operation 211 , the controller 110 may detect the angle of the audio signal that has the highest level of energy from among the remaining audio signals rather than the detected audio signal. For example, if the angle of the detected audio signal is 90°, the audio signal may be mapped with 90°.
The controller 110 may return to operation 209 after detecting the angle of the audio signal that has the highest energy level from among the remaining audio signals in operation 211 .
The controller 110 may repeat the operation above, and if all of the configured angles are detected, that is, if it is determined that no angle that is not detected exists, the controller 110 may terminate the operation.
FIG. 3 is a flowchart of an example of a process, according to various embodiments of the present disclosure. FIG. 4 is a diagram of an example of a system implementing the process of FIG. 3 , according to various embodiments of the present disclosure.
The operation of FIG. 3 will be described in association with the signal flow of FIG. 4 . In operation 301 , the controller 110 may begin recording audio. For example, the controller 110 may recognize a user's request to begin the audio recording. Three microphones of the microphone unit 130 shown in FIG. 4 are used. Three A/D converters 410 may convert the audio signals received from the plurality of microphones into the digital files. The three A/D converters 410 may transfer the audio signals, which have been converted into the digital files, to the controller 110 .
In operation 303 , the controller 110 may detect the position of the speaker. That is, the controller 110 may recognize the angle corresponding to the audio signal, when the audio signal is received. In operation 305 , the controller 110 may select one of the three microphones. Here, the microphones may be omnidirectional microphones. In operation 307 , the controller 110 may record the audio signal using the selected microphone. In operation 309 , the PCM file creating unit 117 and the speaker position detecting unit may receive the audio signal, which has been converted into the digital signals, from the A/D converter 410 . The coder 121 of the controller 110 may encode the angle information, which is received from the speaker position detecting unit 111 , the PCM file containing the audio signal. In addition, the coder 121 of the controller 110 may also encode time information into the PCM file. The time information may include a period of time for recording the audio signal, or the start time and the end time of the recording. The coder 121 of the controller 110 may transfer the compressed audio file to the memory 160 to store the same therein.
FIG. 5 is a diagram of an example of a stored audio signal, according to various embodiments of the present disclosure.
FIG. 5 shows the file recorded as a result of executing the process of FIG. 3 , and the horizontal axis in FIG. 5 denotes time in which the unit may be a second. In addition, the vertical axis thereof denotes the magnitude of the audio signal in which the unit may be a decibel (dB). FIG. 5 shows an example in which the audio signals corresponding to several angles are stored as a single file. It shows that the audio signals, and the angles, at which the audio signals are received, are stored together. In addition, it shows that the recording time of each audio signal is stored as well. The recording time may be expressed as the length of the section for the audio signal of each speaker in the file.
Referring to the recorded file, the audio signal A ( 510 a ) occurs at an angle of 0° ( 520 a ). The audio signal B ( 510 b ) occurs at an angle of 90° ( 520 b ). The audio signal C ( 510 c ) occurs at an angle of 180° ( 520 c ). The audio signal D ( 510 d ) occurs at an angle of 270° ( 520 d ). Comparing the section of the audio signal A with the section of the audio signal B, the section of the audio signal A ( 510 a ) is shorter than the section of the audio signal B ( 510 b ). This means that the recording time for the audio signal A ( 510 a ) is shorter than the recording time of the audio signal B ( 510 b ).
FIG. 6 is a diagram of an example of a system for rendering audio, according to various embodiments of the present disclosure.
Referring to FIG. 6 , the controller 110 may receive the compressed and stored audio file from the memory 160 . The controller 110 may transfer the compressed audio file to the decoder 123 . In addition, the controller 110 may transfer the angle information corresponding to the compressed audio file to the user angle selecting unit 127 . The user angle selecting unit 127 may transfer the angle information to the touch screen 150 . The touch screen 150 may display all angles identified by the angle information to allow the user to select at least one thereof. The touch screen 150 may transfer the angle selected by the user to the user angle selecting unit 127 . The user angle selecting unit 127 may transfer the angle selected by the user to the PCM file creating unit 117 . The PCM file creating unit 117 may transform only the audio signal corresponding to the selected angle into a PCM file, and may transfer the same to the D/A converter.
The D/A converter 610 may convert the PCM file into an analog signal and feed the analog signal to the speaker 140 . The D/A converter 610 may transfer the converted audio signal to the speaker 140 , and the speaker 140 may output the audio signal.
FIG. 7 is a diagram illustrating an example of a rendered audio signal, according to various embodiments of the present disclosure.
FIG. 7 shows the reproduced audio signal, and the horizontal axis denotes the time in which the unit may be a second. In addition, the vertical axis denotes the magnitude of the audio signal in which the unit may be a decibel (dB). When the user wishes to listen to only the audio signal at an angle of 90° ( 520 b ), the audio signal 510 b corresponding to the angle of 90° among all of the audio signals is reproduced. That is, the audio signals corresponding to the angles rather than 90° may not be reproduced. If the controller 110 recognizes the user's selection for the audio signal of 180°, the controller 110 may reproduce only the audio signal corresponding to the angle of 180° among all of the files.
FIG. 8 is a flowchart of an example of a process, according to various embodiments of the present disclosure. FIG. 9 is a diagram of an example of a system implementing the process of FIG. 8 , according to various embodiments of the present disclosure.
The operation of FIG. 8 will be described in association with the signal flow of FIG. 9 . In operation 801 , the controller 110 may perform the audio recording. The controller 110 may recognize a user's request to begin the audio recording. As shown in FIG. 9 , three microphones may be used by the controller 110 to receive audio signals. Three A/D converters 910 may convert the audio signals received from the plurality of microphones into digital files. The three A/D converters 910 may transfer the audio signals, which have been converted into the digital files, to the controller 110 .
In operation 803 , the controller 110 may detect the position of the speaker. For example, the controller 110 may recognize the angle corresponding to a received audio signal. As shown in FIG. 9 , the audio signals received by the microphone are converted into the digital signals through the A/D converters 910 to be then transferred to the speaker position detecting unit 111 . The speaker position detecting unit 111 may recognize the angles corresponding to the received audio signals, and may transfer information corresponding to the angles to the beamformer 113 .
In operation 805 , the beamformer 113 of the controller 110 may form a beam at the detected angle of the speaker. In instances in which several audio signals are received at different angles through the microphones, the beamformer 113 may form a beam at an angle of the audio signal that has the highest energy level. In operation 807 , the controller 110 may store the audio signal recorded by forming the beam, and angle information and time information corresponding thereto.
In operation 809 , the controller 110 may determine whether or not the position of the speaker has changed. The speaker position detecting unit 111 may recognize the angle of a received audio signal to thereby determine that the position of the speaker has changed. If the speaker position detecting unit 111 of the controller 110 determines that the angle of the received audio signal, i.e., the angle of the speaker, is changed, the controller may return to operation 803 . If the speaker position detecting unit 111 of the controller 110 determines that the angle of the speaker is not changed, the controller may return to operation 805 .
As shown in FIG. 9 , the beamformer 113 of the controller 110 may transfer the audio signal, which is obtained by implementing the beam, to the PCM file creating unit 117 . The PCM file creating unit 117 of the controller 110 may create the audio signal received from the beamformer 113 as a PCM file to transfer the same to the coder 121 . In operation 809 , the coder 121 may compress the PCM file and the angle information received from the speaker position detecting unit 111 to create an audio file. In addition, the coder 121 of the controller 110 may compress the time information of the received audio signal in the audio file as well. The coder 121 may store the compressed audio file in the memory 160 .
FIG. 10 is a diagram of an example of a stored audio signal, according to various embodiments of the present disclosure. FIG. 10 shows the file recorded through the operation of FIG. 8 , and the horizontal axis thereof denotes the time in which the unit may be a second. In addition, the vertical axis thereof denotes the magnitude of the audio signal in which the unit may be a decibel (dB). FIG. 5 shows an example in which that the audio signals corresponding to several angles are stored as a single file. In this example, the audio signals, which are received through the beamforming, and the angles, at which the audio signals are received, are stored together. In addition, the recording time of each audio signal may be stored, in the file as well. The recording time may be expressed as the length of the section for the audio signal of each speaker in the file.
Referring to the recorded file, the audio signal A ( 1010 a ) occurs at an angle of 0° ( 1020 a ). The audio signal B ( 1010 b ) occurs at an angle of 90° ( 1020 b ). The audio signal C ( 1010 c ) occurs at an angle of 180° ( 1020 c ). The audio signal D ( 1010 d ) occurs at an angle of 270° ( 1020 d ). Comparing the section of the audio signal A ( 1010 a ) with the section of the audio signal B ( 1010 b ), the section of the audio signal A ( 1010 a ) is shorter than the section of the audio signal B ( 1010 b ). This means that the recording time for the audio signal A ( 1010 a ) is shorter than the recording time of the audio signal B ( 1010 b ).
FIG. 11 is a diagram of a system for rendering recorded audio signals, according to various embodiments of the present disclosure.
Referring to FIG. 11 , the user angle selecting unit 127 of the controller 110 may receive angle information corresponding to each audio signal from the memory 160 . The decoder 123 of the controller 110 may receive the compressed audio file from the memory 160 , and may decompress the same. The PCM file creating unit 117 of the controller 110 may receive the audio signal from the decoder 123 , and may transform the same into a PCM file. The audio signal transformed by the PCM file creating unit 117 may be transferred to the D/A converter 1110 so that the angle information is received from the user angle selecting unit 127 and only the audio signal corresponding to the angle is to be reproduced.
The D/A converter 1110 may convert the PCM file of a digital signal into an analog signal and feed the analog signal to the speaker 140 . The D/A converter 1110 may transfer the converted audio signal to the speaker 140 , and the speaker 140 may output the audio signal.
FIG. 12 is a flowchart of an example of a process, according to various embodiments of the present disclosure. FIG. 13 is a diagram of an example of a system for implementing the process of FIG. 12 , according to various embodiments of the present disclosure.
The operation of FIG. 12 will be described in association with the signal flow of FIG. 13 . In operation 1201 , the controller 110 may begin recording audio. For example, the controller 110 may recognize a user's request to begin the audio recording. As shown in FIG. 13 , three microphones are used by the controller 110 to receive the audio signals. A plurality of A/D converters 1310 may convert the audio signals received from three microphones into digital files. Three A/D converters 1310 may transfer the audio signals, which have been converted into the digital files, to the controller 110 .
In operation 1203 , the controller 110 may detect the positions of a plurality of speakers. That is, when a plurality of audio signals is received, the controller 110 may recognize the angles corresponding to the audio signals. As shown in FIG. 13 , the audio signals received by the three microphones are converted into digital signals by the A/D converter 1310 to be then transferred to the speaker position detecting unit 111 . The speaker position detecting unit 111 may recognize the angles corresponding to the received audio signals, and may transfer an indication of each angle to the beamformers 113 a to 113 c.
In operation 1205 , the beamformers 113 a to 113 c of the controller 110 may form beams at each all of the detected angles, respectively. In addition, the beamformers 113 a to 113 c of the controller 110 may form the beams only at angles of the audio signals that have greater energies than a predetermined value. As shown in FIG. 13 , the beamformers 113 a to 113 c of the controller 110 may transfer the audio signals, which are obtained by implementing the beams, to the PCM file creating units 117 a to 117 c . The PCM file creating units 117 a to 117 c of the controller 110 may transform the audio signals received from the beamformers 113 a to 113 c into the PCM files to transfer the same to the coder 121 . In operation 1207 , the coder 121 may create audio files by associating the PCM files with a plurality of pieces of the angle information received from the speaker position detecting unit 111 to thereby compress the same. In addition, the coder 121 of the controller 110 may compress the time information of the received audio signals in the audio file as well. The coder 121 may store the compressed audio files in the memory 160 .
FIG. 14 is a diagram of a stored audio signal, according to various embodiments of the present disclosure.
FIG. 14 shows the file recorded through the operation of FIG. 12 , and the horizontal axis thereof denotes the time in which the unit may be a second. In addition, the vertical axis thereof denotes the magnitude of the audio signal, in which the unit may be a decibel (dB). FIG. 14 shows an example in which the audio signals corresponding to the angles are stored as respective files. In addition, it is assumed that the audio signals of the files are recorded in an order of time in FIG. 14 . In the example FIG. 14 , the audio signals received through the beamforming, and the angles, at which the audio signals are received, may be stored together. In addition, it shows that the recording time of each audio signal is stored as well. The recording time may be expressed as the length of the section for the audio signal of each speaker in the file.
Referring to the recorded file, the audio signal A ( 1410 a ) stored in File 1 occurs at an angle of 0° ( 1420 a ). The audio signal B ( 1410 b ) stored in File 2 occurs at an angle of 90° ( 1420 b ). The audio signal C ( 1410 c ) stored in File 3 occurs at an angle of 180° ( 1420 c ). The audio signal D ( 1410 d ) stored in File 4 occurs at an angle of 270° ( 1420 d ).
In addition, although it is not shown in the drawing, the respective representations of all audio signals may be encapsulated in the same file. For example, when another audio signal occurs at the angle of 0° ( 1420 a ), another audio signal 1410 a may be stored in File 1 . If another audio signal additionally occurs after the audio signal 1410 d is stored, the additionally created audio signal may be stored after the audio signal 1410 d in File 1 . In addition, if another audio signal additionally occurs in the middle of storing the audio signal 1410 c , the additionally created audio signal may be stored at the same time as the audio signal 1410 c of the speaker C ( 1401 c ) in File 1 .
FIG. 15 is a diagram of an example of a system for rendering a stored audio signal, according to various embodiments of the present disclosure.
Referring to FIG. 15 , the user angle selecting unit 127 of the controller 110 may receive the position information, i.e., the angle information corresponding to the speaker from the memory 160 . The user angle selecting unit 127 may transfer the received angle information to the touch screen 150 , and the touch screen 150 may display the angles corresponding to the received angle information. The user angle selecting unit 127 may recognize the angle selected by the user on the touch screen 150 . The user angle selecting unit 127 may transfer the selected angle to the decoder 123 , and the decoder 123 may receive only the file corresponding to the selected angle from the memory 160 . The decoder 123 may decompress the received file, and may perform the buffer and mixing process 1570 with respect to the file corresponding to the angle selected by the user angle selecting unit 127 . The controller 110 may transfer the processed file to the PCM file creating unit 117 , and the PCM file creating unit 117 may transform the transferred file to a PCM file. The file created by the PCM file creating unit 117 may be transferred to the D/A converter 1510 . The D/A converter 1510 may convert the PCM file of the digital signal into an analog signal and feed the analog signal to the speaker 140 . The D/A converter 1510 may transfer the converted audio signal to the speaker 140 , and the speaker 140 may output the audio signal.
FIG. 16 is a diagram illustrating an example a process for recording audio, according to various embodiments of the present disclosure. Three microphones may be arranged in different directions from each other. One or more beams may be formed through a combination of three microphones.
As shown in the drawing, three microphones 1641 , 1642 , and 1643 are disposed in different directions from each other, and four beams 1611 , 1612 , 1613 , and 1614 may be formed through a combination of the three microphones 1641 , 1642 , and 1643 . Each of the beams 1611 , 1612 , 1613 , and 1614 may receive the audio signal only at its formed angle. The received audio signals may be stored together with angle information corresponding thereto.
FIG. 17 is a diagram of an example of a user interface for rendering audio, according to various embodiments of the present disclosure.
Referring to FIG. 17 , the controller 110 may display a UI on the touch screen 150 , which allows the user to reproduce an audio signal that is associated with a desired direction. In an embodiment, the UI may include identifiers, which indicate the locations of the speakers relative to a microphone array used to record the sound produced by the speakers. The identifiers may be displayed on the circle to correspond to the angles of the speakers. As shown in the drawing, an identifier A ( 1701 a ), an identifier B ( 1701 b ), an identifier C ( 1701 c ), and an identifier D ( 1701 d ) are displayed at the positions corresponding to 0°, 90°, 180°, and 270°, which may be approximate locations of the speakers relative to the microphone array.
If the user selects at least one of the identifiers, the controller 110 may reproduce the audio file associated with the angle corresponding to the identifier. In addition, if the user selects the all-play button 1750 , the controller 110 may reproduce all of the audio files through the speaker. All of the audio files may be the files that include the audio signals at all angles.
FIG. 18 is a diagram of an example of a user interface for rendering audio, according to various embodiments of the present disclosure.
Referring to FIG. 18 , the controller 110 may display a list that allows the user to select an audio signal that is associated with a desired direction. The list may include an identifier that indicates the speaker, a play button 1850 , a stop button 1860 , and a recording time 1870 . If the user selects one of the identifiers 1801 a to 1801 d , the controller 110 may reproduce the stored audio file corresponding to the selected identifier through the speaker 140 . For example, when the user selects the play button 1850 in order to listen to the audio signal of the identifier A ( 1801 a ), the controller 110 may reproduce the stored audio file associated with the identifier 1801 a for 3 min 40 sec.
In addition, when one of the identifiers is selected by the user, the controller 110 may provide section information corresponding to the selected identifier. The section information may be the information indicating the start time and the end time of the recorded audio signal of the speaker corresponding to the selected identifier among the entire recording time. The controller 110 may express the section information as images or numbers.
For example, when the user selects the identifier A ( 1801 a ), the controller 110 may provide the section information corresponding to the selected identifier A ( 1801 a ). The section information of the identifier A ( 1801 a ) may be the information stating that the audio signal is recorded from the time of 3 min to the time of 6 min 40 sec of the whole recording time of 27 min 35 sec. The controller 110 may provide the section information when the user selects the identifier A ( 1801 a ), or may display the section information in the list or in the reproduced image when the recording time is selected or while the audio file is reproduced.
FIG. 19 is a diagram of an example of a user interface for rendering audio, according to various embodiments of the present disclosure.
The controller 110 may identify the speakers of the recorded audio signals as well as the audio signals according to the angles. To this end, the controller 110 may pre-store speaker recognition information using a sound-shot function before performing the audio recording. The speaker recognition information may include the waves of the audio signals and photos of the speakers. The sound-shot function refers to the function of storing the audio signal recorded when taking a photo, together with the photo.
For example, if the user photographs the face of the speaker A ( 1900 a ) and records the audio signal 1910 a of the speaker using the sound-shot function, the controller 110 may map the photo with the audio signal to thereby store the same as a single audio file 1901 a in the memory 160 . As shown in FIG. 19 , the photos of the speaker A ( 1900 a ), the speaker B ( 1900 b ), the speaker C ( 1900 c ), and the speaker D ( 1900 d ) may be stored together with the audio signal wave 1910 a of the speaker A ( 1900 a ), the audio signal wave 1910 b of the speaker B ( 1900 b ), the audio signal wave 1910 c of the speaker C ( 1900 c ), and the audio signal wave 1910 d of the speaker D ( 1900 d ) as files 1901 a to 1901 d , respectively. The audio signal waves may be distinct from each other depending on the features of the human voice, so the audio signal wave may be used to identify the speakers.
In another embodiment, in order to recognize the speakers, the user may pre-store the voices of the speakers as the speaker recognition information before the recording of the audio signals. According to this, the controller 110 may record the voices of the speakers to be stored in the memory 160 , and may use the same for the comparison later. Additionally or alternatively, when storing the voices of the speakers, the user may also store the names of the speakers, and/or other information that can be used to indicate the speakers' identities.
In another embodiment, during a phone call with those who are stored in the contact information, the controller 110 may store the voices of the speakers in the memory 160 to use the same as the speaker recognition information.
FIG. 20 is a diagram of an example of a process for recording audio, according to various embodiments of the present disclosure.
As mentioned in FIG. 19 , the controller 110 may take photos of the speakers, and may pre-store the photos and the audio signals in the memory 160 using the sound-shot function, in order to identify the speaker of the recorded audio signal according to the angles. Referring to FIG. 20 , the controller 110 may compare the waves of the audio signals stored at the angles with the audio signal waves of the sound-shot files stored in the memory 160 . If the controller 110 finds the sound-shot file that has an audio signal wave that matches the wave of the stored audio signal at each angle, the controller 110 may map the photo of the sound-shot file with the audio signal stored at each angle to thereby store the same. For example, as shown in FIG. 20 , the speaker A ( 2001 a ), the speaker B ( 2001 b ), the speaker C ( 2001 c ), and the speaker D ( 2001 d ) may form the beams 2011 to 2014 to receive the audio signals of the speakers, respectively. The memory 160 may have the photos and the audio signals of the speakers 2001 a to 2001 d . The controller 110 may compare the received audio signal waves of the speakers with the audio signal waves stored in the memory 160 to thereby map the same to match each other to be then stored.
In another embodiment, the controller 110 may compare the received audio signal waves of the speakers with the audio signal waves that have been pre-recorded and pre-stored for the comparison. The controller 110 may compare the received audio signal waves of the speakers with the audio signal waves stored in the memory 160 to determine the respective identities of the speakers.
In another embodiment, the controller 110 may compare the received audio signal waves of the speakers with the audio signal waves of the users who are represented in the contact information. The controller 110 may compare the received audio signal waves of the speakers with the audio signal waves stored in the memory 160 to determine the identities of the speakers.
Referring to the files recorded according to the various embodiments above, the audio signal A ( 2010 a ) stored in File 1 occurs at an angle of 0° ( 2020 a ) by the speaker A ( 2001 a ). The audio signal B ( 2010 b ) stored in File 2 occurs at an angle of 90° ( 2020 b ) by the speaker B ( 2001 b ). The audio signal C ( 2010 c ) stored in File 3 occurs at an angle of 180° ( 2020 c ) by the speaker C ( 2001 c ). The audio signal D ( 2010 d ) stored in File 4 occurs at an angle of 270° ( 2020 d ) by the speaker D ( 2001 d ).
FIG. 21 is a diagram of an example of a user interface for rendering audio, according to various embodiments of the present disclosure.
As mentioned in FIG. 20 , the audio files may be stored according to the speaker through the speaker recognition. The controller 110 may create documents with respect to the files stored according to the speakers, using a speech-to-text (STT) function.
As shown in FIG. 21 , the controller 110 may create the minutes 2100 as one of the documents. The minutes 2100 may include identifiers 2101 or photos of the speakers for identifying the speakers, STT-transformed text 2103 , the recording time of the audio file 2105 , and play buttons 2107 for reproducing the audio file. For example, the controller 110 may transform the audio file of the speaker A ( 2101 a ), which is recorded first, into the text, and may record the same in the minutes 2100 ordered by time. The controller 110 may include the play button 2107 for reproducing the audio file corresponding to the recording time 2105 of “00:00:00˜00:00:34” in the minutes 2100 .
FIGS. 1-21 are provided as an example only. At least some of the steps discussed with respect to these figures can be performed concurrently, performed in a different order, and/or altogether omitted. It will be understood that the provision of the examples described herein, as well as clauses phrased as “such as,” “e.g.”, “including”, “in some aspects,” “in some implementations,” and the like should not be interpreted as limiting the claimed subject matter to the specific examples.
The above-described aspects of the present disclosure can be implemented in hardware, firmware or via the execution of software or computer code that can be stored in a recording medium such as a CD-ROM, a Digital Versatile Disc (DVD), a magnetic tape, a RAM, a floppy disk, a hard disk, or a magneto-optical disk or computer code downloaded over a network originally stored on a remote recording medium or a non-transitory machine-readable medium and to be stored on a local recording medium, so that the methods described herein can be rendered via such software that is stored on the recording medium using a general purpose computer, or a special processor or in programmable or dedicated hardware, such as an ASIC or FPGA. As would be understood in the art, the computer, the processor, microprocessor controller or the programmable hardware include memory components, e.g., RAM, ROM, Flash, etc. that may store or receive software or computer code that when accessed and executed by the computer, processor or hardware implement the processing methods described herein. In addition, it would be recognized that when a general purpose computer accesses code for implementing the processing shown herein, the execution of the code transforms the general purpose computer into a special purpose computer for executing the processing shown herein. Any of the functions and steps provided in the Figures may be implemented in hardware, software or a combination of both and may be performed in whole or in part within the programmed instructions of a computer. No claim element herein is to be construed under the provisions of 35 U.S.C. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for”.
While the present disclosure has been particularly shown and described with reference to the examples provided therein, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present disclosure as defined by the appended claims.
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A method comprising: detect a first acoustic signal by using a microphone array; detecting a first angle associated with a first incident direction of the first acoustic signal; and storing, in a memory, a representation of the first acoustic signal and a representation of the first angle.
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BACKGROUND OF THE INVENTION
The present invention relates to rough milling cutters for machining hypoid gears and the like. More particularly, this invention is directed to an improved cutter design which permits independent radial and axial adjustment of each blade while maintaining a relatively simple configuration.
Prior milling cutters of this type as exemplified by U.S. Pat. Nos. 2,236,909 and 2,978,792, whose disclosures are herein incorporated by reference, provided no means to adjust the cutter blades axially of the cutter body while relying on a combination of shims and wedges to effect radial adjustment. Another design shown in U.S. Pat. No. Re 22,892 provided means to effect simultaneous radial and axial adjustment, but provided no means to effect either radial or axial adjustment without effecting the other. Still another, more recent, design shown in U.S. Pat. No. 4,093,391, whose disclosure is herein incorporated by reference, discloses a cutter design which would permit axial, but not radial, adjustment. This design also employs a separate outer locking ring to retain the cutter blades in adjusted position.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a milling cutter which has greater versatility due to its independent axial and radial adjustability.
It is further an object of the present invention to provide a milling cutter which is more easily machined for two reasons: (1) the cutter blades may be machined outside the cutter body; (2) the blades and mounting slots need not be machined to such fine tolerances due to the use of an adjustment block.
It is a further object to provide a milling cutter having greater rigidity and being of simpler design by eliminating the need for a locking ring.
These and other objects are achieved by a milling cutter having a one piece body with blade receiving slots therein. The bottom of each slot has a slight top-to-bottom taper which engages with a complementary taper on an adjustment block. An attaching finger on the adjustment block has an aperture therein which is tapped with a left-hand thread while an aligned aperture in the cutter body is tapped with a right-hand thread. These aligned apertures receive a differential screw which when rotated moves the adjustment block axially relative to the cutter body and the upper surface of the block radially relative to the cutter body. This upper surface forms the support for the cutter blades. The outer portion of the cutter body has two tapped apertures above each blade-receiving slot that threadingly engage two cap screws. These cap screws engage the outermost surface of the cutter blade clamping it in axial adjusted position against the adjustment block.
These and other objects, advantages and features of the present invention will be beter understood by reference to the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a side view of the rough milling cutter of the present invention with only a few of the blade-receiving slots being shown in order to simplify the drawing;
FIG. 2 is a partial top view of the milling cutter depicted in FIG. 1;
FIG. 3 is a more detailed view of the individual blade-receiving slots;
FIG. 4 is a partial section of the milling cutter shown in FIG. 1 taken along line 3--3 thereof; and
FIG. 5 is a side view of the adjustment block for the milling cutter of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The milling cutter of the present invention is shown generally at 10. The milling cutter 10 is for roughing hypoid gears or the like and has a generally cylindrical configuration with an axial mounting recess 12 extending along the central axis. As can best be seen in FIG. 2, mounting recess 12 has a slight taper from one side of the milling cutter to the other. As an alternative, the taper may be formed along a portion of recess 12 and the remaining portion be cylindrical. The shaft (not shown) upon which the milling cutter is mounted has a corresponding taper to help control radial runout. The back of the milling cutter is recessed at 14 to receive a stabilizing plate (not shown) which may be integral with, or keyed to, the mounting shaft. The milling cutter may be bolted to the stabilizing plate by extending means (not shown) through apertures 16. A fifth aperture 18 is for gauging purposes while tapped holes 19 are used to assist in removing the cutter from the shaft by running screws therethrough into contact with the stabilizing plate.
A plurality of blade-receiving recesses or slots 20 (only some of which are shown) are equally spaced around the cutter body. These slots are positioned inwardly from the outer periphery 22 of the cutter body. The bottom surface 23 of the slot is inclined from horizontal (as shown in FIG. 2) by an angle "β" giving the slot a generally tapered configuration for reasons discussed in more detail herebelow. Above each slot are two threaded holes 24 which receive cap screws 26. These screws engage the upper surface of cutter blade 28 to maintain it in axially adjusted position.
Adjustment block 30 (best shown in FIG. 5), has a tapered main portion 32 and an attaching finger 34. The main portion 32 has a first planar surface 36 which, in operative position, extends generally parallel to the longitudinal axis and a second planar surface 37 that forms an angle "α" with a plane which is perpendicular to said first surface. Angles "α" and "β" are complementary (i.e., add up to 90°). The attaching finger 34 projects laterally from the main portion and has a semicircular extremity which is received in a correspondingly shaped recess 40 in the cutter body. The attaching finger 34 has a left-hand thread tapped therein indicated at 42 and the cutter body has a right-handed thread 44 tapped therein in alignment with the first thread, both of which are parallel to sloped surface 23.
In operation, a differential screw 46 is received in both apertures having left and right-hand threads corresponding to the left and right-hand threads in the adjustment block and cutter body, respectively. A suitable differential screw is commercially available as Kennametal STC-9. As the differential screw is rotated, relative axial motion occurs between the adjustment block 30 and cutter body. Due to the complementarily tapered surfaces 23 and 37, the axial movement is translated into radial movement of surface 36 of the adjustment block and, correspondingly, to radial adjustment of the position of the cutter blade.
The use of the adjustment block 30 eliminates the need to grind the bottom surface 23 of the slot and surface 29 of the cutter blade, which would otherwise be in contact, to the extremely close tolerances that such contact would otherwise necessitate. Any discrepancies in the tolerances can be compensated for using the adjustment block. In addition, the one piece design for the cutter body has obvious advantages of simplicity, strength and again, reduction in machining costs, over designs employing a separate locking ring, although the adjustment block could also be used with a two piece cutter design.
As is customary, the slots 20 are positioned at a slight angle, which may be on the order of 12°, with respect to perpendicular. Accordingly, the adjustment block 30 and cutter blade 28 will also be positioned at this angle (see FIG. 2). Also according to the usual practice, there are a plurality of sets of blades, each set being particularly designed to machine a specific portion of the gear tooth. The number of sets may conventionally be two or three and, in the latter case there is provided a first set to cut the left side of the gear tooth, a second set to cut the right side of the gear tooth and a third set to cut the bottom portion between the gear teeth. By way of example, the cutter body may have twenty-eight equally spaced slots to receive seven blades of the first set, seven blades of the second set and fourteen blades of the third set with these last occupying each alternate slot 20. The positions of the blades in the first and second sets alternate in the remaining slots. A drive recess 45 in the back side of the cutter body receives a projecting key (not shown) formed on the stabilizing plate. This permits the drive torque to be transmitted to the milling cutter by means other than the attaching bolts.
The ability to adjust the cutter blade, both axially and radially of the cutter body, by independent means gives greater versatility to the cutter and variety to the gear tooth patterns which can be formed. The amount of material removed can be adjusted by adjusting the radial positions of the blades. An additional feature of this design is that worn or cracked cutter blades can be replaced individually rather than as an entire set of twenty-eight as in the usual case. The present design permits adjustment while retaining the necessary rigidity with a simple configuration that is comparatively inexpensive to manufacture.
Although a particular embodiment has been disclosed, various changes, modifications, alternatives and variations will occur to the skilled artisan in light of the foregoing specification. Accordingly, it is intended that all such changes, modifications, alternatives and variations as are encompassed by the spirit and scope of the appended claims come within the invention.
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Radial adjustment of cutter blades in a roughing hypoid gear cutter is effected by a tapered adjustment block. A differential screw engages threads in the block and in the cutter body to cause relative axial displacement. The taper on the adjustment block in cooperation with a tapered surface on the cutter body translates the axial displacement into a radial displacement of the upper surface of the adjustment block and the corresponding cutter blade. A pair of cap screws permit independent axial adjustment of each cutter blade. A one piece cutter body provides maximum simplicity and rigidity.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to new and useful improvements in drill bits and more particularly to drill bits having improved diamond cutting elements and to the improved cutting elements, per se.
2. Brief Description of the Prior Art
Rotary drill bits used in earth drilling are primarily of two major types. One major type of drill bit is the roller cone bit having three legs depending from a bit body which support three roller cones carrying tungsten carbide teeth for cutting rock and other earth formations. Another major type of rotary drill bit is the diamond bit which has fixed teeth of industrial diamonds supported on the drill body or on metallic or carbide studs or slugs anchored in the drill body.
There are several types of diamond bits known to the drilling industry. In one type, the diamonds are a very small size and randomly distributed in a supporting matrix. Another type contains diamonds of a larger size positioned on the surface of a drill shank in a predetermined pattern. Still another type involves the use of a cutter formed of a polycrystalline diamond supported on a sintered carbide support.
Some of the most recent publications or patents dealing with diamond bits of advanced design, relevant to this invention are Rowley, et al. U.S. Pat. No. 4,073,354 and Rohde, et al. U.S. Pat. No. 4,098,363. An example of cutting inserts using polycrystalline diamond cutters and an illustration of a drill bit using such cutters, is found in Daniels, et al. U.S. Pat. No. 4,156,329.
The most comprehensive treatment of this subject in the literature is probably the chapter entitled STRATAPAX bits, pages 541-591 in ADVANCED DRILLING TECHNIQUES, by William C. Maurer, The Petroleum Publishing Company, 1421 South Sheridan Road, P. O. Box 1260, Tulsa, Okla. 74101, published in 1980. This reference illustrates and discusses in detail the development of the STRATAPAX diamond cutting elements by General Electric and gives several examples of commercial drill bits and prototypes using such cutting elements.
Commercially available diamond cutters consist of disc shaped polycrystalline diamond brazed on a cylindrical stud of tungsten carbide. There are two types generally in use. One is a relatively large diameter cutting disc which is used in soft and medium formations and to some extent in hard formations. Another type has a relatively small diameter cutting disc which is used in hard and very hard formations. The disadvantage of the small cutters is that they are secured to the supporting carbide stud on a relatively small surface area with the result that these cutters undergo much higher shear forces when cutting hard formations. In addition, the small cutters are not very effective when used in softer formations.
These patents and the cited literature show the construction of various diamond bits and related prior art but do not consider the problem of providing adequate bonding of small cutting elements to their supporting studs.
SUMMARY OF THE INVENTION
One of the objects of this invention is to provide a new and improved drill bit having diamond insert cutters having a shape providing better cutting action in hard formations without loss in cutting efficiency in softer formations.
Another object of this invention is to provide a new and improved drill bit having diamond insert cutters having a shape providing superior cutting action in hard formations and having a superior bond to the supporting cutter stud.
Another object is to provide a drill bit having carbide inserts with diamond cutting elements having a shape providing a superior cutting or penetration rate than conventional cutters for the same applied weight in drilling operation.
Still another object of this invention is to provide a drill bit having cylindrical carbide inserts with disc shaped diamond cutting elements secured thereon wherein the cutting discs are of a relatively large diameter but have a smaller cutting surface for that portion of the cutter which penetrated the formation.
Another object of this invention is to provide a new and improved diamond insert cutter for drill bits having a shape providing better cutting action in hard formations without loss in cutting efficiency in softer formations.
Another object of this invention is to provide a new and improved diamond insert cutter for drill bits having a shape providing superior cutting action in hard formations and having a superior bond to the supporting cutter stud.
Another object is to provide a carbide insert with diamond cutting element for drill bits having a shape providing a superior cutting or penetration rate than conventional cutters for the same applied weight in drilling operation.
Another object of the invention is to provide diamond cutting elements for drill bits with a shape that tends to remain sharp in service.
Still another object of this invention is to provide a cylindrical carbide drill bit insert with disc shaped diamond cutting elements secured thereon wherein the cutting discs are of a relatively large diameter but have a smaller cutting surface for that portion of the cutter which penetrated the formation.
Other objects and features of this invention will become apparent from time to time throughout the specification and claims as hereinafter related.
The foregoing objectives are accomplished by a new and improved drill bit as described herein. An improved drill bit for connection on a drill string has a hollow tubular body with an end cutting face and an exterior peripheral stabilizer surface with cylindrical sintered carbide inserts positioned therein having polycrystalline diamond cutting elements mounted on said inserts. The diamond cutting elements have a novel cutting shape facilitating drilling through hard formations with a minimum of breakage. The cutting elements are in the shape of a relatively large disc shaped cutter commonly used for medium and soft formations but have one side cut into a cutting edge of substantially smaller radius. The cutting element has the strength and resistance to breakage of the larger disc but the cutting capacity in hard formations of a smaller diameter cutter. The cutting elements are also disclosed as novel components of the drill.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view partly in elevation and partly in quarter section of an earth boring drill bit with diamond-containing cutting inserts incorporating a preferred embodiment of this invention.
FIG. 2 is a plan view of the bottom of the drill bit shown in FIG. 1 showing half of the bit with cutting inserts in place and half without the inserts, showing only the recesses.
FIG. 3 is a sectional view taken normal to the surface of the drill bit through one of the recesses in which the cutting inserts are positioned and showing the insert in elevation.
FIG. 4 is a sectional view in plan showing the hole or recess in which the cutting insert is positioned.
FIG. 5 is a view in side elevation of one of the cutting inserts.
FIG. 6 is a view of one of the cutting inserts in plan relative to the surface on which the cutting element is mounted.
FIG. 6A is an enlarged view of the cutting insert shown in FIG. 6 which shows more detail of the shape of the cutting disc.
FIG. 7 is a top view of the cutting insert shown in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description, unless otherwise noted, the general description of the drill bit is that of the assignee's prior pending applications, viz., Radtke, U.S. Ser. No. 220,306, filed Dec. 29, 1980 and now abandoned; Ser. No. 158,389 issued Apr. 6, 1982 as Dennis U.S. Pat. No. 4,323,130; Ser. No. 296,811, issued May 3, 1983 as Radtke U.S. Pat. No. 4,381,825; Ser. No. 303,721 issued Aug. 2, 1983 as Radtke U.S. Pat. No. 4,396,077; and Ser. No. 303,960 issued Apr. 17, 1984 as Radtke U.S. Pat. No. 4,442,909.
Referring to the drawings, there is shown a drill bit 1 having improved cutting elements comprising a preferred embodiment of this invention. The drill bit also has replaceable drilling nozzles held in place by a threaded arrangement which has proven advantageous in previous drill bit designs manufactured by the assignee of this invention. The threaded arrangement for securing nozzles may be used in other types of drill bits but is particularly useful in this bit because of the close proximity of the nozzles to the cutting surface of the bit and the bottom of the drill hole which results in a very high rate of wear.
Many features in the drill bit are described in above-mentioned above-mentioned Dennis U.S. Pat. No. 4,323,130; and abandoned Radtke U.S. Ser. No. 220,306, filed Dec. 29, 1980 (which discloses an improved arrangement for securing replaceable nozzles in drilling bits by means of a metal or hard metal retaining ring).
This improved drill bit comprises a tubular body 2 which is adapted to be connected as by a threaded connection 3 to a drill collar 4 in a conventional drill string. The body 2 of drill bit 1 has a passage 5 which terminates in a cavity 6 formed by end wall 7 which is the cutting face of the drill bit. Drill bit 1 has a peripheral stabilizer surface 8 which meets the cutting face 7 at the gage cutting edge portion 9.
The stabilizer portion 8 has a plurality of grooves or courses 10 which provide for flow of drilling mud or other drilling fluid around the bit during drilling operation. The stabilizer surface 8 also has a plurality of cylindrical holes or recesses 11 in which are positioned hard metal inserts 12. These hard metal inserts 12 are preferably of a sintered carbide and are cylindrical in shape and held in place in recesses 11 by an interference fit with the flat end of the insert being substantially flush with the stabilizer surface 8.
The cutting surface or cutting face 7 of the drill bit body 2 is preferably a crown surface defined by the intersection of outer conical surface 13 and inner negative conical surface 14. Crown surfaces 13 and 14 have a plurality of sockets or recesses 15 spaced in a selected pattern. In FIG. 2, it is seen that the sockets or recesses 15 and the cutting inserts which are positioned therein are arranged in substantially a spiral pattern.
In FIGS. 3 and 4, the sockets or recesses 15 are shown in more detail with the cutting inserts being illustrated. Each of the recesses 15 is provided with a milled offset recess 16 extending for only part of the depth of the recess 15. The recesses 15 in crown faces 13 and 14 receive a plurality of cutting elements 18 which are seen in FIGS. 1 and 2 and are shown in substantial detail in FIGS. 3, 5, 6 and 7.
Cutting elements 18 which were previously used were the STRATAPAX cutters manufactured by General Electric Company and described in Daniels, et al. U.S. Pat. No. 4,156,329, Rowley, et al, U.S. Pat. No. 4,073,354 and in considerable detail in ADVANCED DRILLING TECHNIQUES by William C. Maurer. The STRATAPAX cutting elements 18 consist of a cylindrical supporting stud of sintered carbide. The supporting stud is beveled at the bottom, has edge tapered surfaces, a top tapered surface and an angularly oriented supporting surface. A small cylindrical groove is provided along one side of the prior art supporting stud for use with a key for preventing rotation. A disc shaped cutting element is bonded on the angular supporting surface, preferably by brazing or the like. The disc shaped cutting element is a sintered carbide disc having a cutting surface of polycrystalline diamond.
In the past, the cutting element discs have been available in only two sizes. The larger size has a diameter of 0.524 in. and is used for drilling soft, medium and medium-hard formations. The smaller size has a diameter of 0.330 in. and is used for drilling hard and extra hard formations. The smaller size cutting discs are able to cut through hard formations because of the smaller arc of cutting surface which engages the formation being drilled.
The smaller discs, however, have the disadvantage of not being very efficient in drilling through softer formations. The smaller discs have a further disadvantage arising from the fact that greater shear forces are encountered in drilling hard formations and the smaller discs are bonded to the supporting studs in a much smaller surface area. As a result, the smaller discs are more efficient in drilling through hard formations but they are sheared off the supporting studs with a much higher frequency than the larger discs. Consequently, there has been a substantial need for cutting discs which work well in hard formations and in softer formations, and which are not easily lost by shearing off.
In the preferred embodiment (see FIGS. 5-7) of this invention, the carbide studs 19 have the diamond cutting elements 26 brazed thereon, as in the conventional STRATAPAX type cutters. The cutting elements 26, however, are cut into a configuration which provides a short radius arcuate cutting surface for cutting hard formations and has a main body portion of substantially larger radius which provides a larger bonding area for securing the disc to the supporting stud 19. In addition, the transition surface from the short radius cutting surface to the main body portion provides a cutting surface which works well in softer formations. The supporting stud 19 is also cut or formed so that the surface behind the cutting element 26 has a contour which is a continuation of that surface. As will be described below, this contour of the cutting element and the end portion of the supporting stud is effective to resist dulling and breakage of the cutters.
FIGS. 5, 6 and 7 show different views of the cutting elements and supporting studs. FIG. 6A is and enlarged view of FIG. 6 which includes certain more or less critical dimensions of the improved cutters. The supporting studs 19 for the cutters are typically 0.626 in. in diameter and 1.040 in. long at the longest dimension. The inclined face 24 is at about 20° relative to the longitudinal axis or to an element of the cylindrical surface of the stud. Side bevels 123 are at about 30° on each side and have a smooth contour which is an extension of the contour of the cutting disc 26. The end relief configuration 23 is at about 20° from a normal intersecting plane and has the same configuration as the cutting end surface of the cutting disc. This cutting element design does not require the edge groove in the supporting stud for an anti-rotation key since the cutter has no tendency to rotate.
The cutting discs have a thickness of about 0.139 in. and a surface layer of polycrystalline diamond at least 0.02 in. thick. The improved cutting discs of this invention may be constructed in the desired shape originally or may be cut to shape from a larger disc. Referring to FIG. 6A, cutting disc 26 is preferably formed from one of the large diameter cutting discs and has a radius R 1 of 0.262 in. for the bottom half thereof (the rear half when considered in relation to the cutting function.
The cutting edge 126 has a radius corresponding to the radius of one of the small cutting discs which have been used for drilling hard formations. Cutting edge, in the preferred embodiment, has a radius R 2 of 0.165 in. (the same radius as the small cutting discs) from a center offset by a distance O 1 of 0.097 in. from the true center of the disc. Intermediate arcs 127 and flat tangential surfaces 128 interconnect cutting surface 126 with the main or uncut portion of the cutting disc. Arcs 127 have radii R 3 of 0.203 in. from centers offset by a distance O 2 of 0.059 in. from the true center of the disc.
This disc therefore has a lower half or main body portion of large radius (0.262 in.) tapering along arcs 127 and tangential lines to a somewhat pointed end having a cutting edge 126 of small radius (0.165 in.). The various radii given are based on the sizes of cutting discs which are commercially available at the present time. Obviously, other sizes could be used as materials become available for constructing them. The same configuration shown on cutting edge 126, intermediate arcs 127 and flats 128 continues for the supporting stud 19 as seen in FIG. 7. This allows the structure to maintain a sharp cutting edge as the cutter wears.
Supporting studs 19 of cutting elements 18 and the diameter of recesses 15 are sized so that cutting elements 18 will have a tight interference fit in the recesses 15. The recesses 15 are oriented so that when the cutting elements are properly positioned therein the disc shaped diamond faced cutters 26 will be positioned with the cutting surfaces facing the direction of rotation of the drill bit. When the cutting elements 18 are properly positioned in sockets or recesses 15 the cutting elements 26 on supporting stud 19 are aligned with the milled recesses 16 on the edge of socket or recess 15. While the use of recesses or sockets 15 with milled offset recesses 16 is preferred, the cutting elements 18 can be used in any type of recess or socket which will hold them securely in place.
The drill bit body 2 has a centrally located nozzle passage 30 and a plurality of equally spaced nozzle passages 31 toward the outer part of the bit body. Nozzle passages 30 and 31 provide for the flow of drilling fluid, i.e. drilling mud or the like, to keep the bit clear of rock particles and debris as it is operated. The outer nozzle passages 31 are preferably positioned in an outward angle of about 10°-25° relative to the longitudinal axis of the bit body. The central nozzle passage 30 is preferably set at an angle of about 60° relative to the longitudinal axis of the bit body. The outward angle of nozzle passages 31 directs the flow of drilling fluid toward the outside of the bore hole and preferably ejects the drilling fluid at about the peak surface of the crown surface on which the cutting inserts are mounted.
The arrangement of nozzle passages and nozzles provides a superior cleaning action for removal of rock particles and debris from the cutting area when the drill bit is being operated. The particular arrangement of nozzles and the means of securing the nozzles in place is not a part of the claimed invention, but is described to provide a proper setting for the use of the improved cutting elements in a commercially successful drill bit. Nozzle passage 31 comprises a passage extending from drill body cavity 6 with a counterbore cut therein providing a shoulder 43. The counterbore is provided with a peripheral groove in which there is positioned O-ring 35. The counterbore is internally threaded and opens into an enlarged smooth bore portion which opens through the lower end portion or face of the drill bit body. Nozzle member 36 is threadedly secured in the counterbore against shoulder 43 and has a passage 37 providing a nozzle for discharge of drilling fluid. Nozzle member 36 is a removable and interchangeable member which may be removed for servicing or replacement or for interchange with a nozzle of a different size or shape, as desired. The threaded nozzle arrangement is not a part of this invention and is described in more detail in U.S. patent applications Ser. No. 296,811, filed Aug. 27, 1981, Ser. No. 303,721, filed Sept. 21, 1981, and Ser. No. 303,960, filed Sept. 21, 1981.
OPERATION
The operation of this drill bit should be apparent from the foregoing description of its component parts and method of assembly. Nevertheless, it is useful to restate the operating characteristics of this noval drill bit to make its novel features and advantages clear and understandable.
The drill bit as shown in the drawings and described above is primarily a rotary bit of the type having fixed diamond surfaced cutting inserts. Many of the features described relate to the construction of a diamond bit of a type already known. However, these features are used in the bit in which the improved diamond cutter arrangement of this invention is used.
This drill bit is rotated by a drill string through the connection by means of the drill collar 4 shown in FIG. 1. Diamond surfaced cutting elements 18 cut into the rock or other earth formations as the bit is rotated and the rock particles and other debris is continuously flushed by drilling fluid, e.g. drilling mud, which flows through the drill string and the interior passage 5 of the drill bit and is ejected through nozzle passages 30 and 31 as previously described. The central nozzle 30 is set at an angle of about 30° to flush away cuttings and debris from the inside of the cutting down.
The peripheral or stabilizer surface 8 of drill bit body 2 is provided with a plurality of sintered carbide cylindrical inserts 12 positioned in sockets or recesses 11 which protect against excessive wear and assist in keeping the bore hole to proper gage to prevent the drill bit from binding in the hole. The grooves or courses 10 in stabilizer surface 8 provide for circulation of drilling fluid, i.e. drilling mud, past the drill bit body 2 to remove rock cuttings and debris to the surface.
As previously pointed out, the construction and arrangement of the cutting elements and the method of assembly and retention of these elements is especially important to the operation of this drill bit. The drill bit is designed to cut through medium hard rock and is subjected to very substantial stresses. The cutting elements 18 are STRATAPAX type cutting elements (STRATAPAX is the trademark of General Electric Company) modified as described above. Although reference is made to STRATAPAX type cutting elements, equivalent cutting elements made by other manufacturers could be used.
The cutting elements 26, as described above, are cut into a configuration which provides a short radius arcuate cutting surface for cutting hard formations and has a main body portion of substantially larger radius which provides a larger bonding area for securing the disc to the supporting stud 19. In addition, the transition surface from the short radius cutting surface to the main body provides a cutting surface which works well in softer formations.
The supporting studs 19 for the cutters are typically 0.626 in. in diameter and 1.040 in. long at the longest dimension. The inclined face 24 is at about 20° relative to the longitudinal axis or to an element of the cylindrical surface of the stud 19. Side surfaces 123 are a continuation of the surface of the cutting surfaces 126, 127 and 128. The end bevel 23 is at about 20° from a normal intersecting plane and is a continuation of the surface of cutting edge 126.
The cutting discs have a thickness of about 0.139 in. and a surface layer of polycrystalline diamond at least 0.02 in. thick. The improved cutting discs of this invention have a radius R 1 of 0.262 in. for the bottom half thereof (the rear half when considered in relation to the cutting function), which is the size of the larger commercially available cutting discs. The cutting edge 126 has a radius corresponding to the radius of one of the small cutting discs which have been used for drilling hard formations, viz. a radius R 2 of 0.165 in. This disc therefore has a lower half or main body portion of large radius (0.262 in.) tapering along arcs 127 and tangential lines to a somewhat pointed end having a cutting edge 126 of small radius (0.165 in.). The various radii given are based on the sizes of cutting discs which are commercially available at the present time. Obviously, other sizes can be used as materials become available for constructing them.
When the drill bit is operated under a normal load, the depth of penetration per revolution of the bit is usually no more than 0.0625 in. Under these conditions, only the cutting edge 126 of small radius (0.165 in.) penetrated the formation. The cutting disc has an area of penetration into the formation, at a rate of 0.0625 in. per revolution, of 0.00491 in. 2 which is 63% of the penetration area for the larger (0.262 in.) radius discs. These discs, while having a tapered and rounded cutting edge 126 for cutting hard formations, have essentially the full surface area of the larger (0.262 in) radius cutting discs for bonding to the supporting studs 19. As a result of this construction, the cutting discs are substantially less likely to be sheared off in use and also provide the larger tapered cutting surface for making the transition between harder and softer formations. As previously mentioned, the use of a contour in the end of the supporting stud 19 which matches the contour of the cutting disc 26 results is a very substantial reduction in wear of the cutters. In addition, there is reduced deviation and lower torque resulting from lower bit weight requirements.
While this invention has been described fully and completely with special emphasis upon a single preferred embodiment, it should be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described herein.
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A drill bit for connection on a drill string has a hollow tubular body with an end cutting face and an exterior peripheral stabilizer surface with cylindrical sintered carbide inserts positioned therein having polycrystalline diamond cutting elements mounted on said inserts. The diamond cutting elements have a novel cutting shape facilitating drilling through hard formations with a minimum of applied weight on the bit. The cutting elements are in the shape of a relatively large disc shaped cutter commonly used for medium and soft formations but have the sides shaped into a cutting edge of substantially smaller radius. The cutting element has the strength and resistance to breakdown of the larger disc but the cutting capacity in hard formations of a smaller diameter cutter. The cutting elements are also disclosed as novel components of the drill.
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