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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of German application No. 10 2010 006 094.1 filed Jan. 28, 2010, which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a method for hardening the surface of a component in a wind turbine, in particular the surface outer layer of a component in a wind turbine.
BACKGROUND OF THE INVENTION
[0003] Microscopic cracks in the respective part frequently appear, as a result of high Hertzian pressure, in heavily loaded regions of drives, for instance in heavily stressed regions of bearing surfaces of drives or tooth flanks of gear wheels. Microscopic cracks of this type may result in premature faults and corresponding failures of the respective part. The crack formation frequently occurs on the outer surfaces and/or in the region of the periphery of the heavily loaded contact surfaces. Micro defects of this type reduce the operating time and the service life of the respective part, for instance of the drive and the drive housing. In numerous plants, for instance in wind turbines, the thus necessary replacement of the respective component, for instance of the drive or parts thereof, is generally complicated and expensive.
[0004] The hardening processes and processing technologies used to date, such as rolling, hard turning or blasting material peening, do not achieve increased internal stress particularly of the heavily loaded contact regions and therefore reduce the high tensile load. Only internal stresses of a maximum of 400 MPa can currently be achieved.
[0005] DE 10 2007 009 470 A1 and WO 93/20247 A1 describe methods for the surface peening, in particular for the ultrasound ball peening of a part, in particular a gas turbine. Ultrasound blasting material peening is characterized in that a sub-region of the surface of a part is hardened by applying a blasting material. The blasting material preferably consists of small balls with a diameter of less than 4 mm.
SUMMARY OF THE INVENTION
[0006] The object of the present invention consists in providing an advantageous method for hardening the surface of a component in a wind turbine. This object is achieved by a method as claimed in the independent claim. The dependent claims contain further advantageous embodiments of the invention.
[0007] The inventive method for hardening the surface of a component in a wind turbine is characterized in that the component to be hardened has a surface and the surface is applied with a blasting material by means of ultrasound waves. The component to be hardened can be in particular parts of bearings or the drive of the wind turbine. In particular, the component can include a part of a drive or a drive housing, a bearing surface, in particular of a bearing, for instance a bearing surface of a roller bearing, or of a drive, a gear wheel or a pinion, in particular a drive pinion. The component to be hardened can be in particular a tooth flank of a gear wheel.
[0008] By means of ultrasound blasting material peening, in other words applying the surface to be hardened with a blasting material by means of ultrasound waves, the internal stress of the respective component is increased and the susceptibility to cracking is thus reduced. The service life and the operating time of the respective component are increased in this way by approximately 20%.
[0009] The ultrasound waves can preferably be emitted with the aid of a piezo electric transducer. For instance, ultrasound waves can be emitted with a frequency between 10 kHz and 30 kHz, preferably 20 kHz. It is particularly advantageous if the ultrasound waves are amplified. This can take place for instance with the aid of an acoustic amplifier.
[0010] The blasting material can preferably include a relatively heavy material, like for instance tungsten carbide, and/or consist of tungsten carbide. In addition, the blasting material can include balls. The blasting material can preferably include balls with a diameter of more than 1 mm, advantageously with a diameter of more than 5 mm, or can exclusively consist of blasting balls with a diameter of more than 1 mm, advantageously with a diameter of more than 5 mm. It has emerged that the use of tungsten carbide balls and the use of balls with a relatively large diameter, in particular of more than 5 mm, can achieve particularly high internal compressive stress results, since the balls are in this case embodied in a relatively large and heavy fashion.
[0011] With the aid of the inventive method, internal stresses, in particular of bearing surfaces of wind turbine bearings and wind turbine drives, for instance gear wheel drive systems, of more than 800 MPa can be achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Further features, characteristics and advantages of the present invention are described in more detail below with reference to an exemplary embodiment with respect to the appended figures. Here the described features are advantageous both individually and also in combination with one another.
[0013] FIG. 1 shows a schematic representation of a wind power plant.
[0014] FIG. 2 shows a schematic representation of a first cross-section through a part of an apparatus for implementing the inventive method on a gear wheel.
[0015] FIG. 3 shows a schematic representation of a second cross-section through a part of an apparatus for implementing the inventive method on a gear wheel.
[0016] FIG. 4 shows a schematic representation of a first cross-section through a part of an apparatus for implementing the inventive method on the interior surface of a roller bearing outer ring.
[0017] FIG. 5 shows a schematic representation of a second cross-section through a part of an apparatus for implementing the inventive method on the inner surface of a roller bearing outer ring.
[0018] FIG. 6 shows a schematic representation of a first cross-section through a part of an apparatus for implementing the inventive method on the outer surface of a roller bearing inner ring.
[0019] FIG. 7 shows a schematic representation of a second section through a part of an apparatus for implementing the inventive method on the outer surface of a roller bearing inner ring.
DETAILED DESCRIPTION OF THE INVENTION
[0020] An exemplary embodiment of the invention is described in more detail below with the aid of FIGS. 1 to 7 . FIG. 1 shows a schematic representation of a wind power plant 1 . The wind power plant 1 includes a tower 2 , a pod 3 and a rotor hub 4 . The pod 3 is arranged on the tower 2 . The rotatably mounted rotor hub 4 is arranged on the pod 3 . At least one rotor blade 5 is fastened to the rotor hub 4 . The wind power plant 1 typically includes two or three rotor blades 5 .
[0021] The wind power plant 1 also includes at least a rotational axis 6 , a main bearing 30 , a drive 7 , a brake 8 and a generator 9 . The rotational axis 6 , the main bearing 30 , the drive 7 , the brake 8 and the generator 9 are arranged inside the pod 3 . A center to center difference is essentially possible in the drive 7 . Different components can therefore have different rotational axes. In addition, the wind power plant 1 can also be embodied without drives.
[0022] FIG. 2 shows a schematic representation of a cross-section through part of an apparatus for implementing the inventive ultrasound shot peening method. The apparatus includes a peening chamber 10 , within which the shot peening is implemented. Part of a component to be hardened, in the present exemplary embodiment part of a drive pinion 11 , is arranged within the peening chamber 10 . The drive pinion 11 includes a rotational axis 13 . FIG. 2 shows a cross-section through the drive pinion 11 along the rotational axis 13 , in other words an axial cross-section. The drive pinion 11 includes a number of teeth 24 , of which at least one part is arranged within the peening chamber 10 . The surface to be hardened of the teeth 24 of the gear pinion 11 is identified with reference character 26 .
[0023] At least one part of a sonotrode 17 is also arranged within the peening chamber 10 . The sonotrode 17 is preferably arranged opposite the surface 26 to be hardened. The sonotrode 17 is connected to an amplifier 16 , preferably an acoustic amplifier. The amplifier 16 is also connected to a transducer, preferably in the form of a piezo electric emitter.
[0024] A cavity 27 is disposed between the sonotrode 17 and the drive pinion 11 within the peening chamber 10 . A number of balls 18 are arranged in this cavity 27 . The balls 18 preferably consist of tungsten carbide. The balls 18 advantageously have a diameter of more than 1 mm, preferably of more than 5 mm. A homogenous hardening of the surface 26 is herewith achieved.
[0025] In order to implement the inventive method, ultrasound waves with a frequency between 30 kHz and 10 kHz, advantageously with a frequency of 20 kHz, are generated with the aid of the transducer 14 . The ultrasound waves are then amplified with the aid of the acoustic amplifier 16 . The amplified ultrasound waves are transmitted by means of the sonotrode into the peening chamber 10 , and/or into the cavity 27 disposed therein. The ultrasound waves cause the balls 18 inside the peening chamber 10 to vibrate and move inside the peening chamber 10 . The balls 18 are in this way reflected by the surface of the sonotrode 17 , by the surface 26 to be hardened and by the walls of the peening chamber 10 . In addition, the balls 18 collide with one another. As a result of the random scattering of the balls 18 , a homogenous treatment of the surface 26 to be hardened is achieved.
[0026] FIG. 3 shows a schematic representation of a cross-section according to FIG. 2 through an apparatus for implementing the inventive method. Contrary to FIG. 2 , the drive pinion 12 is shown in FIG. 3 in a radial cross-section, in other words in a cross-section at right angles to the rotational axis 13 . The view of the remaining parts in FIG. 3 can essentially correspond to the cross-section shown in FIG. 2 , with only the part 11 and/or 12 to be hardened being arranged differently. Alternatively the cross-section shown in FIG. 3 , in respect of all parts, may be a cross-section at right angles to the cross-section shown in FIG. 2 . The longitudinal axis of the apparatus is identified in both FIGS. 2 and 3 with reference character 15 .
[0027] The teeth 24 of the drive pinion 12 shown in FIG. 3 include tooth flanks 25 . With the aid of the inventive method, the tooth flanks 25 can in particular be effectively hardened, since as a result of the random scattering of the balls, the whole surface to be hardened can be evenly treated.
[0028] FIGS. 4 and 5 show a cross-section through part of an apparatus for implementing the inventive method. FIGS. 4 and 5 show the hardening of the inner bearing surface 21 of a roller bearing outer ring 19 and/or 20 . Here the roller bearing outer ring 19 in FIG. 4 is shown in an axial cross-section in respect of a rotational axis 23 . FIG. 5 shows the roller bearing outer ring 20 in a radial cross-section in respect of the rotational axis 23 . Similarly to the embodiments rendered in conjunction with FIGS. 2 and 3 , FIGS. 4 and 5 may be two cross-sections arranged at right angles to one another and the same arrangement or however the same cross-section, with the roller bearing outer ring 19 and/or 20 being arranged differently.
[0029] The same applies to FIGS. 6 and 7 , in which a cross-section is shown through an apparatus for hardening the outer bearing surface 22 of a roller bearing ring 28 and/or 29 . FIG. 6 shows part of the roller bearing inner ring 28 in an axial cross-section in respect of the rotational axis 23 , while FIG. 7 shows part of the roller bearing inner ring 29 in a radial cross-section in respect of the rotational axis 23 .
[0030] The inventive method described in conjunction with FIG. 2 can be implemented in a similar fashion with the aid of the embodiments shown in FIGS. 3 to 7 .
[0031] As a result, an internal stress of the surface of the drive pinion 11 , 12 , in particular of the surface of the tooth flanks 25 , of the outer bearing surface 22 and of the inner bearing surface 21 of the roller bearing ring 19 , 20 , 28 , 29 of more than 800 MPa can be achieved with the aid of the inventive method.
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A method for hardening a surface of a component in a wind turbine is disclosed. The component to be hardened includes a surface and the surface is applied with a blasting material by ultrasound waves. The component is a part of a drive or a drive housing, a bearing surface, a gear wheel or a pinion. The ultrasound waves are emitted with the aid of a piezo electric transducer.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to precipitated amorphous silica having low surface area and enhanced flavor compatibility, and processes for making it. The precipitated silica is especially well-adapted for use in dentifrices containing cetylpyridinium chloride.
2. Description of the Related Art
Modern dentifrices often contain an abrasive substance for controlled mechanical cleaning and polishing of teeth, and optionally a chemical cleaning agent, among other common ingredients, such as humectants, flavors, therapeutic ingredients, such as an anticaries agent, rheology control agents, binders, preservatives, colors, and sudsing agents, among others. Oral care products also often contain therapeutic agents, such as anti-microbial agents. Cetylpyridinium chloride (“CPC”) is an anti-microbial agent used for this purpose, such as in mouthwashes and toothpastes. There is an increased desire among dentifrice manufacturers to incorporate anti-microbial agents in dentifrice applications for the control of malodor and/or other therapeutic action, with CPC being one of the more favored. It is cost effective and generally recognized as safe. By contrast, some alternative anti-microbial agents currently being used in dentifrices have come under increasing scrutiny for possible contribution to the increased resistance of some bacterial strains to antibiotics. CPC is not considered to contribute to this health problem.
CPC is a cationic (“positively”) charged compound. CPC's antimicrobial action is generally understood to result from its ability to bind to anionically (“negatively”)-charged protein moieties on bacterial cells present in the mouth. This CPC attachment mechanism results in a disruption of normal cellular function of bacteria and contributes to the prevention of plaque formation and other bacterial actions.
A problem encountered in CPC usage in dentifrices has been that CPC tends to indiscriminately bind to negatively-charged surfaces. In particular, co-ingredients of toothpaste formulations having negatively-charged surfaces also may bind to CPC before it performs any antimicrobial action. Once bound to these nontargeted surfaces, the CPC is generally unavailable to perform any meaningful antimicrobial action.
In this regard, silica is often used as an abrasive in dentifrices. For instance, silica's abrasive action is used for pellicle removal from teeth. Most conventional silicas used in dentifrices have negatively-charged surfaces. Consequently, CPC adsorbs onto such conventional silica powders. For reasons explained above, the adsorption of CPC upon silica or other co-ingredients of the dentifrice is highly undesirable.
U.S. Pat. No. 6,355,229 describes a CPC compatible dentifrice formulation containing guar hydroxypyropyltrimonium chloride. The guar complex has a higher affinity toward binding to negatively-charged species. It preferentially binds to anionic components leaving CPC free to bind to plaque.
U.S. Pat. No. 5,989,524 describes a silica that is compatible with flavors obtained by treating the surface of the silica originating from the reaction of an alkali metal silicate with an inorganic or organic acidic agent with the aid of an organic compound capable of developing hydrogen or ionic bonds with the Si—OH silanol groups or the SiO anionic groups at the silica surface. The organic agent can be added to the silica in the form of slurry before or after salts are removed, or can be sprayed on to dry silica.
A number of patent publications describe processes for making composite synthetic silica particles, including the following.
U.S. Pat. No. 2,731,326 describes a process of preparing xerogels in which a silica gel is stabilized so that the pores of the gel do not collapse upon drying. It involves a two-stage precipitation process where in the first stage silica gel is formed, and in the second stage a layer of dense amorphous silica is formed over the gel particles in order to provide sufficient reinforcement such that the pores do not collapse upon drying. The gel particles have a particle size in the range of 5 to 150 millimicrons (nm), and preferably have an average diameter of from 5 to 50 millimicrons. The resulting reticulated particles can be dewatered and dried into powder form. The '326 patent states that when silica particles have a specific surface area of greater than 200 m 2 /g, it is preferred to replace the water with an organic liquid, and then dehydrate the silica particles. The '326 patent describes silica products with preferred specific surface areas 60 to 400 m 2 /g. The '326 patent indicates little advantage is obtained in carrying the process of accretion to an extreme. The preferred products of the '326 patent process of accretion are limited so that the original dense ultimate units of the aggregates do not lose their identity and the original aggregates structure is not obscured.
U.S. Pat. No. 2,885,366 describes a process used to deposit a dense layer of silica over particles other than silica.
U.S. Pat. No. 2,601,235 describes a process for producing built-up silica particles in which a silica sol heel is heated above 60° C. to make nuclei of high molecular weight silica. The nuclei is mixed with an aqueous dispersion of active silica made by acidulating alkali metal silicate, and the mixture is heated above 60° C. at a pH of 8.7 to 10, such that active silica accretes to the nuclei.
U.S. Pat. No. 5,968,470 describes a process to synthesize silica having controlled porosity. It involves the addition of silicate and acid to a solution of colloidal silica with or without an electrolyte added (salt). The porosity can be controlled based upon the amount of colloidal silica added in the first step of the reaction. Silica with BET surface areas ranging from 20 to 300 m 2 /g, CTAB specific surface areas from 10 to 200 m 2 /g, oil absorption (DBP) ranging from 80 to 400 m 2 /g, pore volumes from 1 to 10 cm 3 /g, and mean pore diameters from 10 to 50 nm could be synthesized. The intended use of materials produced by this process is in the paper and catalysis marketplace.
U.S. Pat. No. 6,159,277 describes a process for the formation of silica particles with a double structure of a core of dense amorphous silica and a shell of bulky amorphous silica. A gel is formed in a first step. The gel is then aged, wet pulverized, and then sodium silicate is added in the presence of an alkali metal salt in order to form amorphous silica particles on the surface of the milled gel particles. The resultant double structure silica material has an average particle diameter of 2 to 5 micrometers and a surface area of 150 to 400 m 2 /g. The resultant material is said to have improved properties for use in as a delustering agent in paint and coatings.
Patent publications that describe use of silicas in dentifrice or oral cleaning compositions include the following.
U.S. Pat. No. 5,744,114 describes silica particles adopted for formulation into dentifrice compositions having a unique surface chemistry as to be at least 50% compatible with zinc values, and have a number of OH functions, expressed as OH/nm 2 , of at most 15 and a zero charge point of from 3 to 6.5. The '114 patent describes a process of preparing silica particles by the reaction of silicate with an acid to form a suspension or gel of silica. The gel/suspension is then separated, washed with water and treated with acid to adjust the pH below 7.
U.S. Pat. No. 5,616,316 describes silica that is more compatible with customary dentifrice ingredients. In addition to many other ingredients, cationic amines are mentioned.
Another problem associated with usage of conventional silicas in dentifrices is that they often have flavor compatibility problems. That is, the conventional silicas tend to interact with flavorants included in the same dentifrice in a manner that creates off-flavors, making the product less palatable. This off-flavor problem accompanying use of some conventional silicas in dentifrices is highly undesirable from a consumer satisfaction standpoint.
A need exists for silicas that can be used together with anti-microbial agents such as CPC in oral cleaning compositions such as dentifrices without impairing the respective functions of either ingredient. Silicas that are more flavor compatible are also in need. In general, the low surface area silica disclosed in this invention may be useful whenever it is desirable to limit the interaction of the silica particulate with desirable additives and components found in dentifrice formulations. The present invention meets these needs and others as will become readily apparent from the disclosure that follows.
SUMMARY OF THE INVENTION
This invention relates to a unique low surface area silica product. This silica product is particularly useful in dentifrice compositions containing cetylpyridinium chloride (“CPC”) or other therapeutic agents. CPC does not appreciably bind to these low surface area silica products. Therefore, when contained in a dentifrice composition, an increased amount of CPC remains available for its antimicrobial duties while the silica abrasive remains unimpaired by CPC attachment, and able to provide the mechanical cleaning and polishing action common to abrasive silica products. Additionally, the low surface area silica product is highly compatible with many dentifrice flavorants. The inventive silica product reduces the possibility of off-flavors when present together with flavorants. Also, the low surface area silica product is highly compatible with fluoride ion sources such as sodium fluoride. The low surface area silica product does not adversely interact with or impair those anticaries agents or their function.
Dentifrices that contain this silica product offer the benefit that CPC also can be used which remains at an effective antibacterial level in the dentifrice despite the presence of silica abrasive. As another benefit and advantage, dentifrices containing the low surface area silica product have superior flavor attributes. The flavor compatibility of the low surface area silica product of this invention is superior to current commercial dental-grade silica materials, as has been demonstrated in experiments described herein. In this respect, the inventive precipitated silica product generally has a % CPC Compatibility value of at least 20%, particularly greater than 40%, and more particularly greater than 60%, and even more particularly greater than 70%. The “% CPC Compatibility” characteristic of the silica is determined by a testing procedure explained in the more detailed descriptions provided below.
In one aspect, the invention relates to a precipitated silica product comprising surface-treated silica particulate including silica particles having a median diameter of 1 to 100 micrometers that supports deposits of a relatively denser amorphous “active” silica material at particulate surfaces in an amount effective to provide a BET specific surface area of from 1 to 50 square meters per gram, preferably 1 to 40 square meters per gram, more preferably less than 30 square meters per gram, and in amount effective to reduce attachment of CPC thereto as compared to the silica particulate without the surface deposits. In one particular aspect, the silica particulate is in the form of silica aggregates or agglomerates formed of the silica particles.
The inventive low surface area silica product may be produced via process including at least the steps of providing silica particulate as a preformed material or forming it in-situ, followed by precipitating active silica upon the silica particulate effective to satisfy the specific surface area and reduced CPC attachment requirements described elsewhere herein. The denser silica material deposited on the silica particulate “coats” the underlying silica substrate particulate primarily in the sense that it penetrates into and/or blocks the opening of the pores of the underlying silica particulate to effectively reduce the surface area of the silica particulate substrate.
The oral cleaning compositions that can be benefited by incorporation of the low surface area silica product of this invention include, for example, dentifrices, chewing gums, and mouthwashes, and the like. The term “dentifrice” means oral care products in general such as, without intending to be limited, toothpastes, tooth powders, and denture creams. The low surface area silica particulate of the invention also have wider cleaning utility and application, including, for instance, as a metal, ceramic or porcelain cleaning or scrubbing agent.
For purposes herein, the term “silica particulate” means finely divided silica, and the term encompasses silica primary particles, silica aggregates (i.e., unitary clusters of a plurality of silica primary particles), silica agglomerates (i.e., unitary clusters of a plurality of silica aggregates), singly or in combinations thereof. The term “denser”, as used in herein, refers to a lower porosity silica particulate. Quantitative BET surface area measurements taken before and after deposition of the active silica on the silica substrate particulate can be compared to determine qualitatively if a less porous (i.e., more dense) particulate has been created, i.e., as indicated by a measurable reduction (not increases or absence of change) in the specific surface area value.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an SEM of a surface-treated silica made according to Example 3 described herein.
FIG. 2 is an SEM of a commercial silica product, Zeodent® 113, which does not have the surface-treatment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the preceding summary, the present invention is directed to a unique low surface area silica product, which is particularly useful in dentifrice compositions containing therapeutic agents, such as CPC. The low surface area silica product of the present invention limits the ability of CPC to bind to these products. Consequently, loss of CPC to inadvertent interaction to silica abrasive is minimized.
The low surface area silica product may be produced by a general process scheme, in which:
1) a slurry of amorphous silica particulate is provided either by slurrying up a prefabricated silica material obtained in dry finely divided form, or alternatively from an ongoing production run in which fresh precipitated silica is in slurry or wet cake form without ever having been dried into powder form, followed by;
2) precipitating active silica upon the substrate silica particulate effective to satisfy the specific surface area and reduced CPC interaction requirements described herein.
Sourcing of Silica Particulate “Substrate” Material
Regarding the silica particulate provision of above general step 1), an amorphous silica particulate is provided. If provided in dry form, the dried crude silica used as the “particulate” to be surface-modified according to this invention includes commercially obtainable precipitated silicas, such as Zeodent® 113, Zeodent® 115, Zeodent® 153, Zeodent® 165, Zeodent® 623, Zeodent® 124 silicas, and so forth, which are available from J.M. Huber Corporation. These commercially available silicas typically are in aggregate form.
The dry finely divided silica particulate also may be obtained from a supply of premanufactured material made earlier at the same or different production facility where procedures used for the surface area reduction step can be performed at a later time.
The dry precipitated silicas to be used as the substrate particulate for the surface area reduction operation generally should have a median particle size of 1 to 100 μm, a BET specific surface area value of approximately 30 to 100 m 2 /g, and a linseed oil absorption of approximately 40 to 250 ml/100 g. Zeodent® 113, for example, typically has a median particle size of approximately 10 μm, BET surface area value of approximately 80 m 2 /g, a linseed oil absorption of approximately 85 ml/100 g. The silica particulates used as the substrate material for the coating operation, described below, preferably are constituted of silica particles having a median diameter of 1 to 100 micrometers. Substrate materials, such as high structure precipitated silica, silica gels and pyrogenic silica, with BET surface area greater than 100 m 2 /g, such as about 100 to 800 m 2 /g, or linseed oil absorption greater than 120 ml/100 g, such as about 120 to 400 ml/100 g, can be used in the present invention, although longer surface area reduction times (active silica deposition times) will be required to lower the BET surface area to desired levels.
The dry precipitated silicas must be slurried in an aqueous medium before they can be subjected to the dense silica coating application procedure described herein. Generally, the dry silicas are slurried to a solids content that creates a pumpable mixture, generally of from about 1 to about 50%.
Alternatively, crude undried liquid phase silica materials can be prepared in situ during a common production run scheme as the surface area reduction operation. Alternatively, a crude silica wet cake can be stored for later slurrying, or stored as a slurry thereof, until the surface area reduction procedure is performed at a subsequent time, without ever drying the silica solids to powder form. The solids content of the slurry provided before the surface area reduction operation is performed will be the same as that described above in connection with the dry silicas.
The liquid phase source of precipitated silicas generally should have constituent particle sizes, overall particle size, BET specific surface area value, and linseed oil absorption properties comparable to those respective values described above in connection with the dry source form of the silica. To the extent they meet those physical criteria, the liquid phase silicas can include amorphous precipitated silicas, silica gels or hydrogels pyrogenic silica and colloidal silicas. In one aspect, the silica particulates provided in situ are in aggregate or agglomerate form.
The silicas can be produced by acidulating an alkali metal silicate with a mineral acid, such as sulfuric acid, or organic acid, with heating. Synthetic amorphous precipitated silicas are generally prepared by admixing alkaline silicate solutions with acids with heating, stirring, and then filtering or centrifuging to isolate the precipitated silica solids as a wet cake form thereof. The reaction media may optionally contain an electrolyte, such as sodium sulfate. Wet cake of silica generally contains about 40 wt % to about 60 wt % water, and the remainder is principally solids. The precipitated reaction mass generally is filtered and washed with water to reduce the Na 2 SO 4 levels to tolerable levels. Washing of the reaction product is generally conducted after filtering. The pH of the washed wet cake can be adjusted, if necessary, prior to proceeding to subsequent steps described herein. If necessary, the washed wet cake is slurried to a solids content of between 1 to 50% before the surface area reduction procedure is performed on it. As previously noted, if the silica is dried, or dried and comminuted to a desired size, it must be reslurried before the surface area reduction procedure can be conducted on the crude silica.
To the extent they meet other requirements discussed herein, the crude silica to be used as a source of the substrate particulate for surface area reduction described herein can be, for example, precipitated silicas made as described in U.S. Pat. Nos. 4,122,161, 5,279,815 and 5,676,932 to Wason et al., and U.S. Pat. Nos. 5,869,028 and 5,981,421 to McGill et al., which teachings are incorporated herein by reference.
Surface Area Reduction of Silica Particulate “Substrate” Material
Regarding the surface area reduction of above general step 2), after slurrying the crude silica particulate in an aqueous medium, active silica is generated in the same medium for a time period and under conditions sufficient to provide dense amorphous silica deposits on the substrate particulate sufficient to reduce the BET surface area and CPC's potential for binding to it. In general, the slurried crude silica particulate intermediate product is dispersed in an aqueous medium in which active silica is generated by acidulating an alkali metal silicate with a mineral acid therein. The resulting mixture is gently agitated or mixed, such as with a paddle mixer, for a sufficient period of time to ensure that the active silica and substrate silica particulates are substantially uniformly dispersed. The resulting low surface area silica product is filtered or otherwise dewatered, washed, and dried as needed.
In this regard, the methodology used to provide the active silica in the medium that is deposited as an amorphous silica material on the surfaces of the substrate particulate generally involves similar chemistries and conditions applied to make the crude or substrate particulate, except that the addition rates of the silicate and acid used for formation of active silica must be sufficiently slowed in order to insure the active silica deposits on the existing substrate silica particles and does not form separate precipitated particles. The addition of active silica too rapidly will result in the formation of separate precipitated silica particles and will not result in the desired decrease in surface area of the substrate silica. It is desirable to use temperatures ranging from 60 to 100° C., pH from 7 to 10, and an active silica deposition rate such that the specific surface area of the of the silica particulate material is reduced. Optionally, a salt such as Na 2 SO 4 can be added in an amount such that the desired decrease in surface area is still obtained. Reaction temperatures of greater than 90° C. and pH greater than 9 are preferred for use during the surface area reduction portion of the process.
In one aspect, the surface area reduction process is manipulated appropriately to ensure that the extent of deposition of active silica is at a rate and in an amount effective to provide a BET specific surface area of from 1 to 50 square meters per gram, preferably 1 to 40 square meters per gram, more preferably less than 30 square meters per gram. It also should be in amount effective to reduce binding of CPC thereto as compared to the silica particulate that has not been exposed to a surface area reduction process.
In addition, the inventive precipitated silica product has a % CPC Compatibility value generally of at least 20%, particularly greater than 40%, more particularly greater than 60%, and can be even greater than 70%. The “% CPC Compatibility” characteristic of the silica is determined by a testing procedure explained in the examples that follow.
The resulting low surface area silica also generally has a median particle size ranging between about 1 to about 100 microns, and preferably in one embodiment ranges between about 5 and about 20 microns. The particle size of the silicas is measured using a Horiba Particle Analyzer. Model LA-910 manufactured by Horiba Instruments, Boothwyn, Pa.
The resulting silica product can be spray dried in a similar manner as the treatment performed on the crude freshly prepared silicas. Alternatively, the wet cake obtained can be reslurried, and handled and supplied in slurry form or supplied as a filter cake, directly.
Also, drying of silicas described herein can be effected by any conventional equipment used for drying silica, e.g., spray drying, nozzle drying (e.g., tower or fountain), flash drying, rotary wheel drying or oven/fluid bed drying. The dried silica product generally should have a 1 to 15 wt. % moisture level. The nature of the silica reaction product and the drying process both are known to affect the bulk density and liquid carrying capacity. Further, care must be taken that the drying operation and subsequent operations do not detrimentally affect the structure of the silica obtained in the precipitation stage. The dried low surface area silica product is in a finely divided form. In one particular embodiment, the water content of the precipitated silica-containing fractions is about 25% by weight or more for all times until the drying procedure is performed on the low surface area silica product.
To decrease the size of the dried low surface area silica particles further, if desired, conventional grinding and milling equipment can be used. A hammer or pendulum mill may be used in one or multiple passes for comminuting and fine grinding can be performed by fluid energy or air-jet mill. Products ground to the desired size may be separated from other sizes by conventional separation techniques, e.g., cyclones, classifiers or vibrating screens of appropriate mesh sizing, and so forth.
There are also ways to reduce the particle size of the resulting silica product before isolation and/or during the synthesis of the silica product that affect the size of the dried product or product in slurry form. These include but are not limited to media milling, the use of high shear equipment (e.g. high shear pump or rotor-stator mixers), or ultrasound devices. Particle size reduction carried out on the wet silica product can be done at anytime before drying, but more preferably during formation of the core and/or the deposition of the active silica onto the core. Any particle size reduction done on the dry or wet silica product should be done in a way not to significantly reduce the CPC compatibility of the final product.
The recovery of the dried silica in the present invention does not require silica dewatering and dehydration to be performed with an organic solvent replacement procedure. The isolation of the silica product can be performed from an aqueous medium without occurrence of product degradation.
Dentifrice Compositions
Dentifrices that contain the above-described low surface area silica product offer the benefit that therapeutic agents, such as CPC also can be used which remains at an effective antibacterial level in the dentifrice despite the presence of silica abrasive. The low surface area silica particles show decreased interaction with CPC and as a result there remains an increase in the free CPC in the dentifrice available to improve antibacterial efficacy.
While CPC is used herein as representative of dentifrice therapeutic agents, other antimicrobial agents, (cationic, anionic and nonionic) are contemplated by the invention. Other suitable antimicrobial agents include bisguanides, such as alexidine, chlorhexidine and chlorhexidine gluconate; quarternary ammonium compounds, such as benzalkonium chloride (BZK), benzethonium chloride (BZT), cetylpyridinium chloride (CPC), and Domiphen bromide; metal salts, such as zinc citrate zinc chloride, and stannous fluoride; sanguinaria extract and sanguinarine; volatile oils, such as eucalyptol, menthol, thymol, and methyl salicylate; amine fluorides; peroxides and the like. Therapeutic agents may be used in dentifrice formulations singly or in combination.
As another benefit and advantage, dentifrices containing the low surface area silica product have a superior flavor attributes. The flavor compatibility of the low surface area silica product of this invention is superior to a higher surface area silica material, as has been demonstrated in experiments described herein. Dentifrice compositions incorporating the low surface area silica product described herein generally contain the silica in an effective amount for abrasive and polishing action. This amount can vary, depending on other ingredients of the formulation, for example, but generally will range from about 5 to about 50 wt %.
Dentifrice compositions incorporating the low surface area silica product described herein preferably also contain CPC in an antimicrobial effective amount. This amount can vary, depending on other ingredients of the formulation and limitations placed upon its use by regulating authorities (e.g. FDA), for example, but generally will range from about 0.01 to about 1 wt %., preferably from about 0.1 to about 0.75 wt. %, most preferably from about 0.25 to 0.50 wt. %.
Other additives commonly used or otherwise beneficial in dentifrices also optionally may be included in the formulation. A pharmaceutically acceptable carrier for the components of dentifrice compositions containing the low surface area silica product of the present invention is optional and can be any dentifrice vehicle suitable for use in the oral cavity. Such carriers include the usual components of toothpastes, tooth powders, prophylaxis pastes, lozenges, gums, and the like and are more fully described thereafter.
Flavoring agents optionally can be added to dentifrice compositions. Suitable flavoring agents include oil of Wintergreen, oil of peppermint, oil of spearmint, oil of sassafras, and oil of clove, cinnamon, anethole, menthol, and other such flavor compounds to add fruit notes, spice notes, etc. These flavoring agents consist chemically of mixtures of aldehydes, ketones, esters, phenols, acids, and aliphatic, aromatic and other alcohols.
Sweetening agents, which can be used, include aspartame, acesulfame, saccharin, dextrose, levulose and sodium cyclamate. Flavoring and sweetening agents are generally used in dentifrices at levels of from about 0.005% to about 2% by weight
A water-soluble fluoride compound optionally can be added and present in dentifrices and other oral compositions in an amount sufficient to give a fluoride ion concentration in the composition at 25° C., and/or when it is used of from about 0.0025% to about 5.0% by weight, preferably from about 0.005% to about 2.0% by weight, to provide additional anticaries effectiveness. A wide variety of fluoride ion-yielding materials can be employed as sources of soluble fluoride in the present compositions. Examples of suitable fluoride ion-yielding materials are found in U.S. Pat. No. 3,535,421, and U.S. Pat. No. 3,678,154, both being incorporated herein by reference. Representative fluoride ion sources include: stannous fluoride, sodium fluoride, potassium fluoride, sodium monofluorophosphate and many others. Stannous fluoride and sodium fluoride are particularly preferred, as well as mixtures thereof.
Water is also present in the toothpastes and dentifrices according to another embodiment of this invention. Water employed in the preparation of suitable toothpastes should preferably be deionized and free of organic impurities. Water generally comprises from about 2% to 50%, preferably from about 5% to 20%, by weight, of the toothpaste compositions. These amounts of water include the free water which is added plus that which is introduced with other additives and materials, such as humectant.
In preparing toothpastes, it often is necessary to add some thickening or binder material to provide a desirable consistency and thixotropy. Preferred thickening agents are carboxyvinyl polymers, carrageenan, hydroxyethyl cellulose and water-soluble salts of cellulose ethers such as sodium carboxymethyl cellulose and sodium carbokymethyl hydroxyethyl cellulose. Natural gums such as gum karaya, xanthan gun, gum arabic, and gum tragacanth can also be used. Thickening agents in an amount from about 0.5% to about 5.0% by weight of the total composition generally can be used.
Silica thickeners can also be used to modify toothpaste rheology. Precipitated silica, silica gels and fumed silica can be used. Silica thickeners can be added generally at a level of about 5% to about 15%.
It is also often desirable to include some humectant material in a toothpaste to keep it from hardening. Suitable humectants include glycerin (glycerol), sorbitol, polyalkylene glycols such as polyethylene glycol and polypropylene glycol, hydrogenated starch hydrolyzates, xylitol, lactitol, hydrogenated corn syrup, and other edible polyhydric alcohols, used singly or as mixtures thereof. Suitable humectants can be added generally at a level of from about 15% to about 70%.
Chelating agents optionally can be added to the dentifrices of the invention, such as alkali metal salts of tartaric acid and citric acid, or alkali metal salts of pyrophosphates or polyphosphates.
Other optional ingredients and adjuvants of dentifrices, such as those described in U.S. Pat. No. 5,676,932 and Pader, M., Oral Hygiene Products and Practice, Marcel Dekker, Inc., New York, 1988, for instance, also can be added as needed or desired. These other optional adjuvants, additives, and materials that can be added to the dentifrice compositions of the present invention include, for example, foaming agents (e.g., sodium lauryl sulfate), detergents or surfactants, coloring or whitening agents (e.g., titanium dioxide, FD&C dyes), preservatives (e.g., sodium benzoate, methyl paraben), chelating agents, antimicrobial agents, and other materials that can be used in dentifrice compositions. The optional additives, if present, generally are present in small amounts, such as no greater than about 6% by weight each.
In all cases, the ingredients used in dentifrice formulations, such as thickening gums, foaming agents, etc., are selected to be compatible with the therapeutic agents and flavors.
Additionally, while the usefulness of the abrasive cleaning material of this invention is specifically illustrated in oral cleaning compositions, it is will be appreciated that the low surface area silica of this invention has wider usefulness. For instance, it can be used in metal, ceramic or porcelain cleaning or scrubbing and as a CMP (Chemical Mechanical Planarization) polishing agent.
EXAMPLES
The following examples are presented to illustrate the invention, but the invention is not to be considered as limited thereto. In the following examples, parts are by weight unless indicated otherwise.
The following examples 1-10 describe runs in which CPC compatible silica products were produced as part of a single “in situ” continuous production run.
Example 1
40 L of sodium silicate (13%, 3.32 M.R., 1.112 S.G.) was added to a 400-gallon reactor and was heated to 95° C. with stirring at 75 RPM. Sodium silicate (13%, 3.32 M.R., 1.112 S.G.) and sulfuric acid (11.4%) were then simultaneously added to the reactor at rates of 7.8 L/min and 2.3 L/min, respectively, for 47 minutes. After 47 minutes, sodium silicate addition was stopped and the pH was adjusted to 9.5+/−0.2 with continued addition of sulfuric acid (11.4%). (This formed the substrate silica.) Once the pH reached 9.5, sodium silicate (13%, 3.32 M.R., 1.112 S.G.) and sulfuric acid (11.4%) were simultaneously added at rates of 1.1 L/min and 0.4 L/min, respectively, for 300 minutes(active silica addition time). If necessary, the acid rate was adjusted to maintain pH 9.5+/−0.2. After 300 minutes, the flow of sodium silicate was stopped and the pH was adjusted to 5.0+/−0.2 with the addition of sulfuric acid (11.4%) at 2.3 L/min. The batch was digested for 10 minutes at pH 5.0+/−0.2, was filtered, washed to a conductivity<1500 μS, and spray dried.
Example 2
40 L of sodium silicate (13%, 3.32 M.R., 1.112 S.G.) was added to a 400-gallon reactor and was heated to 95° C. with stirring at 50 RPM. Once the temperature stabilized at 95° C., a Silverson in-line mixer coupled to the reactor by a re-circulation line was set to 100 Hz with re-circulation of 100 Hz. Sodium silicate (13%, 3.32 M.R., 1.112 S.G.) and sulfuric acid (11.4%) were then simultaneously added to the reactor at rates of 7.8 L/min and 2.3 L/min, respectively, for 47 minutes. After 15 minutes, the stir rate was increased to 75 RPM. After 47 minutes, the Silverson in-line mixer was stopped. Sodium silicate addition was also stopped and the pH was adjusted to 9.5+/−0.2 with continued addition of sulfuric acid (11.4%). (This formed the substrate silica.) Once the pH reached 9.5, sodium silicate (13%, 3.32 M.R., 1.112 S.G.) and sulfuric acid (11.4%) were simultaneously added at rates of 1.1 L/min and 0.4 L/min, respectively, for 300 minutes (active silica addition time). If necessary, the acid rate was adjusted to maintain pH 9.5+/−0.2. After 300 minutes, the flow of sodium silicate was stopped and the pH was adjusted to 5.0 with the addition of sulfuric acid (11.4%) at 2.3 L/min. The batch was digested for 10 minutes at pH 5.0, was filtered, washed to a conductivity <1500 μS, and spray dried.
Examples 3-6
For these examples, 50 L of sodium silicate (13%, 3.32 M.R., 1.112 S.G.) was added to a 400-gallon reactor and was heated to 95° C. with stirring at 50 RPM. Once the temperature stabilized at 95° C., a Silverson in-line mixer coupled to the reactor by a re-circulation line was set to 100 Hz with re-circulation of 100 Hz. Sodium silicate (13%, 3.32 M.R., 1.112 S.G.) and sulfuric acid (11.4%) were then simultaneously added to the reactor at rates of 9.8 L/min and 2.9 L/min, respectively, for 47 minutes. After 15 minutes, the stir rate was increased to 75 RPM. After 47 minutes, the Silverson in-line mixer was stopped (silica substrate formed) and the flow of sodium silicate (13%, 3.32 M.R., 1.112 S.G.) was adjusted to a specified rate. Once the pH reached 9.5, the sulfuric acid (11.4%) rate was adjusted to maintain pH 9.5+/−0.2. After a specified active silica addition time, the flow of sodium silicate was stopped and the pH was adjusted to 5.0+/−0.2 with the addition of sulfuric acid (11.4%) at 2.9 L/min. The batch was digested for 10 minutes at pH 5.0+/−0.2, was filtered, washed to a conductivity<1500 μS, and spray dried. The specified silicate rate and active silica addition time are given below in Table 1.
TABLE 1
Adjusted silicate
Active Silica
Example
rate, L/min
Addition Time, min.
3
2.8
150
4
3.3
150
5
3.3
120
6
1.8
150
FIG. 1 is an SEM of a low surface area silica made according to Example 3 described herein. FIG. 2 is an SEM of a commercial silica product, Zeodent® 113.
Example 7
50 L of sodium silicate (13%, 3.32 M.R., 1.112 S.G.) was added to a 400-gallon reactor and was heated to 95° C. with stirring at 50 RPM. Once the temperature stabilized at 95° C., a Silverson in-line mixer coupled to the reactor by a re-circulation line was set to 60 Hz with re-circulation of 100 Hz. Sodium silicate (13%, 3.32 M.R., 1.112 S.G.), sulfuric acid (20.0%) and water were then simultaneously added to the reactor at rates of 11.7 L/min, 1.88 L/min and 1.60 L/min, respectively, for 47 minutes. After 15 minutes, the stir rate was increased to 75 RPM. After 47 minutes, the Silverson in-line mixer was stopped and the flow of sodium silicate (24.4%, 3.32 M.R., 1.227 S.G.) was adjusted to 1.60 L/min (substrate silica formed). The water pump rate was set to 0.0 L/min. Once the pH reached 9.5, the sulfuric acid (20.0%) rate was adjusted to maintain pH 9.5+/−0.2 (˜0.79 L/min). After a total batch time of 197 minutes, 150 minutes of which is the active silica addition time, the flow of sodium silicate was stopped and the pH was adjusted to 5.0+/−0.2 with the addition of sulfuric acid (20.0%) at 2.9 L/min. The batch was digested for 10 minutes at pH 5.0+/−0.2, was filtered, washed to a conductivity<1500 μS, and spray dried.
Examples 8-11
For examples 8-11, Example 3 was reproduced up to substrate formation following the step of adjusting the pH to 9.5+/−0.2. The varying active silica addition times are given below in Table 2. Thereafter, a two-gallon aliquot of the reaction mixture was taken to the laboratory. After the temperature was stabilized at 95° C., sulfuric acid (11.4%) was added at a rate of 17 ml/min until pH 5.0+/−0.2 was reached. The reaction mixture was then digested for 10 minutes while maintaining pH 5.0+/−0.2, was filtered, washed with ˜7500 ml of distilled water, and was oven dried overnight at 105° C.
TABLE 2
Active Silica
Addition Time
Example
(min.)
8
30
9
60
10
90
11
120
A number of properties were measured for the silica products obtained in Examples 1-11, which are summarized in Table 3.
For Examples 1-11, as well as other examples summarized herein, the “CPC Compatibility characteristic value was determined in the following manner.
CPC Compatibility Test
27.00 g of a 0.3% solution of CPC was added to a 3.00 g sample of the silica to be tested. The silica was previously dried at 105° C. to 150° C. to a moisture content of 2% or less, and the pH of the sample was measured to ensure the 5% pH was between 5.5 and 7.5. The mixture was shaken for a period of 10 minutes. Accelerated aging testing requires agitation of the test specimen for 1 week at 140° C. After agitation was complete, the sample was centrifuged and 5 ml of the supernatant was passed through a 0.45 μm PTFE milli-pore filter and discarded. An additional 2.00 g of supernatant was then passed through the same 0.45 μm PTFE milli-pore filter and then added to a vial containing 38.00 g of distilled water. After mixing, an aliquot of the sample was placed in a cuvette (methyl methacrylate) and the U.V. absorbance was measured at 268 nm. Water was used as a blank. The % CPC Compatibility was determined by expressing as a percentage the absorbance of the sample to that of a CPC standard solution prepared by this procedure with the exception that no silica was added.
The “% Active Silica” values were determined by calculation from the batch parameters. Active silica is determined by knowing the volume of active silica used and the silicate concentration, S.G. and M.R. Likewise, the total batch silica is calculated by knowing the total volume of silica used and silicate concentration, S.G. and M.R. % Active silica equals g Active silica divided by g total batch silica times 100. For instance in Example 1:
Silicate used is 13%, 3.32 M.R., 1.112 S.G.
Vol. of active silica=(1.1 l/min) (300 min) =330 liters
Vol. of substrate silica=40 Liters+(7.8 l/min)(47 min)=406.6 liters
Total silica vol.=330+406.6=736.6 liters
% Active silica = ( 330 L ) ( 0.13 ) ( 1.112 ) ( 3.32 ) ( 60 / 261.2 ) ( 1000 ) ( 736.6 L ) ( 0.13 ) ( 1.112 ) ( 3.32 ) ( 60 / 261.2 ) ( 1000 ) = 44.80
As is seen in the above calculation when computing in situ % active silica, all terms except the volumes cancel so that the % active silica equals the active silica volume/total silica volume. When starting with a premanufactured silica substrate, which is measured in weight values, one must use the above equation to convert active silica to a weight measure, such as grams to put all ingredients on the same basis.
The BET and Linseed Oil Absorption values were determined by procedures described in U.S. Pat. No. 5,981,421, which teachings are incorporated herein by reference.
TABLE 3
% CPC
Oil
Median
%
Ex-
Compati-
BET
%
Absorbtion
Particle
Active
ample
bility
(m 2 /g)
H 2 O
(cc/100 g)
Size (μm)
Silica
1
65.0
4
6.6
49
13.9
45
2
78.2
9
5.8
49
7.5
45
3
84.8
21
6.3
47
10.9
45
4
82.8
10
7.5
37
9.9
55
5
79.1
22
8.1
32
7.9
45
6
80.6
9
5.8
45
5.1
35
7
88.0
17
7.2
38
8.6
45
8
46.2
11
1.2
51
5.1
14
9
70.9
15
1.2
52
5.4
25
10
82.0
3
0.8
58
6.8
33
11
84.4
10
1.3
53
8.9
40
The following Examples 12-17 describe additional runs in which the deposition of the active silica material was performed in situ on a silica substrate particulate as part of a single continuous process flow.
Examples 12-17
Substrate Formation:
Sodium silicate solution (105 ml, 13%, 3.32 M.R., 1.112 S.G.) was added to a one-gallon stainless steel reactor and was heated to 85° C. with stirring at 300 RPM. Sodium silicate (13%, 3.32 M.R., 1.112 S.G.) and sulfuric acid (11.4%) were simultaneously added to the reactor at rates of 20.6 and 6.2 ml/min, respectively, for 47 minutes. After 47 minutes, the flow of silicate to the reactor was stopped and the pH was adjusted to 5.5+/−0.2 with the continued addition of sulfuric acid (11.4%). The reaction mixture was then digested for 10 minutes at 93° C.
Surface Area Reduction:
After the substrate was digested, the pH of the solution was brought to target after digestion pH with the addition of sodium silicate solution (13%, 3.32 M.R., 1.112 S.G.) at target silicate rate and was continued for a specified active silica addition time. During this time the temperature was adjusted to second reaction temperature and maintained at this temperature for the remainder of the batch. Once the target pH was reached, sulfuric acid (11.4%) was added at a specified second acid rate to maintain the target pH during the remainder of the reaction. For the higher pH examples 16-17 the sodium silicate rate was increased to 5.8 ml/min. at this time. If necessary, the flow of acid was adjusted to maintain pH. At the end of the active silica addition time, the addition of acid and silicate was stopped, the final batch pH adjusted, if necessary and the batch was dropped. It was washed with approximately 2 gallons of de-ionized water, and dried in an oven overnight at 105° C. The process variables for examples 12-17 are given in Table 4 below.
TABLE 4
Example
Example
Example
Example
Example
Example
12
13
14
15
16
17
pH after substrate
7
7
7
9
9.5
9.5
digestion
Target silicate rate,
2.4
2.9
2.4
2.4
2.9
2.9
ml/min.
Active silica
240
300
240
240
150
150
addition time,
min.
2 nd reaction Temp,
75
75
93
75
95
95
° C.
2 nd Acid rate,
0.8
1.9
0.8
0.8
2.6
2.6
ml/min.
Final silicate rate,
2.4
2.9
2.4
2.4
5.8
5.8
ml/min.
Final pH
7.0
7.0
7.0
7.0
7.0
5.5
A number of properties were measured for the low surface area silicas of Examples 12-17, which are summarized in Table 5.
TABLE 5
Oil
Median
%
Ex-
% CPC
BET
%
Absorbtion
Particle
Active
ample
Compat.
(m 2 /g)
H2O
(cc/100 g)
Size (μm)
Silica
12
52.2
23
4.7
71
32.3
35
13
60.5
26
4.3
71
49.5
45
14
68.2
24
4.5
73
32.4
35
15
58.6
19
4.2
69
27.1
35
16
78.0
13
4.6
53
32.2
45
17
87.6
11
4.9
48
44.0
45
The following Examples 18-23 describe additional runs in which the deposition of the active silica material was deposited on premanufactured silica powders.
Example 18
Deionized water, specified premanufactured silica (substrate) and optionally anhydrous sodium sulfate were added to a two-gallon stainless steel reaction vessel and taken to a reaction temperature with continuous stirring at 400 RPM. Temperature and stirring rate were held constant for the duration of the batch. Sodium silicate (3.32 molar ratio) and sulfuric acid were added simultaneously at specified rates for a specified reaction time. The sulfuric acid addition rate was adjusted slightly when necessary to maintain the reaction slurry target pH. After the specified reaction time, addition of the sodium silicate was stopped and sulfuric acid was added to a pH of a 5.0±0.2. The resulting reaction media was filtered using a Buchner funnel and washed with approximately 4000 mL of deionized water. The washed, de-watered slurry was then oven dried overnight at 105° C.
TABLE 6
Example No.
18
19
20
21
22
23
Silica
Zeodent ®
Zeodent ®
Zeodent ®
Zeodent ®
Zeodent ®
Zeodent ®
Substrate
105
105
114
114
114
114
Substrate
30
30
30
25
25
25
% solids
Substrate wt, g
750
750
750
500
500
500
Water, ml
1750
1750
1750
1500
1500
1500
Na2SO 4 , g
0
0
0
32
0
358
Reaction Temp.
75
75
75
95
95
95
(° C.)
Sodium Silicate
13.0
13.0
13.0
13.0
13.0
24.4
Conc. (% Solids)
Sodium Silicate
13.1
15.0
15.0
24.8
24.8
20
addition rate,
ml/min
Sulfuric acid
11.4
11.4
11.4
11.4
11.4
20.0
Conc. (% solids)
Acid addition
4.1
4.7
4.7
6.0
7.5
5.1
rate, ml/min.
Target pH
7.0
7.0
7.0
9.5
9.5
9.0
Simultaneous
173.9
243.5
243.5
150.0
150.0
60.0
Addition (min)
% Active Silica
25
35
35
45
45
35
A number of properties were measured for the silica products obtained for Examples 18-23, which are summarized in Table 7.
TABLE 7
Example No.
18
19
20
21
22
23
% CPC
45.0
70.6
27.2
55.0
49.3
24.7
Compatibility
% Active Silica
25
35
35
45
45
35
% H2O
3.59
3.94
5.83
3.10
1.80
1.60
BET Surface
15
7
23
3
12
14
Area (m2/g)
Oil Absorption
46
45
78
69
67
81
(ml/100 g)
Median Particle
7.0
6.5
5.6
7.7
6.9
7.4
Size (μm)
FLAVOR COMPATIBILITY STUDIES
Experimental studies were performed to assess the flavor compatibility of low surface area silica product representative of this invention.
Procedure for Flavor Compatibility Analysis:
Sample Preparation:
0.5 g samples of a silica product were weighed to 2 decimal place accuracy-and loaded into 15 ml amber glass screw top with polypropylene hole cap vials w/PTFE/Silicone septa (available from Supelco part # 27049). Using a gas tight syringe, 10 μLs of a Natural Spearmint Essential Oil (Available from Sigma Aldrich Cat. # W30322-4) was added to the samples, taking care to evenly distribute the oil on the sample, and not to wet the inside of the glass vial with the oil. The vials were then capped and the samples agitated on a vortex mixer for approximately 10 seconds to ensure even distribution of the oil on the sample. The samples were then allowed to equilibrate prior to analysis at room temperature, 22.5 to 23.5° C., for about 12 hours. The samples were not agitated immediately prior to analysis. Two specimens were tested for each sample and the results averaged.
Headspace Sampling:
The samples were then sampled for 5 minutes at room temperature using a 65 μm Polydimethylsiloxane-Divnylbenzene Solid Phase microextraction (SPME) fiber (Available from Supelco, #57310-U) and a manual fiber holder assembly (Supelco #57330-U). Room temperature was maintained between 22.5 and 23.5C during the analysis. After a 5-minute exposure, the fiber was withdrawn from the sample vial and desorbed into the GCMS system and analyzed under the following conditions.
Chromatography Conditions:
A Hewlett Packard 5890 GC with 5972 Mass Selective Detector was used for this analysis.
Column: Restek Stabilwax, 60 m, 0.25 mmID, 0.25 μgm film
Injection: 250° C., 25 ml/min split, 1 mm split liner
Carrier: He 28 cm/sec @ 100° C.
Oven Program:
50° C., hold 4 minutes
4° C./min to 100° C., hold 0 minutes
8° C./min to 200°, hold 0 minutes
25° C./min to 240° C., hold 4 minutes
Detector: MS 280° C., scan mode, 30-550AMU.
The oil of spearmint reference was prepared in the same manner as described above, except without the addition of any silica. Ten of the major oil of spearmint constituent peaks were chosen for data collection to evaluate the effect of different silicas on the intensity of these flavor components. It is theorized that a change in peak intensity of some of the flavor components is proportional to changes in perceived flavor.
Example 24
Flavor compatibility data was collected for samples of spearmint oil standard, silica product made according the procedures described in Example 3 and for Zeodent® 113 silica for purposes of having their flavor compatibility assessed in the manner described above, and the data is summarized below in Table 8.
TABLE 8
Std. Oil
Zeodent 113 silica
Ex. 3
Peak
Peak
Peak
Area ×
Area ×
% change
Area ×
% change
Peak ID
10 4
10 4
from oil
10 4
from oil
a-pinene
870
668
−23.2
831
−4.6
b-pinene
852
739
−13.8
833
−3.1
myrcene
2502
2226
−12.4
2421
−3.7
limonene
14722
14648
−1.7
14602
−0.8
eucalyptol
2121
200
−91.2
1800
−15.0
3-octanol
657
30
−95.4
575
−12.6
b-terpineol
389
9
−97.8
324
−16.4
menthone
316
45
−85.9
343
8.5
dihydrocarvone
1087
211
−80.7
1315
21.0
carvone
19920
3951
−80.0
24317
22.0
For these tests, the temperature of the room was controlled between 22.5 and 23.5° C. throughout the data collection. As can be seen, the inventive low surface area silica product had much less effect than higher surface area Zeodent 113 silica on the various major components of a typical toothpaste flavor and therefore would provide increased flavor compatibility.
It will be understood that various changes in the details, materials, and arrangements of the parts which have been described and illustrated herein in order to explain the nature of this invention may be made by those skilled in the art without departing from the principles and scope of the invention as expressed in the following claims.
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Precipitated silica product having low surface area and enhanced flavor compatibility. The precipitated silica product is especially well-adapted for use in dentifrices containing cetylpyridinium chloride, which do not attach to the low surface area silica product in a meaningful level and thus remain available for antimicrobial action. Processes for making the low surface area silica product are also provided.
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BACKGROUND OF THE INVENTION
This invention relates to an ozone generator.
A conversion cell for generation of ozone generally comprises two electrodes having an insulator therebetween. The insulator does not occupy the entire space between the confronting surfaces of the electrodes, but a gas space is left between the insulator and one of the electrodes. The gas space has an inlet port and an exit port. The inlet port is connected to a source of a feed gas under pressure and the outlet port is connected to a volume at lower pressure than the supply pressure of the feed gas. Accordingly, the feed gas, which contains oxygen, flows through the gas space. The electrodes are normally of approximately equal surface area, and an alternating potential of 5 kv or more and a frequency of 0.05-3 kHz, is established between the electrodes, for example by connecting the electrodes to opposite ends of the secondary winding of a transformer, the primary winding of which is connected to an alternating current source at a considerably lower voltage. A corona discharge is established in the gas space. Some of the oxygen molecules present in the gas space disassociate into atoms, and some of the oxygen atoms combine with oxygen molecules to create ozone molecules.
It is desirable that the ozone remain at a relatively low temperature, because at temperatures above about 48° C. an ozone molecule readily disassociates into an oxygen atom and an oxygen molecule, and there is a high probability that oxygen atoms will recombine to form oxygen molecules. A large proportion (80% to 90%) of the electrical energy supplied to the conversion cell of a conventional ozone generator is not utilized directly in the conversion of oxygen to ozone, and this excess energy is dissipated as heat. One mechanism for generation of heat is the rapid reversals of electrical stress applied to the dielectric and the gas present in the gas space. Most conventional ozone generators require liquid cooling or a refrigeration system to remove the heat generated by the excess energy supplied to the conversion cell.
Using oxygen as the feed gas, the gas supplied at the outlet of an ozone generator that is currently available may contain up to about 2% by weight ozone. Because of the input energy required and the resulting generation of heat, few conventional ozone generators are able to generate continuously a gas mixture containing more than 2% by weight ozone.
U.S. Pat. No. 4,869,881 (Collins) discloses an ozone generator in which a silicon controlled rectifier (SCR) is connected in parallel with the primary winding of a transformer the secondary winding of which is connected to the electrodes of the conversion cell. The SCR is repeatedly fired in order to chop the DC voltage provided by a power supply into pulsed DC voltage. The frequency at which the SCR is fired is controlled by a potentiometer.
U.S. Pat. No. 4,128,768 (Yamamoto et al) discloses an ozone generator in which silicon controlled rectifiers are used to convert a direct current supplied by a power supply to alternating form for application to the primary winding of the transformer.
In accordance with the disclosure of Yamamoto et al, the voltage applied to the electrodes of the conversion cell varies cyclically, and as the potential difference between the electrodes increases, the potential difference across the gas space increases to a threshold value, at which discharge takes place, and immediately falls to zero, and this cycle repeats several times within each cycle of the alternating voltage between the electrodes.
U.S. Pat. No. 1,845,670 (Lebrun) discloses a transformer-driven ozone generator.
U.S. Pat. No. 4,410,495 (Bassler et al) discloses an ozone generator having a cylindrical conversion cell in which the outer electrode is composed of multiple sleeves spaced apart along the cell. The sleeves are connected through respective switches to an alternating current source.
U.S. Pat. No. 4,603,031 (Gelbman) discloses a cylindrical conversion cell in which the gas space is defined between the insulator and the exterior surface of the inner electrode, and the inner electrode is apertured. Feedstock gas is supplied to the gas space by way of the interior of the inner electrode and the apertures in the inner electrode.
U.S. Pat. No. 4,690,803 (Hirth) discloses an ozone conversion cell in which the gas space is defined between the exterior surface of the insulator and the interior surface of the outer electrode. The insulator is carried by the inner electrode and is provided with a protective layer of passivating glass.
U.S. Pat. No. 4,966,666 (Waltonen) discloses a cylindrical conversion cell in which the insulator is in the form of a rod having a helical groove at its exterior surface, and the groove constitutes the gas space to which feedstock gas is supplied. It will be recognized by those skilled in the art that a gas space in the form of a helical groove provides a long dwell time for the feedstock gas in the conversion cell.
SUMMARY OF THE INVENTION
In accordance with a first aspect of the invention, an ozone generator comprises a d.c. power supply having first and second d.c. terminals, and a transformer. The transformer's primary winding has a first end connected to the first d.c. terminal and also has a second end. A controllable switch defines a current path between first and second electrodes, one of which is an anode and the other of which is a cathode. The first electrode of the switch is connected to the second d.c. terminal of the power supply and the second electrode of the switch is connected to the second end of the primary winding. The ozone generator also comprises a conversion cell having first and second electrodes connected to the opposite ends respectively of the transformer's secondary winding.
In accordance with a second aspect of the invention, a conversion cell for an ozone generator comprises a first electrode that is hollow and has a right cylindrical internal surface, a second electrode that has a right cylindrical external surface of smaller radius than the internal surface of the first electrode, and an insulator sleeve having coaxial right cylindrical internal and external surfaces. The insulator sleeve is disposed within the first electrode and the second electrode is disposed within the insulator sleeve, and a gas space is defined between the insulator sleeve and one of the electrodes, which is formed in its right cylindrical surface with two annular grooves at its two opposite ends respectively. O-rings are fitted in the grooves respectively for sealing the gas space at opposite respective ends of the conversion cell.
In accordance with a third aspect of the invention, a conversion cell for an ozone generator comprises a first electrode that is hollow and has a right cylindrical internal surface, a second electrode that has a right cylindrical external surface of smaller radius than the internal surface of the first electrode, and an insulator sleeve having coaxial right cylindrical internal and external surfaces. The insulator sleeve is disposed coaxially within the first electrode and the second electrode is disposed coaxially within the insulator sleeve, whereby first and second gas spaces are defined between the insulator sleeve and the first and second electrodes respectively. The first and second gas spaces are sealed at opposite respective ends of the conversion cell and are in open communication with each other.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention, and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings in which:
FIG. 1 is a simplified schematic diagram of an ozone generator embodying the present invention,
FIG. 2 is a longitudinal sectional view of the preferred form of the conversion cell of the ozone generator,
FIG. 3 is a more detailed diagram of the ozone generator shown in FIG. 1, and
FIG. 4 is a longitudinal sectional view of an alternative construction of the conversion cell.
In the different figures, like reference numerals designate corresponding components, and primed reference numerals designate components that have similar functions to components that are designated by corresponding unprimed reference numerals.
DETAILED DESCRIPTION
The ozone generator shown in FIG. 1 comprises a drive circuit 40 and a conversion cell 44.
The conversion cell is shown in detail in FIG. 2 and comprises an inner electrode 2, which is tubular in form, an outer tubular electrode 6, and a sleeve 10 of electrically insulating material. Typically, the length of the outer electrode 6 is between about 22 cm and about 45 cm, depending on the desired output of ozone.
The external diameter of sleeve 10 is 8.89 cm +/-0.025 mm and its internal diameter is 8.51 cm +/-0.025 mm. The internal and external surfaces of sleeve 10 are concoaxial to within 0.025 mm. The external diameter of electrode 2 is 8.453 cm +/-0.025 mm and the internal diameter of electrode 6 is 8.946 cm +/-0.025 mm. An annular groove 14 is machined in the interior surface of electrode 6 at each end thereof, and an O-ring 18 is fitted in each groove. Similarly, an annular groove 22 is machined in the exterior surface of electrode 2 at each end thereof, and O-rings 26 are fitted in the grooves respectively. Electrode 2 is fitted inside sleeve 10, and sleeve 10 is fitted inside electrode 6, and O-rings 18 and 26 support sleeve 10 relative to electrodes 2 and 6 so that the internal surface of electrode 6 and the external surface of electrode 2 are substantially coaxial with the internal and external surfaces of sleeve 10. An annular gas space 28 of uniform radial extent is defined between electrode 6 and sleeve 10 and is bounded by the O-rings 18 and an annular gas space 32 of uniform radial extent is defined between electrode 2 and sleeve 10 and is bounded by the O-rings 26. The O-rings 18 and 26 permit relative movement of the electrodes 2 and 6 and the sleeve 10, to accommodate differential thermal expansion while maintaining the electrodes 2 and 6 and the sleeve 10 in coaxial relationship and ensuring that the electrodes and sleeve do not inadvertently become disassembled.
The outer electrode 6 is formed at its two opposite ends with respective internally threaded holes 30, which communicate with the gas space 28, and the inner electrode 2 is formed at its two opposite ends with respective internally threaded holes 34, which communicate with the gas space 32. The holes 30 and 34 at one end of the conversion cell receive respective externally threaded fittings which are connected by a flexible tube 36, providing a flow path between the gas spaces 28 and 32. The holes 30 and 34 at the opposite end of the conversion cell receive respective fittings (not shown), for connection to a source of feed gas and to a utilization device respectively.
The preferred material for the electrodes 2 and 6 is aluminum, because it is inexpensive and is easily formed to the tolerances that are required. The preferred material for sleeve 10 is pyrex glass, because it is a very good insulator and therefore application of alternating electrical stress to the sleeve does not generate a large displacement current, which can only be dissipated as heat.
The drive circuit 40 is shown in FIG. 1 and comprises power supplies 48 and 66, an oscillator 80 and an output section 82.
The power supply 66 is a d.c. power supply having a positive output terminal connected to a positive supply rail 70 and a negative output terminal connected to a negative supply rail 72. A capacitor 78 is connected between rails 70 and 72.
The power supply 48 has power supply terminals 50, 52 connected to the hot and neutral wires respectively of a source of alternating current at 110 volts RMS and 60 Hz, such as a public utility supply. Power supply terminal 50 is connected to the anode of a diode 58.
A resistor 74 and a capacitor 76 are connected in parallel between the cathode of diode 58 and the negative supply 48 rail 72. Thus, the power supply provides a fairly smooth d.c. voltage at the cathode of diode 58.
The cathode of diode 58 is connected to provide operating current to oscillator 80, which is a relaxation oscillator comprising a variable resistor 84 and a capacitor 86 connected in series and a bidirectional breakdown diode 88 having one terminal connected to the point 90 between resistor 84 and capacitor 86. The opposite terminal of breakdown diode 88 is connected to the output terminal 94 of the oscillator.
The output terminal 94 of oscillator 80 is connected to the gate of an SCR 92, which is connected in series with the primary winding 96 of a transformer 100 between the positive and negative supply rails 70 and 72. A diode 104 is connected anti-parallel to SCR 92. The secondary winding 108 of transformer 100 is connected at its opposite ends to the conversion cell 44, which is depicted in FIG. 1 by its equivalent circuit comprising three capacitors 110, 112 and 114 connected in series and two switches 116 and 118 connected in parallel with capacitors 110 and 114 respectively. Capacitor 110 and switch 116 represent the gas space 28, capacitor 112 represents the insulator sleeve 10, and capacitor 114 and switch 118 represent the gas space 32. When the voltage between the electrodes 2 and 6 is sufficiently low that no discharge takes place in the gas spaces, switches 116 and 118 are non-conductive, whereas when a discharge occurs in one of the gas spaces, the corresponding switch 116 or 118 is conductive.
In normal operation of the ozone generator, the d.c. power supply 66 establishes rail 70 at a positive potential of about 140 volts relative to rail 72 and supplies sufficient current to sustain conduction of SCR 92.
In steady-state operation of the ozone generator, the voltage at the point 90 between variable resistor 84 and capacitor 86 varies in accordance with a sawtooth waveform, the period of which depends on the capacitance of the capacitor 86, the resistance of the resistor 84 and the breakover voltage of the breakdown diode 88. Immediately before the potential at point 90 reaches the breakover voltage of the breakdown diode, the potential at the gate of the SCR 92 is held to the potential of the negative supply rail 72 by the resistor 124 that is connected between the output terminal of the oscillator and rail 72.
Each time the voltage at the point 90 reaches the breakover voltage of breakdown diode 88, breakdown diode 88 becomes conductive and current flows to the output terminal 94 of the oscillator. Capacitor 86 is rapidly discharged into the gate of SCR 92, which becomes conductive. The voltage effective across the primary winding 96 of transformer 100 causes a current to flow through the primary winding, and accordingly conduction of the SCR is sustained. The current increases in accordance with a sinusoidal waveform. A current is also induced in the secondary winding of transformer 100, resulting in a potential being developed between the electrodes 2 and 6. When the potential is first developed across the conversion cell, the gas in the gas spaces is non-conductive and accordingly switches 116 and 118 of the cell's equivalent circuit are non-conductive. The voltage between electrodes 2 and 6 increases until there is a discharge in the gas spaces, and the voltage between the electrodes 2 and 6 then abruptly drops. When the voltage between the electrodes drops, the current in the secondary winding 108 of transformer 100 reverses and this induces a current in the primary winding that is opposed to the current supplied by rails 70 and 72. The anode of SCR 92 is driven negative relative to the negative rail 72, and accordingly the SCR becomes non-conductive. The energy that is provided to the conversion cell 44 by the driver circuit 40 but is not used to generate ozone is excess energy and would be dissipated as heat in the conversion cell 44 if not returned to the driver circuit. The excess energy is returned to the driver circuit 40 through diode 104, the primary winding 96 of transformer 100 and rail 70 and is stored in capacitor 78 until the sequence of operations is repeated when the voltage at the point 90 again reaches the breakdown voltage of breakdown diode 88.
Since the SCR 92 is turned off as soon as a discharge takes place in the conversion cell, and the excess energy is returned to the drive circuit 40, there is little energy dissipated as heat in the conversion cell, and therefore most of the power consumed by the conversion cell is used to generate ozone and is not dissipated as heat. Therefore, the illustrated ozone generator is more efficient than conventional ozone generators. The maximum current that can flow in the conversion cell 44 depends on the quantity of gas in the conversion cell, and this in turn depends on the mass rate of flow of feed gas. Since little heat is generated by operation of the conversion cell even at low flow rates the cell remains below about 38° C. at an ambient temperature of 18.5° C. without need for forced cooling, e.g. by means of a fan. If the ozone generator is to be used under circumstances where the ambient temperature is higher than about 26° C., a fan (not shown) may be used to supply cooling air in order to keep the temperature of the conversion cell well below 48° C.
The output of the conversion cell (mass of ozone per unit time) depends on the pressure with which feed gas is supplied to the conversion cell, the mass rate of flow of feed gas into the conversion cell, and the frequency of the oscillator. As the oscillator frequency increases, the number of discharges per unit time also increases.
It has been found that in operation of the preferred embodiment of the invention, employing a conversion cell about 23 cm long and supplying oxygen as the feed gas, the concentration of ozone in the gas leaving the conversion cell is well in excess of 2% by weight and can reach as high as 10% by weight. The rate of supply of feed gas can be reduced to an arbitrarily low level without adverse effects. Little heat is generated in the insulator sleeve due to displacement current.
Oscillator 80 is able to operate over a wide range of frequencies, from about 50 Hz to about 2 kHz. In use, resistor 84 is adjusted so that oscillator 80 operates at a frequency close to the resonant frequency of the tank circuit, which depends on the dimensions of the conversion cell and is typically about 1.1 kHz.
The resonant period of the tank circuit composed of the secondary winding of transformer 100 and the conversion cell 44 is composed of a charging interval during which the potential between the electrodes 2 and 6 increases, an interval during which the discharge takes place, and a recovery interval. The duration of the charging interval depends on the voltage at which the discharge takes place and on the rate of change of the voltage between the electrodes 2 and 6 during the charging interval, which in turn depends on the frequency at which the current in the tank circuit would oscillate if no discharge took place.
FIG. 3 illustrates a modification of FIG. 1 in which an on-off switch 53 and the switched path of a solid state relay 54 are connected between the power supply terminal 50 and the anode of diode 58. A variac 62 has its fixed terminals connected to the anode of diode 58 and the power supply terminal 52 respectively. A full-wave rectifier 66' is connected between the movable terminal of the variac 62 and power supply terminal 52. The positive and negative output terminals of rectifier 66 and connected to rails 70 and 72 respectively.
On initial start-up of the drive circuit shown in FIG. 3, the switched path of relay 54 is non-conductive, and accordingly relay 54 is unable to supply current to rectifier 66'. Terminal 50 is connected through switch 53, a current limiting resistor 128 and a diode 132 to rail 70, which is connected to the control terminal 134 of relay 54 through a resistor 136. Capacitor 78 charges until the voltage at terminal 134 is sufficient to cause the switched path of relay 54 to become conductive, and variac 52 and rectifier 66' will then latch relay 54 in its conductive state and drive rail 70. A zener diode 140 is connected between terminal 134 and the negative rail 72 to limit the voltage that can be applied to the control terminal of relay 54 and thus protect relay 54 from transients.
In the event of a fault such that the anode of SCR 92 is not driven negative relative to rail 72 and therefore SCR 92 is not reverse biased to the non-conductive state, capacitor 78 will discharge through primary winding 96 and SCR 92 until the voltage at the terminal 134 falls below the control voltage of relay 54. The switched path of relay 54 then becomes non-conductive and no longer supplies current to oscillator 80 or output section 82. Resistor 128 is sized so that at the normal input voltage it cannot supply sufficient current to maintain SCR 92 in the conductive state. Accordingly, SCR 92 is deprived of sustaining current and the SCR becomes non-conductive and remains non-conductive even though diode 132 supplies current to rail 70.
Transformer 100 is a low leakage transformer capable of generating a sufficient potential difference between electrodes 2 and 6 to cause a discharge to take place in the conversion cell and must be able to provide sufficient current at that potential difference to support the discharge. The current depends on the size of the conversion cell, and in the case of a cell as shown in FIG. 2 that is about 45 cm long a current of 0.4 A is suitable.
FIG. 4 illustrates a cell construction that is similar to the one shown in FIG. 2 except that only one gas space is defined, between the external surface of insulator sleeve 10 and the internal surface of electrode 6. O-rings 22' support electrode 2 relative to sleeve 10, and in the event that a fan is used to provide a flow of cooling air over the external surface of electrode 6 and through the interior of electrode 2, the O-rings 22' serve to prevent air from passing between electrode 2 and the sleeve 10 and leading to release of ozone into the ambient air.
The cell construction shown in FIG. 2 is preferred over that shown in FIG. 4. Two conversion cells, as shown in FIGS. 2 and 4 respectively and each 23 cm long, were compared, and under the same conditions of oscillation frequency, feed gas pressure and mass rate of flow of feed gas, the cell construction shown in FIG. 2 was found to provide a significantly greater output of ozone and to consume significantly less energy per unit mass of ozone generated.
It will be appreciated that the invention have been described, and that variations may be made therein without departing from the scope of the invention as defined in the appended claims and equivalents thereof. In particular, the invention is not restricted to the power supply and oscillator that are shown in FIG. 3, and it may, for example, be desirable to employ a full-wave rectifier to supply operating current for the oscillator. Further, the invention is not restricted to the use of a bidirectional breakdown diode in the relaxation oscillator, and other devices, such as a unijunction transistor, could be used instead.
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A conversion cell for an ozone generator comprises a first electrode that is hollow and has a right cylindrical internal surface, a second electrode that has a right cylindrical external surface of smaller radius than the internal surface of the first electrode, and an insulator sleeve having coaxial right cylindrical internal and external surfaces. The insulator sleeve is disposed coaxially within the first electrode and the second electrode is disposed coaxially within the insulator sleeve, whereby first and second gas spaces are defined between the insulator sleeve and the first and second electrodes respectively. The first and second gas spaced are sealed at opposite respective ends of the conversion cell and are in open communication with each other.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of European Patent Office application No. 10157977.9 EP filed Mar. 26, 2010, which is incorporated by reference herein in its entirety.
FIELD OF INVENTION
[0002] The present invention relates to an arrangement for directing a lightning current within a wind turbine and to a wind turbine comprising this arrangement.
BACKGROUND OF INVENTION
[0003] Wind turbines are located in areas that are unprotected from meteorological conditions in order to tap the full potential of the wind.
[0004] Due to this siting in exposed areas and due to the shape of wind turbines, there is a high probability of lightning strokes which may cause severe damage. For this reason, wind turbines are equipped with lightning protection systems for protecting their components against lightning impacts.
[0005] As shown in the simplified schematical figure FIG. 3 , wind turbines, generally, comprise a tower 23 d, a nacelle and a rotor system 83 .
[0006] The bed frame 103 of the nacelle is connected to the tower 23 d via a yaw system for enabling movement of the nacelle on top of the tower 23 d. The bed frame 103 further supports the drive train of the wind turbine which is installed inside of the nacelle.
[0007] The rotor system 83 , comprising hub and rotor blades, is connected to the drive train. The drive train itself comprises at least a shaft 93 , a generator 113 and a braking system 13 c, 23 c and may further comprise a gearbox 123 . The braking system comprises a brake calliper 13 c and a brake disk 23 c.
[0008] In case of a lightning stroke, significant parts of the lightning current may pass through or near all wind turbine components. Thus, the lightning current has to be directed over an electrically conducting path to ground in such a way that damages to the components are avoided.
[0009] Some of the components on this conducting path have to be electrically coupled although they are moveable in relation to each other.
[0010] Those interconnections are, beside the hub/nacelle interconnection, also the yaw clamp/tower interconnection 13 d, 23 d on top of the tower and brake calliper/brake disk interconnections 13 c, 23 c, wherein the brake calliper/brake disk interconnections 13 c, 23 c may be located on the generator shaft or elsewhere in the wind turbine.
[0011] In this context, FIG. 4 a and FIG. 4 b show a prior art realisation of a yaw system comprising a lightning current protection unit for transferring a lightning current from the nacelle 14 to the tower 24 of the wind turbine.
[0012] FIG. 4 a shows a cross-sectional view and FIG. 4 b shows a topview of this realisation.
[0013] The realisation comprises basically a block-shaped conductive brush 44 , a spring 54 for pressing the brush 44 onto the yaw ring, a wire 144 for connecting electrically the brush 44 to the nacelle 14 and a bracket-shaped lightning brush casing 134 in which the brush 44 and the spring 54 are located.
[0014] The parts of the unit are assembled in advance, and then, the entire assembly is mounted with bolts 154 between the yaw clamps 14 a, 14 b.
SUMMARY OF INVENTION
[0015] A drawback of this realisation is the fact that a number of different parts has to be assembled in a confined space.
[0016] Another drawback of this realisation is that free space near the components is required to mount the assembly.
[0017] In addition, maintenance of the unit is difficult because the casing has to be detached or opened for exchanging parts or performing other maintenance measures.
[0018] Moreover, this known arrangement does not function in an efficient way because the lightning current is not conducted the direct way.
[0019] Concerning the lightning protection of braking systems of wind turbines, it is known to mount a number of brushes on a static part, which is a kind of brush holder. The brushes are in electrical contact with the static part and form an electrical connection to the brake disk.
[0020] Disadvantageously, this known arrangement does not function in an efficient way because the lightning current is not conducted the direct way.
[0021] Moreover, this known arrangement is complex because a number of parts have to be mounted.
[0022] In addition, a certain space has to be provided for mounting these parts.
[0023] Therefore, it is the aim of the present invention to provide an improved arrangement for directing a lightning current within a wind turbine which is space-saving as well as more efficient and less complex than lightning protection arrangements known in the art.
[0024] The aim of the invention is achieved by the features of the independent claims.
[0025] Further aspects of the invention are subject of the dependent claims.
[0026] The present invention relates to an arrangement for directing a lightning current within a wind turbine. The arrangement comprises a first component, a second component, a contact element and a guideway. One of the two components is arranged moveably in relation to the other. The contact element is arranged in a way that the first component is electrically connected to the second component in order to direct a lightning current within the wind turbine. Moreover, the contact element is guided moveably by the guideway. According to the invention, the guideway is at least partly integrated in the first component.
[0027] The inventive arrangement has the advantage that it consists of fewer parts and less complex parts compared to known lightning protection arrangements. Thus, the manufacturing and storage costs are reduced.
[0028] Moreover, the arrangement as a whole is less complex and can be mounted more easily.
[0029] Maintenance of the inventive arrangement is facilitated because the parts can be fitted and replaced in a simple manner.
[0030] Even the adjustment of the resilient connection is easily possible.
[0031] The inventive arrangement functions efficiently and the risk of failure is reduced because a lightning current is conducted over the shortest path between the components.
[0032] In addition, it is no longer necessary to mount a lightning protection arrangement externally of the components. Thus, space is cleared which can be used otherwise, for instance for strenghtening structurally the yaw clamps.
[0033] The invention will be described by way of example in more detail in the following.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] The drawings FIG. 1 and FIG. 2 show preferred configurations and do not limit the scope of the invention.
[0035] FIG. 1 shows a cross-sectional view of an arrangement according to an embodiment of the invention,
[0036] FIG. 2 shows a cross-sectional view of an arrangement according to another embodiment of the invention,
[0037] FIG. 3 shows a schematic represention of the basic components of a wind turbine as described above, and
[0038] FIG. 4 a and FIG. 4 b show the prior art as described above.
DETAILED DESCRIPTION OF INVENTION
[0039] FIG. 1 shows a cross-sectional view of a part of a wind turbine comprising a yaw clamp 11 and a tower 21 .
[0040] The yaw clamp 11 forms part of a yaw system which is mounted between the nacelle and the tower 21 . The nacelle and the yaw clamp 11 are able to move on top of the tower 21 .
[0041] In order to achieve a lightning protection effect, a contact element 41 is installed between the yaw clamp 11 and the tower 21 .
[0042] The contact element 41 is mounted at least partly integrated in the yaw clamp 11 in radial direction. For this reason, a guideway 31 is provided in the yaw clamp 11 . This guideway 31 is realised in form of a recess, for instance a radial hole. Alternatively, the guideway 31 may be constructed as a channel or as a groove.
[0043] A first end of this contact element 41 is pressed onto the tower 21 to form a sliding contact. The contact element 41 is either resilient by itself or mounted resiliently. The first end of the contact element 41 may be pressed directly onto the surface of the tower 21 or onto a sliding element attached to the tower 21 . A second end of the contact element 41 is connected to the yaw clamp 11 .
[0044] According to an embodiment of the invention the contact element 41 comprises a conductive rod. The conductive rod 41 is made of a material which is able to conduct and support a lightning current within a wind turbine like carbon, graphite, metal or a composite material comprising one or more of these materials.
[0045] In a preferred embodiment of the invention, the rod is made of a graphite-copper composite material. Advantages of this material are a good conductivity and a low wear rate. An alternative material that could be used instead is a silver-graphite composite material. This material has an even better conductivity than a copper-graphite composite.
[0046] The conductive rod 41 comprises a first end and a second end. According to another embodiment of the invention, the required pressing force of the conductive rod 41 is achieved by mounting an electrically conducting spring 51 tensely between the second end of the rod 41 and the yaw clamp 11 . Thus, a constant pressing force of the rod 41 is ensured in spite of wearing of the rod 41 over the time and unevennesses of the sliding surface of the tower 21 are compensated. Of course, different types of springs can be used.
[0047] The rod 41 is connected via the spring 51 to the yaw clamp 11 in a firm but detachable manner.
[0048] According to a further embodiment of the invention, this firm but detachable connection is achieved by a screw connection 61 at the outer end of the guideway 31 .
[0049] In yet a further embodiment of the invention, this connection is realised by mounting a grub screw 61 in the guideway 31 which engages with a threading 71 provided at the outer end of the guideway 31 . This allows for easily changing the rod 41 or the spring 51 and it also allows for adjusting the spring force in a simple way by turning the grub screw 61 . Thus, maintenance of the arrangement is facilitated.
[0050] FIG. 2 shows a cross-sectional view of a part of a braking system of the wind turbine comprising a brake disc 22 which is arranged rotatably within a double acting brake calliper 12 . The brake calliper 12 comprises a first calliper half 12 a and a second calliper half 12 b.
[0051] In order to achieve a lightning protection effect, a contact element 42 is arranged between the brake calliper 12 and the brake disc 22 .
[0052] The contact element 42 is mounted at least partly integrated in the brake calliper 12 . For this reason, a guideway 32 is provided in the brake calliper 12 . This guideway 32 is realised in form of a recess, for instance a radial hole. Alternatively, the guideway 32 may be constructed as a channel or as a groove.
[0053] In an embodiment of the invention, shown in FIG. 2 , the guideway 32 is provided near the calliper set divide 12 a 12 b.
[0054] As aforementioned, the brake calliper 12 comprises a first calliper half 12 a and a second calliper half 12 b. As shown in FIG. 2 , the guideway 32 is arranged in the first calliper half 12 a.
[0055] A first end of the contact element 42 is pressed onto the brake disk 22 to faun a sliding contact. The contact element 42 is either resilient by itself or mounted resiliently. The contact element 42 may be pressed directly onto the surface of the brake disk 22 or onto a sliding element attached to this brake disk 22 .
[0056] The second end of the contact element 42 is connected to the first calliper half 12 a.
[0057] According to an embodiment of the invention, the contact element 42 comprises a conductive rod. The conductive rod 42 is made of a material which is able to conduct and support a lightning current within a wind turbine like carbon, graphite, metal or a composite material comprising one or more of these materials.
[0058] In a preferred embodiment, the rod is made of a graphite-copper composite material. Advantages of this material are a good conductivity and a low wear rate. An alternative material that could be used instead is a silver-graphite composite material. This material has an even better conductivity than a copper-graphite composite.
[0059] The conductive rod 42 comprises a first end and a second end. According to an embodiment of the invention, the required pressing force of the rod 42 is achieved by mounting a conductive spring 52 tensely between the second end of the rod 42 and the first calliper half 12 a. Thus, a constant pressing force of the rod 42 is ensured in spite of wearing of the rod 42 over the time, and unevennesses of the sliding surface of the brake disk 22 are compensated. Of course, different types of springs 52 can be used.
[0060] The rod is connected via the spring 52 to the first calliper half 12 a in a firm but detachable manner. According to an embodiment of the invention, this firm but detachable connection is achieved by a screw connection 62 at the outer end of the guideway 32 .
[0061] In a preferred embodiment of the invention, this connection is realised by mounting a grub screw 62 in the guideway 32 which engages with a threading 72 provided at the outer end of the guideway 32 . This allows for easily changing the rod 42 or the spring 52 . It also allows for adjusting the spring force in a simple way by turning the grub screw 62 . Thus, maintenance of the arrangement is facilitated.
[0062] In another embodiment of the invention, additional guideways 32 and contact elements 42 may be arranged in the brake calliper 12 in the first 12 a and/or in the second half 12 b.
[0063] In yet another embodiment of the invention, the above described braking system is located on the shaft near the generator and is used for securing the shaft, for instance for maintenance purposes. As a matter of course, the braking system may also be installed elsewhere in the wind turbine.
[0064] The wind turbine can comprise an arrangement according to the invention either in a calliper brake or in one or more yaw clamps; and it can, of course, comprise such an arrangement in one or more calliper brakes as well as in at least one yaw clamp.
[0065] It becomes clear to a person skilled in the art that the arrangement, according to the invention, can also be used to conduct a lightning current between other electrical conductive components in a wind turbine, in particular for directing a lightning current from a hub to a nacelle.
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The present invention relates to an arrangement for directing a lightning current within a wind turbine. The arrangement includes a first component, a second component, a contact element and a guideway. One of the two components is arranged moveably in relation to the other. The contact element is arranged in a way that the first component is electrically connected to the second component in order to direct a lightning current within the wind turbine. The contact element is guided moveably by the guideway. According to the invention, the guideway is at least partly integrated in the first component.
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[0001] This application claims the benefit of U.S. provisional Application No. 60/656,400, filed Feb. 28, 2005 and entitled PILFER-PROOF ATTACHMENTS FOR WATCH AND JEWELRY BOXES.
BACKGROUND
[0002] Shoplifting is, in general, a big problem in the retail watch and jewelry industry. For example, a shoplifter will ask to be shown several watches or pieces of jewelry at the same time, and will remove one or more watches and/or pieces of jewelry from their box. The merchant, without realizing that any items are missing from the boxes, will then return the boxes to their display or storage position. The merchant will only realize items are missing from the boxes when he or she shows the boxes to another customer, which might be a few days later.
[0003] As known in the industry, in order to reduce the above-described shoplifting problem, merchants often tie down watches and pieces of jewelry into their boxes using plastic ties. This deters a would-be-thief from removing items from the box. However, it is very easy for thieves to cut and remove the ties, thereby leaving the watches and/or jewelry unsecured in the box and easy to remove. Additionally, if a merchant wants to show a watch or piece of jewelry to a customer, the merchant must cut the tie and remove it from the box. Thus, the merchant has no way to re-secure the watch or jewelry item unless he or she has spare ties of the required size, which are usually not readily available.
SUMMARY
[0004] The disclosure is directed to watch and jewelry boxes including pilfer-resistant arrangements for securing jewelry items, such as watches, rings and bracelets. In certain embodiments, a jewelry box comprises:
[0005] a bottom member including a central cavity or channel arranged to accommodate a jewelry item;
[0006] a fastening member arranged to extend through an opening in a first side of the bottom member, through a closed loop of the jewelry item and into a second side of the bottom member opposite the first side of the bottom member; and
[0007] an anchor member disposed in the second side of the bottom member and arranged to engage the fastening member so as to secure the fastening member in the jewelry box.
[0008] According to another embodiment, a jewelry box comprises:
[0009] a bottom member including a central cavity or channel arranged to accommodate a jewelry item;
[0010] a fastening member comprising a head portion and a pair of prongs extending from said head portion and terminating in hooked ends, wherein said prongs are arranged to extend downward into said central cavity or channel so as to entrap a loop portion of the jewelry item; and
[0011] an anchor member disposed in the bottom member, said anchor member comprising a pair of longitudinally extending ledges bounding said central cavity or channel and arranged to engage said hooked ends.
[0012] According to another embodiment, an arrangement for securing a watch or other piece of jewelry in a box includes:
[0013] a bottom member formed from a U-shaped inner wall and a U-shaped outer wall that is spaced from and connected to said U-shaped inner wall so as to define a hollow, U-shaped cross-section comprising first and second interior side channels and an interior bottom channel extending between said first and second interior side channels, said bottom member including a central exterior cavity or channel arranged to accommodate a jewelry item; and
[0014] a fastening member disposed within said first interior side channel and said interior bottom channel, wherein said fastening member is laterally movable between an open position and a closed position entrapping a loop portion of the jewelry item.
[0015] Additional features and advantages will become apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1A is a partially exploded perspective view of a jewelry box including a pilfer-proof arrangement according to one embodiment.
[0017] FIG. 1B is a cross-sectional view showing the pilfer-proof arrangement of FIG. 1A .
[0018] FIG. 2A is a partially exploded perspective view of a bottom member of a jewelry box including a pilfer-proof arrangement according to another embodiment.
[0019] FIG. 2B is a partial cross-sectional view showing the pilfer-proof arrangement of FIG. 2A .
[0020] FIG. 3A is a partially exploded perspective view of a bottom member of a jewelry box including a pilfer-proof arrangement according to another embodiment.
[0021] FIG. 3B is a partial cross-sectional view showing the pilfer-proof arrangement of FIG. 3A .
[0022] FIG. 4A is a perspective view of a ring box including a pilfer-proof arrangement according to one embodiment.
[0023] FIG. 4B is a side view of the ring box of FIG. 4A .
[0024] FIG. 5A is perspective view of a bottom member of a jewelry box including a pilfer-proof arrangement according to another embodiment.
[0025] FIG. 5B is a perspective view of the jewelry box of FIG. 5A , wherein the pilfer-proof arrangement is in an open position.
[0026] FIG. 5C is a perspective view of the jewelry box of FIG. 5A , wherein the pilfer-proof arrangement is in a closed position.
DETAILED DESCRIPTION
[0027] According to the embodiment of FIGS. 1A and 11B , a jewelry box 100 including a novel pilfer-proof arrangement is shown. The box 100 includes a bottom member 104 and a top member 102 attached to the bottom member 104 . The bottom member 104 includes a central cavity or channel 105 for accommodating a jewelry item 130 . The pilfer-proof arrangement includes a screw 110 which is inserted into a hole 122 in a side 120 of the bottom member 104 of the box and extends through the cavity or channel 105 of the box 100 , through a closed loop of the jewelry item 130 and into an opposite side 150 of the bottom member 104 . Although the jewelry item 130 is shown to be a watch, other jewelry items such as bracelets may instead be placed in the box. An anchor member 140 located in the opposite side 150 of the bottom member 104 of the box engages the screw 110 so as to secure the screw 110 in the box. The anchor member 140 includes a flap 142 defining a hole 144 sized to engage threads 112 of the screw 110 . Thus, the screw 110 secures the jewelry item 130 in the box 100 and prevents the jewelry item from being removed from the box.
[0028] The screw 110 may be inserted into the anchor member 140 by simply pushing the screw 110 through the hole 144 . However, the screw 110 can only be removed from the box 100 by turning the screw, because the flap 142 obstructs the threads 112 and prevents the screw 110 from moving backwards without being turned. Furthermore, the hole 122 may be recessed into the side 120 such that it is impossible to turn the screw 110 with a person's fingers. Thus, the box 100 can be designed such that the screw 110 can only be removed with a screwdriver, thereby making it difficult for a thief to steal the jewelry item 130 . A merchant who wishes to show the jewelry item 130 to a customer must remove the screw 110 with a screwdriver in order to remove the jewelry item 130 from the box 100 . After showing the jewelry item to the customer, the merchant can return the jewelry item 130 to the box 100 and secure the jewelry item by simply pushing the screw 110 into the box 100 .
[0029] Although the screw 110 is shown with several threads, the screw can be molded with as many or as few threads as desired. For example, a screw 110 a which includes two threads 112 may be used so that the screw 110 a can be removed quickly by a merchant with fewer turns. However, using a greater number of threads makes theft more difficult.
[0030] FIGS. 4A and 4B show a ring box 400 having a top member 402 and a bottom member 404 having a central cavity or channel 405 for accommodating a ring 430 . The box 400 includes a pilfer-proof arrangement similar to that of FIGS. 1A and 1B , except that the screw 110 is inserted into a hole 422 in a back side 460 of the bottom 404 of the box and extends through the box 400 , through the cavity/channel 205 and through the loop of the ring 430 , and the anchor member 140 which engages the screw 110 is located on a front side 470 of the bottom 404 of the box. Naturally, the orientations of the hole 422 and the anchor member 140 may be reversed such that the hole 422 is located on the front side 470 and the anchor member 140 is located on the back side 460 .
[0031] FIGS. 2A and 2B show a bottom member 204 of a box 200 (top member not shown) including a pilfer-proof arrangement according to another embodiment. The bottom member 204 includes a central cavity or channel 205 for accommodating a jewelry item 130 . The pilfer-proof arrangement 200 includes a fastening member 210 which is inserted into an opening 222 in a side 220 of the bottom member 204 of the box and extends through the central cavity or channel 205 of the box 200 and inside a closed loop of the jewelry item 130 . The fastening member 210 is a clip having a head portion 212 and a pair of prongs 214 extending from the head portion 212 . The clip 212 is secured in the box 200 by an anchor member 240 located in an opposite side 250 of the bottom member 204 of the box. The anchor member 250 includes a passage 242 having ledges 244 arranged to engage hooked ends 216 of the prongs 214 . To secure the jewelry item 130 in the box 200 , the clip is inserted through the opening 220 until the head portion 212 is flush with the outer surface of the side 220 and the hooked ends 216 pass the ledges 244 . In order for the hooked ends 216 to engage the ledges 244 , the inner diameter of the passage 242 must be somewhat smaller than the distance between the outer edges of the hooked ends 216 .
[0032] In order to remove the clip 210 so that the jewelry item 130 can be removed from the box 200 , one must insert a pin 280 , or a similar item, through a pin hole 290 in the side 250 and push the pin 290 against the head portion 212 of the clip 210 until the clip 210 is backed out of the opening 222 .
[0033] FIGS. 3A and 3B show a bottom member 304 of a box 300 (top member not shown) including another embodiment of a pilfer-proof arrangement. In this embodiment, the box 300 includes an anchor member comprising a pair of longitudinal ledges 392 located inside the bottom member 304 of the box and bounding a central, jewelry-accommodating channel or cavity 305 of the bottom member 304 of the box. The clip 210 is arranged such that the prongs 214 extend vertically downward from the head portion 212 into a lower space 394 of the channel or cavity 305 . The hooked ends 216 of the prongs 214 engage the ledges 392 , and the prongs 214 entrap a portion (e.g., watch strap) of the jewelry item 130 . In order for the hooked ends 216 to engage the ledges 392 , distance between the ledges 392 must be somewhat smaller than the distance between the outer edges of the hooked ends 216 . In order to remove the clip 210 so that the jewelry item 130 can be removed from the box 300 , one must insert a pin (not shown), or a similar item, through a pin hole (not shown) in the bottom side of the box and push the pin upward against the head portion 212 of the clip 210 until the clip 210 is backed out of the bottom portion 394 .
[0034] FIGS. 5A-5C shows a bottom member 504 of a box 500 (top member not shown) according to yet another embodiment. The bottom member 504 of the box 500 includes a central exterior recessed channel 505 for accommodating a watch or jewelry item. The bottom member 504 is formed from a U-shaped inner wall 509 and a U-shaped outer wall 511 that are connected to each other and spaced apart so as to define therebetween a hollow, U-shaped interior cross-section including two interior side channels 504 and 506 and an interior bottom channel 508 extending between the channels 504 and 506 . A removable false base 502 closes the bottom of the channel 508 . A fastening member 510 is disposed within the channels 506 and 508 of the box. The fastening member 510 includes a vertically-extending segment 512 , a jewelry-trapping arm 514 extending laterally from a first end of the vertically-extending segment 512 towards the center of the box, and a sliding arm 516 extending laterally from a second end of the vertically-extending segment 512 . The sliding arm 516 is laterally slidable within the side channel 506 and the bottom channel 508 . The fastening member 510 is movable between an open position and a closed position entrapping the jewelry item 130 by removing the false base 502 (which hides the sliding arm 516 from sight) and sliding the sliding arm 516 laterally towards the center of the box such that the jewelry-trapping arm passes through an opening 507 the inner wall 509 at the side channel 506 and through a closed loop (e.g., watch band) of the jewelry item 130 in the channel 505 . The fastening member 510 may be moved back to the open position by sliding the sliding arm laterally away from the center of the box.
[0035] Each of the above embodiments provides arrangements which reduce the likelihood that jewelry will be stolen from display boxes while a merchant is showing the jewelry to a potential thief. Although the disclosure references specific embodiments described above and illustrated in the drawing figures, additional embodiments and variations within the scope of the invention are possible.
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Watch and jewelry boxes including pilfer-resistant arrangements for securing watches and jewelry items are disclosed. Various embodiments include a fastening member received within the watch or jewelry box and an anchor/retaining member arranged to engage the fastening member. The fastening member and anchor/retaining member cooperate to secure the loop of a ring or a loop portion of a jewelry item within the box in a manner that is resistant to pilfering.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the US National Stage of International Application No. PCT/EP2008/060851, filed Aug. 19, 2008 and claims the benefit thereof. The International Application claims the benefits of German application No. 10 2007 040 607.1 DE filed Aug. 27, 2007. All of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
[0002] The invention relates to a method for the in situ extraction of bitumen or very heavy oil from oil sand deposits close to the surface, thermal energy being introduced into the deposit to reduce the viscosity of the bitumen or very heavy oil, with at least one extraction pipe being used to extract the liquefied bitumen or very heavy oil and at least one pipe being used to introduce thermal energy, the two pipes being routed parallel to one another. The invention also relates to an associated apparatus for implementing the method, with at least one injection pipe for introducing energy into the deposit and at least one extraction pipe for extracting oil from the deposit, both pipes running horizontally in the deposit.
BACKGROUND OF INVENTION
[0003] During the in situ breaking down of bitumen from oil sand by means of steam and horizontal bore holes by means of the SAGD (Steam Assisted Gravity Drainage) method, large quantities of water vapor are required to heat the bitumen. Steam at a temperature of 250° C. with a quality of 0.95, i.e. almost superheated, is typically used. Although this steam has a high energy content, very large quantities of water accumulate and are extracted with the oil back to the surface and have to be processed there with significant outlay.
[0004] When using steam, the use of horizontal injection pipes longer than 1000 m is no longer practical due to the resulting pressure loss, which is known to be a function of the pipe length.
[0005] A SAGD method for extracting very heavy oil is known from U.S. Pat. No. 6,257,334 B1, in which, in addition to a so-called well pair consisting of pipes one on top of the other, further elements are also present, which are intended to improve the heating of the region. Also a facility for the electrical heating of certain regions is known from WO 03/054351 A1, with which a field is generated between two electrodes, heating the region in between them.
[0006] A method for the heavy oil deposit is also known from US 2006/015166 A1, in which a tool with electrodes is provided for the three-phase resistive heating of the deposit to reduce the viscosity of the heavy oil.
SUMMARY OF INVENTION
[0007] On this basis the object of the invention is to propose a method which does not use steam with its pressure loss and to create an associated apparatus.
[0008] The object in respect of the method is achieved by the measures of the claims and in respect of the apparatus by the features of the claims. Developments of the method and the associated apparatus are set out in the respectively dependent claims.
[0009] The subject matter of the invention is a method, wherein water is injected into the reservoir instead of steam and is only evaporated in the reservoir by means of electrical heating. Electrical, i.e. resistive, heating and/or electromagnetic, i.e. inductive, heating can be used for this purpose.
[0010] The inventive feature of inductive heating in particular means that electromagnetic dissipation occurs where electrical conductivity is high. Resistive heating is also suitable. The heating rate can advantageously be regulated by measuring the pressure and/or temperature in particular in the environment of the well pair or at other points. It is thus possible to ensure that certain pressure and temperature threshold values are not exceeded in the process.
[0011] With the invention therefore water is evaporated in situ by electrical heating.
[0012] One particular advantage of the invention is that it avoids the need for expensive water processing installations, as are used with the known SAGD method to eliminate oil residues from the water, for desalination and evaporation purposes. Also expensive consumables for water processing—such as filters, ion exchangers, etc.—are superfluous.
[0013] The low pressure loss with water compared with water vapor means that the in situ breaking down of bitumen can be carried out with much longer pipes than before (>1000 in). The energy costs for heating and evaporating the water can of course not be avoided and are instead incurred in the power plant. The fact that electric current can be transmitted over quite long distances means that power plants of large unit size can be used. The higher energy costs of electric current compared with steam (factor 2 ) can in some instances be offset by the above-mentioned savings.
[0014] Instead of converting the process totally from steam to water injection it is also possible in the context of the invention to switch to a lower steam quality or smaller steam quantity or preheated water, simply providing the missing energy electrically. This reduces the capital costs of the boiler.
[0015] A further advantage of the inventive method finally is that salts can be added to the water to increase conductivity, ensuring efficient heating.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Further details and advantages of the invention will emerge from the description of figures of exemplary embodiments which follows based on the drawing in conjunction with the subclaims, in which drawing:
[0017] FIG. 1 shows an outline of a method for introducing steam into an oil sand reservoir according to the prior art,
[0018] FIG. 2 shows a three-dimensional diagram of elementary units of the reservoir as an oil sand deposit,
[0019] FIG. 3 shows the new method outline according to the inventive procedure and FIGS. 4 to 6 respectively show a section through a reservoir with different arrangements of injection bores or electrodes.
DETAILED DESCRIPTION OF INVENTION
[0020] In FIG. 1 a thick line E shows the ground surface, below which an oil sand deposit is located. Generally a superstructure of rock or material is present below the ground surface, followed by a seam in the form of an oil sand reservoir at a predetermined depth. The reservoir has a height or thickness h, a length l and the predetermined width w. An elementary cell is thus defined, which can be repeated a number of times in respect of the width w. This region as part of the deposit therefore contains the bitumen or very heavy oil and is referred to below in short as the reservoir. With the known SAGD method an injection pipe 101 for steam and an extraction pipe 102 , also referred to as a production pipe, are present and are routed horizontally on the bottom of the reservoir.
[0021] FIG. 1 shows an outline of a method according to the prior art. Shown as 1 is a water desalination unit, downstream of which a steam generator is connected. The injection pipe 101 is used to route steam initially vertically through the top surface of the oil sand deposit and from a certain depth, i.e. on reaching the reservoir, horizontally. The steam heats the area around the injection pipe 101 and reduces the viscosity of the bitumen or very heavy oil present in the oil sand. In the extraction pipe 102 , which runs parallel to the injection pipe 101 , the oil is recovered and fed back by way of the perpendicular region through the covering rock. Oil is then separated from the raw bitumen in a method-related installation 4 and further processing, e.g. flotation or the like, takes place. The water present is fed to a unit 5 for water processing and then fed back into the water desalination unit 1 .
[0022] With the prior art therefore a circuit is largely present in the process sequence with the cited units.
[0023] FIG. 2 shows an oil sand deposit, having a longitudinal extension 1 and a height h. A width w is defined, which is used to define an elementary unit 100 as a reservoir for oil sand. In the prior art the injection pipe 101 and the extraction pipe 102 are routed in a parallel manner on top of one another in a horizontal direction in the unit.
[0024] FIG. 3 shows the conditions in FIG. 1 with an inventive procedure or apparatus. Below the ground surface the initially vertically running injection and extraction pipes 101 , 102 are again present, both running horizontally when they reach the reservoir. The injection pipe 101 and extraction pipe 102 are also configured as electrodes by means of a conductive coating and can thus serve as conductors for an electrical/electromagnetic heating unit to generate heat.
[0025] With the associated apparatus there is no longer a need for a steam generation installation and the water desalination installation connected upstream of it in FIG. 1 . Instead there is a connection to an external—in some instances spatially very remote—power plant for providing electrical power and a unit 12 for the electrical power supply. Separate generators can also be present in some instances. The unit 4 for separating oil and the unit 5 for water processing can be of simpler structure here than in the prior art according to FIG. 1 .
[0026] Simplified method implementation results with the new installation. The electrical energy is advantageously taken from a power plant and a converter is used in the unit 12 to provide the electrical power in suitable form, in particular as high-frequency current. The high-frequency current is passed to current conductors in the reservoir, for example the electrode 106 or 107 , and serves there to generate heat. Inductive heating of the reservoir in particular is realized here. Resistive heating can also take place in some instances.
[0027] The advantage of such a procedure is that only water has to be routed in the injection pipe 101 . The water is evaporated in situ, i.e. in the horizontally running region around the injection pipe 101 , by means of the electromagnetic effect, with the steam being produced in the horizontal region around the pipe 101 . The energy of the steam thus produced is emitted to the reservoir, so that an oil sand/water mixture builds up in the extraction pipe 102 . This is extracted to the ground surface by way of the extraction pipe 102 —in some instances with an additional pump—with an oil separation installation again being provided. The remaining water is processed in the water processing unit and then fed back into the circuit.
[0028] The procedure shown in FIG. 3 has significant advantages compared with water vapor conveyance. Particularly if it is assumed that operation with long lengths 1 takes place in the deposit with the described installation, significant problems would also arise in remote regions with the steam method with regard to providing steam. In situ steam generation allows this problem to be resolved in a surprisingly simple manner.
[0029] The further FIGS. 4 to 6 show various geometric possibilities for realizing the latter principle, the section IV-IV from the figure and/or the view from the front in FIG. 2 respectively being shown. FIG. 3 for example shows an injection pipe 101 and a production pipe 102 , which are disposed a small distance from one another as far as possible on the bottom of the reservoir. The reservoir here is bounded by the width w and the height h. The length l is not shown in the sectional diagram according to FIGS. 3 to 5 .
[0030] With the described arrangement according to FIG. 4 the injection pipe 101 and the production pipe 102 are themselves configured as electrodes. Heating here takes place resistively or inductively. In the described section of the oil reservoir 100 the arrangement shown is repeated a number of times periodically on both sides. Compared with the prior art the known horizontal pipe pair (so-called well pair) is changed in that it can also be used as electrodes.
[0031] In FIG. 5 —based on the diagram according to FIG. 3 —a well pair consisting of an injection pipe 101 and extraction pipe 102 is present. Two electrodes 105 and 106 are also disposed in proximity to the well pair. It is expedient to align these two electrodes at a distance d 1 from the line of the well pair on both sides and to select the height between the injection pipe 101 and the extraction pipe 102 .
[0032] Configuring the horizontal pipes 105 and 106 as electrodes allows inductive energization by electrical connection at the ends of the additional electrode and the injection pipe. The reservoir width w here is for example 100m, the distance from one well pair to the next well pair is typically also around 100 m, with broad limits being set and a range between 50 and 200 m appearing suitable. The horizontal distance of the pipes 105 and 106 from the plane of the well pair is between 0.5 m and around w/2 here.
[0033] FIG. 3 is again used as the basis for the arrangement according to FIG. 6 . Here an arrangement is provided in which just one additional electrode 107 is present per well pair. The electrode 107 here is positioned on the gap between two adjacent well pairs.
[0034] Specifically 1 again shows the oil reservoir, which is repeated a number of times on both sides of the sectional diagram. The horizontal pipe pair, i.e. the well pair, again consists of the injection pipe 101 and production pipe 102 . The horizontal pipe 107 is also present, being configured as an electrode.
[0035] The selected diagram shows a repeating arrangement, in which a further electrode 107 ′ is again present. Inductive energization is thus possible in so far as the ends of the two corresponding electrode pipes are connected electrically.
[0036] The arrangement according to FIG. 5 shows a reservoir width w of 100 m for example. There is a corresponding distance from one well pair to the next, it being possible reasonably to cover a region from 50 to 200 m. The reservoir height, i.e. the thickness of the geological oil stratum, is typically 20 to 60 m. The horizontal distance between the additional pipe and the well pair is identified by w/h. The vertical distance between the two additional electrodes is between 0.1 m and 0.9 h. Distances between 0.1 m and 60 m are exemplary here.
[0037] The electrodes have to be located at the lower end of the steam chamber to be established, i.e. at the lower end of the reservoir. The existing well pipes can preferably serve as electrodes there. Energization of the reservoir and thus heating should preferably take place inductively. Resistive heating of the reservoir is also possible but overheating of the electrodes must then be borne in mind.
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A method for the in situ extraction of bitumen or very heavy oil from oil sand deposits close to the surface, where thermal energy is introduced into the deposit to reduce the viscosity of the bitumen or very heavy oil is provided. Condensed water is used that is introduced into the deposit via an injection pipe and is horizontally conducted inside the pipe within the deposit such that the water can evaporate in situ and the heat can be applied to the deposit. An apparatus including an injection pipe, an extraction pipe, a converter and electrical conductors are also provided.
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Statement of Government Interest
The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor.
This is a continuation of application Ser. No. 07/958,191, filed Oct. 7, 1992 now abandoned.
BACKGROUND OF THE INVENTION
A better way to locate and detect objects which blend into a background or are otherwise obscured has been and still is being sought. Optical systems have been used for detecting objects under water and have relied on the use of range gated conventional imaging. However, the optical systems are not entirely satisfactory since they tend to be incapable of detecting an object that blends into a background, such as, a light colored object on a light colored background, for example. An example of such a system is that disclosed in a published Japanese patent application #59-79285 that provides an object-recognizing device for distinguishing an object on a background that projects relatively broadband white light, not individual wavelengths, for a TV monitor having an innovative logic board to help distinguish an object from the background. Another imaging comparison system using white light is disclosed in the article entitled "Digital Photography" by Glen Southworth, IT Imaging Technology in Research & Development, May 1984. The imaging techniques in this article show a conventional use of the Colorado Video Inc. video-scan-converter-video-subtractor combination to display differences between sequential images illuminated in white light or some nonvarying illumination of sequential scenes. An evolution of atmospheric constituents is being monitored in the paper by A. Papayannis et al. entitled "Multiwavelength LIDAR for ozone measurements in the troposphere and the lower stratosphere", Applied Optics, vol. 29, no. 4, 1 Feb. 1990. Emitted radiation is used to perform a point-by-point monitoring of the ozone absorption due to the effects produced by aerosol and other interference gases.
Thus, there is a continuing need in the state of the art for a technique and system for distinguishing between an object and its background using a number of discrete narrow-band, frequency agile laser source emissions to enhance a backscatter contrast between a sought object and its background.
SUMMARY OF THE INVENTION
The present invention is directed to providing a method and apparatus for enabling the location of an object from its background by an enhanced backscatter contrast therebetween. A frequency agile laser source illuminates the object and background with sequential discrete wavelengths so that a detector provides representative spatially resolved image signals for an interconnected computer that provides spatially resolved images having an enhanced backscatter contrast due to the differences in spectral scattering by the object and background of the discrete wavelengths.
An object of the invention is to provide an improved method and apparatus for detecting an object against a background.
Another object is to provide an improved method and apparatus for detecting an object against a background relying on an illumination by discrete wavelengths of radiation.
Still another object is to provide an improved apparatus and method for detecting an object on a background in which a frequency agile laser emits at discrete sequential wavelengths to enable a detection of spectral scattering contrast between the object and the background.
Another object is to improve the image detection sensitivity by reason of the contrast between the object and its background which also serves to remove scattering noise from interfaces such as the ocean's surface.
Another object is to provide for an improved detection of an object irrespective of the type of detection used, such as black and white video or any suitable detection which has appropriate colored filters.
Another object is to provide for an improved detection of an object suspended near the surface in an attenuating medium by illuminating the medium with a wavelength that does not penetrate deeply into the medium.
These and other objects of the invention will become more readily apparent from the ensuing specification and drawings when taken in conjunction with the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a schematic representative embodiment of the constituents of this inventive concept.
FIGS. 2a and 2b are schematic representations of hypothetical upward scattering curves for both the object and the background, in this case the ocean floor, when illuminated by discrete wavelengths of emission from a frequency agile laser.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The concept of differential imaging in accordance with this inventive concept is to a technique designed to improve the ability for the detection of camouflaged or poorly visible objects through contrast enhancement. By way of example, in general, the detection of a white object on a white background is difficult to detect either by the eye or by conventional imaging techniques. The differential imaging concept disclosed herein relies on the fact that, generally, different materials do not have identical spectral scattering curves over all wavelengths, even if they appear to be similar in color.
Referring now to FIG. 1 of the drawings a representative embodiment of a differential imaging pattern recognition system 10 is depicted operationally deployed as it seeks to locate an object 11 disposed above, at or on a similarly colored background such as the ocean floor 12 which could be sediment, sand or other typical ocean floor materials. An attempt to complicate the location of the object may have been done, such as, an intentional painting of the object so that it is more similar in appearance to the background, in this case, the ocean floor.
FIGS. 2a and 2b show two hypothetical upward scattering curves which are plots of scattering of impinging wavelengths versus wavelength. The upward scattered light is the light that is detected by the eye or a suitable detector. FIG. 2a shows that in the near IR, at around 800 nm, the object scatters much more light than the ocean floor which scatters more or less uniformly as depicted in FIG. 2b. These variations in scattering are due to inherent properties of the object and the background. For some applications this scattering variation near the IR may provide a sufficient enhancement of the contrast between the object and the background. However, in accordance with this inventive concept, if a series of at least two spatially resolved images are taken at different illuminating wavelengths; the different illuminating wavelength, spatially resolved images are digitized; and then the different illuminating wavelength spatially resolved images are compared, the details of the object to be detected become much enhanced.
The differential imaging in accordance with this inventive concept relies upon a tunable laser separately illuminating with two or more wavelengths. The spatially resolved images are compared (one way to compare them is by digitizing them and then subtracting them) with respect to successive wavelengths or between any two or among several other wavelengths. This improves the spatially resolved image contrast by, for example, allowing the subtracting out of the background (in this case, the ocean floor), leaving only the object in the image field.
A related benefit of this technology is that in the case shown, different wavelengths penetrate the transmissive medium (ocean, air) differently. A contrast enhancement can be improved by tuning the illuminating probe beam to wavelengths where the background is not particularly visible due to attenuation of the illuminating probe beam in its path through the medium. An sought object close to an illumination source would stand out while the background would appear dark because the illuminating wavelength is attenuated by the medium. However, if the object to be detected is further away, or as far away as the background (for example, something on the ocean floor), then the medium attenuation does not help in the location of the object.
Differential imaging pattern recognition system 10 includes an illuminator 15 that selectively and sequentially emits, scans discrete wavelengths of light that are within the range of between 180 nm and 10,000 nm in a "flooding" search beam 15a of illumination to cover an area in much the same manner as a floodlight covers an area. A tunable laser, multi-frequency laser or frequency agile laser with an appropriate lens arrangement, if needed, may be selected, such as, for example, a Ti:Sapphire laser as disclosed in the co-pending application of Richard Scheps, entitled "A Multifrequency, Rapidly Sequenced or Simultaneous Tunable Laser," Navy Case 73883, may be used. A number of commercially available Ti:Sapphire lasers with appropriate frequency doublers, triplers and associated frequency synthesizers could be chosen which are all freely available in the art to which this invention pertains. In addition, other frequency sources are available with the qualification that the sources be capable of discrete wavelength emissions in narrow bands. When the illumination is to be through seawater, discrete emissions in the blue-green spectrum may be more desirable to enable an illuminating and reflecting penetration through the water medium for the purposes of detection by means of enhanced scattering contrasts.
A detector 20 is proximately located with respect to the illuminator to receive a reflected spatially resolved image portion of the radiated emissions from illuminator 15. A commercially available black-and-white video camera providing analog, raster-scanned representative spatially resolved image signals might be used, for example, or a CCD array or a suitable still camera could be used having appropriate circuitry for generating the representative spatially resolved image signals. Appropriate filters 20a for filtering out certain light from other sources and non useful background light may or may not be included in association with the detector in accordance with established practices. Whichever recording means is selected for taking the spatially resolved image of the illuminated object-background scene, it must have a sufficient sensitivity and resolution which may include appropriate colored filters to receive the spatially resolved images created by the frequency agile laser emissions and create the representative spatially resolved image signals.
The analog representative spatially resolved image signals from detector 20 are coupled to a video-scan-converter-video-subtractor computer 25. The interconnected computer is suitably coupled to functionally provide a subtraction of one spatially resolved image from another that shows the differences between two or more sequential spatially resolved images for display on an interconnected video monitor 30. These differences in the spatially resolved images are largely attributed to the different levels of scattering which are created by one wavelength of illuminating emission from illuminator 15 or a different wavelength of illuminating emission from illuminator 15 as they are reflected and scattered from object 11 and background 12. Optionally, a different processing of the images other than subtraction could be chosen from those available in the state of the art, such as addition or a suitable logic enhancement technique to effect a comparison of images illuminated by the different wavelengths.
The video-scan-converter-video-subtractor computer is available in the state of the art and could be, for example, an interconnected Model 494 video scan converter to store and effect a high-speed analog/digital conversion while performing a scan format conversion and a Model 492 video subtractor to compare stored digitized images and provide difference video output signals. Both of these units of the video-scan-converter-video-subtractor computer are marketed by Colorado Video Inc. of Boulder, Colo. Other computer components could be selected in the art to effect a high-speed analog, digital and digital analog conversion that is capable of digitizing, storing and displaying the video information while performing a scan format conversion and to provide a dual memory video subtractor useful for single frame or real-time comparison of a reference image and images under analysis. The interconnected scan converter and video subtractor computer are suitably coupled to show the difference between two or more images for display on an interconnected video monitor in accordance with a technique known in the art, for example, see the above referred-to Digital Photography article by Glen Southworth that are to the display of sequential images illuminated of the same light source.
A switch 35 may be coupled to both illuminator 15 and computer 25 to synchronize the sequential illumination by flooded discrete wavelengths 15a from scanning frequency agile laser with the processing of the analog representative image signals in computer 25. Optionally, a separate switch may be dispensed with when the pulsing of the flooding illuminator 15 is controlled from computer 25, such as the internal digital video memory switching arrangement of FIG. 1 in the Southworth article. In either event, the sequences of images are produced by scattering and reflections from object 11 and background 12, when illuminated by the discrete wavelengths, to enable a comparison in computer 25 on a desired sequential basis.
For example, illuminator 15 is actuated by switch 35 to illuminate object 11 and background 12 area to be examined with a flood of a first illuminating wavelength 11. Switch 35 also enables scan-converter-video-subtractor computer 25 to gate in and receive the spatially resolved image received by detector 20 of the reflected and scattered portion of the wavelength l 1 illumination from object 11 and background 12. Next, the object and background are illuminated by a flood of a different wavelength l 2 emitted from illuminator 15 and scattering and reflections of l 2 from the object and background can be gated into scan-converter-video-subtractor computer 25. The spatially resolved images attributed to l 1 and l 2 are appropriately processed in computer 25 to generate signals representative of differences of the reflections and scattering between the reflected object and background attributed to the different illuminating wavelengths l 1 and l 2 . The generated signals are fed to monitor 30 or other appropriate processing circuitry for display or appropriate utilization. More than two reflected wavelengths of emitted wavelengths l 3 through 1 n also can be suitably processed in accordance with this inventive concept until the right combination indicates most clearly what the object is and where it is located.
Operation of the device relies on a tunable laser which is tunable over a range as large as the visible spectrum although not necessarily continuously tunable therethrough. In the example given, the tunable laser of illuminator 15 illuminates a scene containing an object to be illuminated, a white plate, along with the background, on white sand. Since lighter shades or light colors may only appear the same in white light, generally speaking, at least one color at a discrete wavelength emitted from illuminator 15 is transmitted through the air or water and the plate may look or appear darker while the white sand background still appears lighter. It is not necessary to know the emitted laser color beforehand since the laser of illuminator 15 can illuminate the scene with a sequence of colors until one color or another makes the object appear to have a contrast from the background. As far as glare from the surface is concerned, the frequency agile source of illuminator 15 enables the subtracting out of the background glare levels before a search is made for the object or in the same manner as done in DIAL LIDAR. In other words, as the emitted laser emission changes, certain objects stand out, making them potentially easier to recognize. This is largely because of the different scattering coefficients associated with the background and an object of interest.
Obviously, many modifications and variations of the present invention are possible in the light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.
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A frequency agile laser illuminates a scene with floods of emissions of different wavelengths. As the wavelengths, or laser color changes, certain objects will stand out with respect to their background so that detection and recognition is enhanced to permit appropriate action. This technique has application in the location of underwater objects.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.K. Patent Application No. GB0220721.5, filed Sep. 6, 2002, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to systems, apparatus and associated methods for use in the assessment of visual field functions. In its various aspects, the invention if particularly concerned with perimetry testing and visual evoked potential (VEP) testing.
[0003] Perimetry is the systematic measurement of visual field function. It is used in diagnosing different diseases in the eye, optic nerve and central nervous system. The conventional methods for assessment of visual defects of peripheral vision are based on measurement of responses to visual stimuli presented at various locations in the visual field. Several techniques use this approach:
[0004] (i) White-on-white (W-W) perimetry detects visual field impairments by measuring the sensitivity to a small luminance target presented on a homogenous background. The two most commonly used types of W-W perimetry are Goldmann kinetic perimetry and threshold static automated perimetry. With Goldmann or “kinetic” perimetry, a trained perimetrist moves the target whose brightness is held constant. The limits of the visual field are mapped for targets of different sizes and brightness. With threshold static automated perimetry, a computer program is dimmest target the patient can see at each of the test locations is found. The data are used to construct a map of the visual sensitivity of the retina.
[0005] (ii) Short wavelength automated perimetry (SWAP) utilises a blue stimulus to preferentially stimulate the blue cones. A high luminance yellow background is used to adapt to green and red cones and to saturate, simultaneously, the activity of the rods.
[0006] (iii) Frequency-doubling perimetry (FDP) uses rapidly flickering gratings. These stimuli create an illusion (apparent doubling of grating spatial frequency) that allows only a small set of retinal ganglion (M cells) cells to respond.
[0007] These techniques reveal visual defects by comparing patients' results with those obtained with normal observers. A disadvantage of these approaches is that visual sensitivity is measured by psychophysical procedures which usually depend on the criterion used by the observers. This might result in large interindividual differences which reduce the sensitivity of the measurements.
[0008] Objective techniques have also been developed:
[0009] (i) Multifocal electoretinogram (ERG) perimetry. ERGs are electrical signals generated by retinal cells in response to a visual stimulus. MERGs are elicited by a pseudorandom binary m-sequence of luminance patches. The luminance of each sector of a dartboard-like pattern alternates between white and black. MERGs elicited by different patches are analysed by a reverse correlation technique in order to construct a map of the responses of retinal cells.
[0010] (ii) Multifocal visual evoked potential (VEP perimetry. VEPS are electrical signals generated by cortical cells in response to a visual stimulus. The stimulation is also based on a pseudo-random binary m-sequence of visual targets presented in different visual-field locations. A reverse correlation technique is used to analyse the data.
[0011] It is known that the visual cortex has an expanded representation of the fovea because of the high density of ganglion cells in the fovea. The fovea is represented on the surface of the brain. The activity of this area can be recorded by scalp electrodes. The primary visual cortex representing the peripheral parts of the visual field, however, is folded in deeper areas of the brain. These areas of the primary visual cortex contribute little to the VEPs.
[0012] One aspect of the present invention concerns long-distance perimetry, providing new systems, apparatus and associated methods for assessment of visual-field defects which are based on measurement of long-distance interactions between an “inducing” stimulus and a “test” stimulus.
[0013] The term “long-distance interactions” usually refers to interactions between the responses to two stimuli whose separation is larger than the receptive field size. Electrophysiological studies have shown that the responses of cells in cat and monkey retina, lateral geniculate nucleus and visual cortex can be affected by a moving or shifting luminance pattern outside their receptive fields [refs.2-5]. Psychophysical data also have shown that the threshold visibility of a foveal test spot was reduced when a luminance grating is jerked in the periphery of the visual field [refs.6-8]. Measurements of visual evoked potentials (VEPs) in humans have demonstrated that the contrast reversal of a structured image reduced the magnitude of the VEPs elicited by a foveal stimulus.
[0014] One possible explanation of these findings is that long-distance interactions between the peripheral inducing stimulus and the test stimulus may increase the neural internal noise of the cells which are involved in the detection of the test pattern. The increased. internal noise will require a stronger signal in order to maintain a given level of visibility. Another possible explanation is based on the assumption that the long-distance interactions result in cortical transient-to-sustained neurone inhibition.
SUMMARY OF THE INVENTION
[0015] One aspect of the present invention uses the phenomenon of long-distance interactions as a perimetric tool. In essence, a flashing peripheral stimulus reduces the response to a central test spot if the peripheral location has normal functioning. Lack of effect points to a loss of visual function at the peripheral location. The long-distance effect is estimated by methods of psychophysics and visual evoked potentials.
[0016] In accordance with a first aspect of the invention, there is provided apparatus for use in the assessment of visual field functions, including:
[0017] a visual display device adapted to display visual stimulus patterns; and
[0018] a means for generating visual stimulus patterns within a predetermined visual field and for controlling the display of said visual stimulus patterns by said visual display device; wherein:
[0019] said means for generating visual stimulus patterns is adapted to generate a test stimulus for display in a central region of the visual field and to generate an inducing stimulus for display in a peripheral region of the visual field, and to control the visual display device so as to selectively display the test stimulus alone and in combination with the inducing stimulus in accordance with a predetermined test protocol.
[0020] Preferably the means for generating visual stimulus patterns is a computer. Preferably, the visual display device is a plasma monitor.
[0021] In embodiments for use in electrophysiological testing, the apparatus preferably further includes:
[0022] test electrodes for detecting VEPs in response to visual stimuli displayed by said display device; and
[0023] a recording device adapted to record VEP signals from said test electrodes and to compare VEP signals generated in response to the display of the test stimulus alone with VEP signals generated in response to the display of the test stimulus in combination with the inducing stimulus.
[0024] Preferably the recording device is in the form of a second computer. In another embodiment, there are three test electrodes. Preferably, the computer is adapted to calculate a Laplacian response (second spatial derivative of the potential field distribution) from each set of VEP signals.
[0025] Preferably, the computer is adapted to calculate a ratio of the Laplacian response for the test stimulus alone and the Laplacian response for the combination of the test stimulus and inducing stimulus.
[0026] In embodiments for use in psychophysical testing, the apparatus preferably further includes:
[0027] control means operable by a test subject for increasing and decreasing the contrast of the visual stimulus displayed by the display device and for indicating a threshold contrast value.
[0028] Preferably, the computer is adapted to execute a test protocol comprising: generating a first visual stimulus; recording a first threshold contrast value indicated by the test subject using the control means; displaying the stimulus again with a contrast equal to a randomly selected multiple of the first threshold contrast; recording a second threshold contrast value indicated by the test subject using the control means; repeating this process for a predetermined number of iterations; and calculating a mean threshold contrast value from said first, second and subsequent threshold contrast values.
[0029] Preferably, the computer is adapted to calculate a mean threshold value for a stimulus comprising the test stimulus alone and a stimulus comprising the combination of the test stimulus and inducing stimulus, and to calculate the ratio of these two mean threshold values.
[0030] In accordance with a second aspect of the invention, there is provided a method for assessing visual field functions, comprising:
[0031] displaying visual stimulus patterns within a predetermined visual field using a visual display device, said visual stimulus patterns comprising a test stimulus displayed in a central region of the visual field and an inducing stimulus displayed in a peripheral region of the visual field; and selectively displaying the test stimulus alone and in combination with the inducing stimulus in accordance with a predetermined test protocol.
[0032] Preferably, the visual display device is a plasma monitor.
[0033] In embodiments for use in electrophysiological testing, the method preferably further includes:
[0034] deploying at least three test electrodes for detecting VEPs in response to visual stimuli displayed by said display device; and
[0035] recording VEP signals from said test electrodes and comparing VEP signals generated in response to the display of the test stimulus alone with VEP signals generated in response to the display of the test stimulus in combination with the inducing stimulus.
[0036] Preferably, the method includes calculating a Laplacian response (second spatial derivative) from each set of VEP signals and calculating a ratio of the Laplacian response for the test stimulus alone and the Laplacian response for the combination of the test stimulus and the inducing stimulus.
[0037] In embodiments for use in psychophysical testing, the method preferably further includes;
[0038] the test subject operating control means to increase and decrease the contrast of the visual stimulus displayed by the display device and to indicate a threshold contrast value.
[0039] Preferably, the method includes a test protocol comprising: generating a first visual stimulus; recording a first threshold contrast value indicated by the test subject using the control means; displaying the stimulus again with a contrast equal to a randomly selected multiple of the first threshold contrast; recording a second threshold contrast value indicated by the test subject using the control means; repeating this process for a predetermined number of iterations; and calculating a mean threshold contrast value from said first, second and subsequent threshold contrast values.
[0040] Preferably, the method further includes calculating a mean threshold value for a stimulus comprising the test stimulus alone and a stimulus comprising the combination of the test stimulus and inducing stimulus, and calculating the ratio of these two mean threshold values.
[0041] In accordance with a third aspect of the invention, there is provided apparatus for use in the assessment of visual field functions, comprising:
[0042] a visual display device adapted to display visual stimulus patterns;
[0043] a computer adapted to generate visual stimulus patterns within a predetermined visual field and to control the display of said visual stimulus patterns by said visual display device, said computer being adapted to generate test stimuli for display in a first region of the visual field and to generate visual Gaussian noise patterns of different noise densities for display in at least one other region of the visual field, and to control the value display device so as to selectively display the test stimulus alone and in combination with the noise pattern in accordance with a predetermined test protocol;
[0044] at least three test electrodes for detecting VEPs in response to visual stimuli displayed by said display device; and
[0045] a computer adapted to record VEP signals from said test electrodes, to calculate a Laplacian response (second spatial derivative) from each set of VEP signals, and to derive an internal neural noise value for said first region of the visual field from said Laplacian responses and associated Gaussian noise densities.
[0046] In accordance with a forth aspect of the invention, there is provided a method for assessing visual field functions, comprising:
[0047] generating visual stimulus patterns within a predetermined visual field using a visual display device, said stimulus patterns comprising test stimuli displayed in a first region of the visual field and visual Gaussian noise patterns of differing noise densities displayed in at least one other region of the visual field; and selectively displaying the test stimulus alone and in combination with the noise pattern in accordance with a predetermined test protocol;
[0048] deploying at least three test electrodes for detecting VEPs in response to visual stimuli displayed by said display device; and
[0049] recording VEP signals from said test electrodes, calculating a Laplacian response (second spatial derivative) from each set of VEP signals, and deriving an internal neural noise value for said first region of the visual field from said Laplacian responses and associated Gaussian noise densities.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0051] [0051]FIG. 1 is a diagram illustrating one example of the type of visual stimuli employed in embodiments of the present invention; and
[0052] [0052]FIG. 2 is a block diagram illustrating apparatus in accordance with one embodiment of the present invention; and
[0053] [0053]FIG. 3 is a table showing the amplitude ratio between the amplitudes evoked by a test stimulus in the presence and absence of a peripheral stimulus. Open bars=data for a normal observer AX; filled bars=data for a glaucoma patient RB. Three types of peripheral stimuli were used; flickering uniform field, moving radial gratings, and dynamic noise; and
[0054] [0054]FIG. 4 a block diagram illustrating apparatus in accordance with another embodiment of the present invention; and
[0055] [0055]FIG. 5 Squared test amplitude as a function of squared noise contrast. Circles=data for a normal observer AX; square=data for a glaucoma patient RB.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0056] Referring now to the drawings, FIG. 1 shows one example of the type of stimuli used for the purposes of the invention. The drawing illustrates the visual field as a circular dartboard pattern, with an “inducing stimulus” I comprising a series of concentric circles around the periphery of the field and a “test stimulus” T comprising a circular visual checkerboard or noise pattern at the centre of the field. It will be understood that the nature of these stimuli may vary widely. In particular, the inducing stimulus I may vary in terms of its location within the visual field, the type of pattern and the dynamics of the stimulus (generally, the stimuli will comprise time varying patterns, typically including flashing or contrast reversal at a particular frequency). The stimuli are discussed further below.
[0057] The stimuli are generated by a first computer 10 (FIG. 10) and presented by means of any suitable visual display apparatus 12 . The visual display apparatus 12 may comprise any of a variety of will known display devices, including cathode ray tubes, LCD displays, video projectors etc. It is preferred that the display area is relatively large in order to allow a reasonable distance between the test subject and the display. It is particularly preferred that the display 12 comprises a plasma type monitor, which provides a large display are and instantaneous screen updates (as compared with raster-scan type displays).
[0058] As noted above, the first computer 10 generates the stimuli and controls the display apparatus 12 . When the invention is applied for electrophysiological testing, the apparatus further includes a second computer 14 , connected to electrodes 16 for detecting the subject's neural responses, which records and processes signals from the electrodes 16 , as described further below. The first and second computers 10 and 14 are connected to enable the correlation of stimuli and responses. Alternatively, the functions of the first and second computers may be performed by a single computer or by any other suitable arrangement of computers.
[0059] [0059]FIG. 4 shows an alternative arrangement where the second computer 14 acts as a recording device and the signals from the electrodes 16 are passed through an amplifier 1 . A printer 2 is also a part of the system. Three types of peripheral stimulus may be used in this case; flickering uniform field, moving radial grating and dynamic noise.
[0060] When the invention is applied for psychological testing, as also described further below, the second computer 14 and electrodes 16 are not required, and the apparatus further includes a control unit 18 connected to the first computer 10 and operable by the test subject.
[0061] In this example, the inducing stimulus I comprises a circular grating presented in a peripheral sector of the visual field as shown in FIG. 1. This stimulus will be flickering or moving. The test stimulus T may be a checkerboard or visual noise pattern flickering at F Hz.
[0062] The invention may be applied for electrophysiological testing (as shown in FIG. 3) by recording monopolar VEPs elicited by the test stimulus using at least three test electrodes 1 attached on the skin, suitably in a transverse row across the occiput, e.g. at locations O 3 , Oz and O 4 (standard nomenclature for locations on the skull), plus (preferably) a reference electrode, e.g. attached at location Fz. The VEPs from the test electrodes are used to calculate the second spatial derivative of the potential field distribution (Laplacian responses) [refs.10-11]. The Laplacian response, L, may be calculated for example, as
L= 2 Oz−O 4 − O 3 .
[0063] The generators of the early component of the Laplacian responses are located within the primary visual cortex. Laplacian responses have several advantages as compared to monopolar VEPS. They have higher signal-to-noise ratio; they do not depend on the reference electrode; the alpha activity and electrical signals due to eye movements are eliminated. The Laplacian responses may be recognised in a single sweep.
[0064] The Laplacian responses elicited by the test stimulus T are recorded in absence and presence of the inducing stimulus I. The Laplacian responses are attenuated due to long-distance interactions in the visual network. The presence of defects in the area where the inducing stimulus I is displayed might result in a reduced inducing effect. The ratio between the Laplacian responses to the test stimulus T in the absence and presence of the inducing stimulus I can be used to evaluate visual defects in the area where the inducing stimulus I is presented. If the stimulated peripheral area has normal functions, the Laplacian ratio will be less than 1 (i.e. the response to the test stimulus T is affected by the presence or absence of the inducing stimulus I). If the stimulated peripheral area has a visual defect, the Laplacian ratio will be 1 (i.e. the response to the test stimulus T is not affected by the presence or absence of the inducing stimulus I).
[0065] The second computer 14 is adapted and programmed to record the signals from the electrodes 16 and to process the signals as described above.
[0066] [0066]FIG. 3 shows the normal data obtained from a normal observer (AX) and a glaucoma patient (RB) who has reduced sensitivity in both eyes at eccentricity of 10-20 deg. The ratio between the amplitudes of the response to the test stimulus in the presence and absence of a peripheral stimulus is calculated for 3 different types of peripheral stimulation. The results show that these ratios are less than one which might be due to long distance interactions between responses to the test and inducing stimuli. In addition, these ratios are smaller for the normal observer compared to the glaucoma patient. The reduced long-distance interactions effect might be due to the presence of defects in the visual field of the glaucoma patient.
[0067] When the invention is applied for psychophysical testing, the contrast threshold for detection of the test stimulus T is measured by the method of adjustment. The test subject has to fixate the centre of the display 12 . Two buttons on the control unit (or “response box”) 18 enable the subject to decrease and increase the stimulus contrast. Using these buttons the subject varies the contrast until a just noticeable sensation of flicker occurs. Pressing a third button then indicates that the threshold contrast has been reached and the computer 10 will record its value. The stimulus then appears again, but its contrast is randomly selected by the computer 10 to be a multiple (suitably 3-10 times higher or lower) of the measured threshold contrast. The programme repeats the measurements until a suitable number (e.g. 10) thresholds are collected for each experimental condition.
[0068] The mean threshold is determined in the absence and presence of the inducing stimulus. The ratio between these two mean threshold measurements may be used for assessment of visual defects in the area where the inducing stimulus is presented, e.g. in a similar manner to that described above for electrophysiological testing.
[0069] In summary, long-distance perimetry in accordance with the present invention is based on interactions between the responses to an inducing stimulus I and a test stimulus T. The magnitude of visual defects in the early stages of the visual system is evaluated by the ratio between the responses to the test stimulus T in the absence and presence of the inducing stimulus I. This relative measurement will reduce inter-individual differences, as compared with conventional methods based on “absolute sensitivity” measurements.
[0070] The psychophysical test as described above may be applied for patients who can understand and perform the visual task. The electrophysiological test is an objective procedure which requires only fixation at the centre of the display.
[0071] According to another aspect, the invention may also be applied for the purpose of measuring internal neural noise. Internal noise may be associated with neural fluctuations of early visual stages. The method of visual evoked potentials (VEPs) in the presence of external noise may be used to evaluate internal noise at different retinal areas.
[0072] In this case the stimuli presented by the display apparatus 12 consist of test patterns presented at various parts of the retina/visual field. Laplacian responses to contrast reversals of a test stimulus are recorded without noise and in the presence of several densities of external Gaussian dynamic noise, N.
[0073] The power of the test response R t (squared amplitude) could be expressed as follows:
R t =G c P t /( N add+ G s N )
[0074] Where
[0075] P t is the contrast energy of the test stimulus,
[0076] Nadd is the additive internal noise,
[0077] G c is the gain of the response to the central stimulus,
[0078] G s is the gain of the response to the peripheral stimulus, and N is the external noise.
[0079] The above equation consists of three free parameters: G s , G c and Nadd, which could be estimated by fitting the data obtained at several noise levels with the equation.
[0080] [0080]FIG. 5 shows data obtained from the normal observer (circles) and the glaucoma patient (squares). The estimated values for the glaucoma patient are;
G c =1.5 and 3.2
G s =1.5 and 0.3
Nadd=0.4 and 0.5
[0081] The glaucoma patient has a reduced gain of the response to the peripheral stimulus as compared to the normal observer, while the internal additive noises are similar. This approach will provide a tool for estimation of internal noise and response gain of different parts of the retina. This might reflect the presence of visual defects in the peripheral retina of this patient.
[0082] Thresholds are estimated from the contrast-axis intercept of linear regression approximating the contrast response; i.e. if the VEP response is plotted as a function of contrast, the intercept with the contrast-axis (zero response) indicates the threshold contrast. The threshold signal energy is approximately equal to the threshold contrast squared, multiplied by a constant. Threshold signal energy E as a function of external noise density is fitted by equation:
E= ( N+Ni )/ G (1)
[0083] The intercept on the noise density axis, Ni, is the equivalent input noise that is a measure of the internal noise. The slope is a measure of the response gain G.
[0084] The results provide objective information about internal noise and response gain of different parts of the retina.
[0085] Improvements and modifications may be incorporated without departing from the scope of the invention.
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Systems, apparatus and associated methods for use in the assessment of visual field functions. In particular, perimetry testing and visual evoked potential (VEP) testing is performed by a visual display device adapted to display visual stimulus patterns and a means for generating visual stimulus patterns within a predetermined visual field and for controlling the display of said visual stimulus patterns by said visual display device, wherein the means for generating visual stimulus patterns is adapted to generate a test stimulus for display in a central region of the visual field and to generate an inducing stimulus for display in a peripheral region of the visual field, and to control the visual display device so as to selectively display the test stimulus alone and in combination with the inducing stimulus in accordance with a predetermined test protocol.
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FIELD OF THE INVENTION
The present invention relates to a stopper elevator conveyor. The device of this invention is suitable for transferring sterilized stoppers for pharmaceutical containers from a source of sterilized stoppers to a bottle capping machine. It is also suitable for transferring other small discrete objects such as bottle caps and other products of like kind.
BACKGROUND OF THE INVENTION
Elevators, for stoppers and caps for pharmaceutical products as well as for other small discrete products, are designed to transfer these objects to additional equipment such as capping machines and the like. They are designed for high-speed automated assembly processes and, in the pharmaceutical industry particularly, a great concern for sterile working conditions is noted. Elevators are used because in many instances the following equipment using these small discrete objects employs gravity feed and gravity transfer mechanism as the caps or other objects are combined with other parts in the total assembly process.
In addition to the need for extremely sterile conditions in the pharmaceutical industry, it is also necessary that elevators of this type operate efficiently and rapidly. It is well known that the rate of production in automatic assembly is a major factor in the economics of such production. A simple, efficient, rapid delivery system which is capable of transferring small discrete objects such as bottle caps or stoppers to an elevated position for depositing in further processing equipment is needed.
Often times the small discrete objects which are being transferred by such an elevator device come directly from sterilizing means which provide a totally sanitary and sterile product. The operating elevator should then be capable of functioning in a sterile room and should be capable of being refilled easily and quickly to continue production without interruption.
At the present time, a fully automatic, versatile, economical and dependable stopper elevator for the pharmaceutical industry is not available. Accordingly, it is an object of this invention to provided an efficient operating device for transferring small discrete objects such as pharmaceutical stoppers and caps in a manner which is more reliable and efficient than has heretofore been possible.
SUMMARY OF THE INVENTION
Accordingly, it has now been discovered that the above and other objects of the present invention can be accomplished in the following manner. Specifically, the present invention provides for a device for transferring small discrete objects such as pharmaceutical stoppers and caps. The device includes a frame which is movably positionable at a predetermined location for delivery of the objects to an additional piece of equipment for further processing. Typically, this additional piece of equipment would be a capping machine of some type, although the invention is not limited to use with capping machines.
An angularly displaced conveyor is mounted on the frame and has a discharge chute at the predetermined location for discharging the objects, such as into a capping machine or the like. The conveyor includes a conveyor chain means defining a path from a transfer point to the discharge chute. The chain has bucket flight means for conveying objects along that predetermined path.
The device further includes a delivery chute on the frame for transferring the objects to the transfer point so that the objects may be picked up by the bucket flight means and conveyed along the path. The delivery chute includes a first tray which is inclined with the horizontal and has an open lower terminal end adjacent that transfer point so as to feed the objects to the conveyor chain. The delivery chute further includes a second tray which is located within first tray and is positioned at the same or greater angle with respect to the horizon and is positioned to receive the discrete objects. This second tray has an open lower terminal end for feeding objects to the first tray. The delivery chute further includes a vibrating means for oscillating the trays to impart movement of the objects toward the lower terminal ends of both trays.
The device of the present invention further includes a hopper means which is removably mounted on the frame. The hopper means is adapted to hold a quantity of the objects and includes a hopper chute for gravity feeding the objects to the delivery chute and feeding the objects on the second tray.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects of the present invention and the various features and details of the operation and construction thereof are hereinafter more fully set forth with reference to the accompanying drawings, wherein:
FIG. 1 is a side elevational view of a stopper elevator conveyor, showing certain details of construction and delivery in conjunction with an adjacent stopper feeder mechanism of an unassociated bottle capping machine.
FIG. 2 is an end elevational view of the device of FIG. 1 as viewed from the left hand side of the operators position.
FIG. 3 is a perspective view, enlarged, of a typical rubber stopper that may be supplied to conveyor hoppers and delivered under controlled and sterile conditions.
FIG. 4 is an enlarged fragmentary sectional side elevational view taken along line 4--4 of FIG. 2, showing additional details of construction.
FIG. 5 is a sectional plan view taken along the lines 5--5 of FIG. 4.
FIG. 5a is an exploded fragmentary perspective view illustrating details of the armature-coil structural arrangement.
FIG. 6 is a fragmentary perspective view showing details of an individual flight and conveying belt as utilized in this device.
FIG. 7 is an end elevational view similar to FIG. 2, showing a modification of the device shown in FIG. 1.
FIG. 8 is a fragmentary side elevational view of the device illustrated in FIG. 7, showing additional details of the modified construction.
FIG. 9 is a side elevational view of the modification illustrated in FIG. 7 and FIG. 8, in use.
FIG. 10 is an enlarged fragmentary side elevational view of the vibratory feeder chute and its associated angularly displaceable feeder trays.
FIG. 11 is an electrical schematic of the device shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, the device of the present invention is shown generally by the reference numeral 10. A rectangular boxlike structure 11 is mounted on castors 12 which are lockable so that the device can be positioned to align the discharge chute 14 to deliver small discrete objects such as pharmaceutical stoppers and caps to a receptacle 18, such as in a bottle capping machine. Discharge chute 14 also serves to support a belt conventional tensioning means 15 for adjusting the conveyor means 13. Adjustable arm 16 is extended outward to position a sensor means 17 for determining the amount of product contained in the receptacle 18.
Shown in FIG. 3 is a typical pharmaceutical stopper 19. This stopper 19 is broken away in part to show the true geometric configuration in section. These stoppers are often made from elastomers such as rubber. When they are sterilized, they often times are still wet when they are removed from the sterilization operation and transferred to the capping machine. One particular advantage of the present invention is that it allows for drying in a sterilized environment. Thus, stoppers such as 19 as they fall into receptacle 18 remain sterilized and have been subjected to a drying process, as will be described below.
The angularly displaced conveying means 13 is driven by a motor 21 connected through sprocket 22. As seen in FIG. 5, this motor 21 is completely enclosed. The sprocket 22 is fully enclosed by cover 31 and driven by chain 32. All of the lubrication and other contaminating components of the drive system are totally enclosed by the cover 31 to prevent contamination of the objects being transferred by the device. Operation of the electric motor 21 is controlled via control box 23 which is located on frame 11 above the motor 21 and sprocket 22. As shown in FIG. 2, the control box 23 includes several gauges and switches for easy and convenient operation by the operator.
The discrete objects which are being transferred by the elevator 13 are brought to the device in a hopper 24 which is a rectangular box set on top of frame 11. The hopper 24 has a truncated trapezoidal shaped delivery chute 25 from which the supply of stoppers 19 or other products are introduced into the device. While the rectangular box frame 11 is supported on legs 26 attached to lockable coasters 12, which lock the device in place so that it is suitably adjusted with respect to the receptacle 18. The hopper 24 may be removed when it is empty so as to permit an additional supply of stoppers or other objects to be introduced to the system. Handles 27 are provided to allow the operator to lift the empty hopper 24 from the device. The top 28 of the hopper 24 may be opened by pivoting face 28 about hinge 29, using the knob 30. More than one hopper can be used if necessary to keep the device in operation.
Once a hopper 24 has been placed into position on the frame 11, the chute 25 allows a quantity of objects to fall onto the delivery chute. The delivery chute includes a first tray 33 which is oscillated in the direction of arrow 34 shown in FIG. 4, to cause a product to travel to the open lower terminal end of tray 33 where they are picked up by bucket flights 35 and transferred up through the angularly displaced conveyor means 13.
As shown in FIG. 6, the bucket flight 35 has a plurality of holes 36 which permit the passage of air during the transfer ride up the conveying means 13. This allows the warm sterile air in the sterile room to effectively dry the stoppers 19 or other products which might be contained in the bucket flight 35. The bucket flight 35 is attached to a chain conveyor belt 37 which is driven by sprocket 22 and motor 21. Motor 21, being a variable speed motor, can be adjusted to vary the rate of the travel of chain 37 to assist in regulation of the flow of stoppers from the hopper to the conveyor and then to the discharge chute.
Positioned within the tray 33 of the discharge chute is a second tray 38 which, like tray 33, is at an angle with respect to the horizontal. Accordingly, movement of the entire device in the direction of arrow 34, as shown in FIG. 5, causes the objects to move from the inner tray 38 out of the open lower terminal end thereof to fall onto the larger outer tray 33 and again out through the open lower terminal end onto the bucket flight 35.
The inner tray 38 is supported on outer tray 33 through connecting bolts 39. The angle that the tray 38 makes with respect to the tray 33 is shown in FIG. 10. The tray 38 is adjustably held in slot 41 through fastener 42 to position the bottom of the tray 38 with respect to the bottom of the tray 33 by an angle alpha. Alpha may range from zero when the axis 43 of tray 38 is parallel to the bottom of tray 33, such as when smaller stoppers such as 13 mm stoppers are being transported. When larger stoppers are being transported, such as 28 mm stoppers, the angle alpha between the tray 38 and the tray 33 is the largest. A median adjustment of bolt 42 in slot 41 for midway sized stoppers, such as 20 mm stoppers, places the axis of the tray 38 along line 45, in this case approximately halfway between axis 43 and 44. Thus, alpha will range from 0° to 10° or more.
The lower end 46 of tray 33 has a hinged plate 47 mounted, using bracket 48. As is clear from FIG. 4, the hinged plate 47 passes quite close to the bucket flight 35, so that objects being transferred by the tray 33 to the bucket flight 35 do not fall between the two elements. The bracket 48 may contain a hinge mechanism which allows the hinged plate 47 to rise in the event objects somehow become positioned between the hinged plate 47 and the edge of the bucket flight 35.
Also shown in FIG. 4 is a rod 49 which is attached to the inner tray 38 and which moves when the trays 33 and 38 are oscillated in the direction of arrow 34. This vertically directed rod moves or stirs the small discrete objects contained in the truncated chute 25 to facilitate the flow of these objects.
As seen in FIG. 4, mounted on the rectangular boxlike structure 11 is a fixed mounting frame 51 which is a heavy metal casting capable of supporting the trays 33 and 38 as described hereinafter. An upper fixed frame member 52 supports a coil 53 in operating relationship with an armature 54 as illustrated in FIG. 5a. Armature 54 is held by double leaf spring 55 and a thin rod 56 which axially holds the armature. As can be seen in FIG. 5, the thin rod 56 is held by two double leaf springs 55 which extend from the top of the fixed frame 52 downwardly to the lower end and support the armature bar 54. These two double leaf springs 55 are tied to the foward end of two longitudinally extending parallel rectangularly cross sectioned bars 57 which have two additional springs 58 at their other ends. These springs 58 are also mounted in the fixed mounting frame 51. The outer tray 33 is mounted to the longitudinally extending bars 57 by block members 59. Thus operation of the coil 53 and armature 54 will cause the longitudinally extending bars 57 to oscillate as the current is cycled through the coil. This causes the tray 33, and the inner tray 38, to oscillate as well, in the direction shown by arrow 34. By varying the rate of oscillation, accurate control can be kept on the rate of transfer of the small discrete objects through the open end of tray 33 onto flights 35 of the conveyor elevator 13. As is seen in FIG. 5 as well, the end 46 of the tray 33 converges at the open lower terminal end adjacent the hinge plate 47 so that the objects are directed to the bucket flights 35.
An alternative embodiment of the present invention is shown in FIGS. 7 through 9. As shown in FIG. 9, the rectangular boxlike structure 11 contains the angularly displaced conveying means 13 and the control box 23. The frame 11 is held on legs 26 which are movably supported by castors 12. Castors 12, as noted above, can be locked to position the rectangular boxlike frame 11 in an appropriate place for discharging product. The structure of the delivery chute which takes the products from the hopper 24 to the conveyor 13 are not shown in FIGS. 7 through 9, for purposes of clarity, so that the particular details of this embodiment can be more clearly understood. A pair of vertically upstanding members 61 are provided with castors 62, and they are attached to supporting legs 63 whose terminal ends are provided with fixed or non-swivel rollers 64. These support legs 63 extend midway into the feeder assembly housing 11 and contain an indexing member 65 for locating the hopper 24 with respect to the rectangular frame 11. Thus, the operator can insert or remove the hopper 24 in the direction shown by arrow 66.
The hopper can also be raised or lowered in the direction shown by arrow 67 as the vertical upstanding members 61 support an outstanding arm 68 in combination with angle brackets 69. A roller slide assembly 71 is provided to prevent horizontal movement or rocking. The roller slide assembly 71 fits within a u-shaped rail assembly 72 which is opened at the bottom. Movable cross plate 73 is attached via wire 74 to a boss 75 which is centrally located. Boss 75 and plate 73 can be raised or lowered by wire 74 via pulley 76 and a winch and crank assembly 77. One advantage to this design is that the hopper may be a larger size since it no longer needs to be carried by one or two operators. Winch and crank assembly 77 can obviously be replaced by an electric motor, if that embodiment would be desired. The hopper and carrier system shown in this embodiment is filled with small discrete objects such as rubber stoppers, directly from a sterilizing unit as described above, and transported on castors 62 and fixed rollers 64. The roller slide assembly 71 fits into u-shaped rail 72 and the unit is brought into the rectangular boxlike frame 11 until index member 65 indicates that a proper alignment has been made. Index member 65 can conveniently interlock with leg 26, as shown in FIG. 8. At this point, the crank and winch assembly 77 is turned to lower the hopper 24 into position and the device is ready to operate.
Regardless of which assembly is used, either the movable hopper shown in FIGS. 7, 8 and 9 or the hopper shown with handles 27 in FIGS. 1 and 2, once the hopper 24 has been loaded with rubber stoppers or other discrete objects, the device is ready to dispense those objects to a receptacle such as receptacle 18.
In operation, the conveyor means 13 is started so that motor 21 drives chain 32 and sprocket 22 to cause the chain conveyor belt 37 to travel in a clockwise version, looking at FIG. 4. This causes the bucket flights 35 to rise as they pass hinged plate 47. Operation of the coil 53 and armature 54 causes the large tray 33 to vibrate in the direction shown by arrow 34. Smaller tray 38 also moves as it is fixedly mounted to outer tray 33. Vertical rod 49 extends into the truncated trapazoidal shaped delivery chute 25 of hopper 24 cause stoppers, for example, to fall into inner tray 38. Motion in the direction of arrow 34 imparts a straight line movement to the objects since the tray 38 is inclined at an angle with the horizontal.
Objects are fed from the tray 38 out its open lower terminal end onto the first or outer tray 33. Similarly, the objects are moved by the oscillatory motion of coil 53 and armature 34 to cause the objects to move down the inclined vertical face of tray 33 to tray 33's open lower terminal end. The end of tray 33 converges to the hinged plate 47 by means of side walls 46. Hinge plate 47 allows the objects to be placed on the porous bucket flights 35 where any residual moisture is dried in the sterile atmosphere of the clean room. These products are then carried up the conveyor 13 by chain 37 in bucket flights 35, to be deposited into the discharge chute 14. The belt tensioning means 15 is provided to allow some adjustment in the tension of the belt, to compensate for wear and for thermal expansion of the metallic parts.
The small objects such as stoppers fall from the discharge chute 14 into a receptacle 18, such as a feeding portion of a bottle capping apparatus. The level of product in the receptacle 18 is determined by a sensor 17 held by arm 16 so that a maximum limit can be sent. When the maximum limit is sensed, the vibrating coil and armature can be turned off, either automatically or upon operator reaction to a signal such as a warning light on control panel 23. As product no longer is moved by the vibrating coil and armature, product no longer fills the bucket flights and the receptacle 18 will not be over filled. Similarly, when the level in the receptacle 18 reaches a minimum or lower limit, a signal can be given, either by automatically activating the coil and armature or by another signal light notifying the operator that the vibration unit should be restarted.
Controls can be installed to prevent operation of the coil and armature vibrating apparatus when the elevator 13 is not in motion. Similarly, control limits can be installed to cause the motor 21 to stop driving the chain conveyor 37 after a given period of time has elapsed after the vibrating unit has stopped. This permits the stoppers in the chain to be emptied before shutting down the device. Alternatively, the motor 21 can be stopped as soon as the vibrating apparatus stops, thereby preserving a quantity of discrete objects in the various buckets 35. In this embodiment, the apparatus is ready to use as soon as the hopper has been refilled or when the sensor 17 indicates that a supply of product is desireable.
The entire device can be operated automatically, as illustrated in the electronic schematic shown in FIG. 11. Power is provided from a source 101 into terminal block 121. Sensor 103 provides a signal via control relay 119, once power is activated by switch 113 and pilot lamp 115. Motor control 117 engages drive motor 107. Vibrator coil 105 is activated by conventional feeder control 109, and indicator lamp 111.
While particular embodiments of the present invention have been illustrated and described herein, it is not intended to limit the invention and changes and modifications may be made therein within the scope of the following claims.
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A device for transferring small discrete objects such as pharmaceutical stoppers andn caps including a frame movably positionable at a predetermined location for delivery of the objects and an angularly displaced conveyor on the frame having a discharge chute at the predetermined location for discharge in objects thereto. The conveyor includes a conveyor chain apparatus defining a path from a transfer point to the discharge chute. The chain has bucket flight apparatus for conveying the objects along the path. A delivery chute is also on the frame for transferring the objects to the transfer point. The delivery chute includes a first tray inclined with the horizontal and having an open lower terminal end adjacent the transfer point positioned to feed the objects to the conveyor chain. The delivery chute further includes a second tray located within the first tray at the same or greater angle with the horizontal and positioned to receive the objects. The second tray has an open lower terminal end for feeding the objects to the first tray. The delivery chute further includes vibrating apparatus for oscillating both of the trays to impart movement of the objects toward the lower terminal ends of the tray. Finally, a hopper apparatus is provided, which is removably mounted on said frame for holding a quantity of the objects. The hopper apparatus includes a hopper chute for gravity feed of the objects to the delivery chute.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent application Ser. No. 12/605,065 (Attorney Docket No. 36601-703.201, formerly Attorney Docket No. 020979-003920US) filed Oct. 23, 2009, which is a non-provisional of, and claims the benefit of priority of U.S. Provisional Patent Application No. 61/108,420 (Attorney Docket No. 36601-703.101, formerly Attorney Docket No. 020979-003900US), filed Oct. 24, 2008; the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present disclosure relates to medical devices, systems and methods, and more specifically to methods, systems and devices used for anchoring suture and delivery of suture anchors.
[0004] Soft tissue such as tendons, ligaments and cartilage are generally attached to bone by small collagenous fibers which are strong, but which nevertheless still can tear due to wear or disease. Examples of musculoskeletal disease include a torn rotator cuff as well as a torn labrum in the acetabular rim of a hip joint or the glenoid rim in a shoulder joint.
[0005] Thus, treatment of musculoskeletal disease may involve reattachment of torn ligaments, tendons or other tissue to bone. This may require the placement of suture anchors in the humeral head for reattachment of a torn rotator cuff, placement of suture anchors in the acetabular or glenoid rim for reattachment of the torn labrum, placement of tacks to attach labral tissue to the glenoid rim, placement of screws in the vertebral bodies to attach cervical plates for spinal fusion, placement of screws in small joint bones for stabilizing reduced fractures, etc. A suture anchor is a device which allows a suture to be attached to tissue such as bone. Suture anchors may include screws or other tubular fasteners which are inserted into the bone and anchored in place. After insertion of the anchor, the tissue to be repaired is captured by a suture, the suture is attached to the anchor (if not already pre-attached), tension is adjusted, and then the suture is often knotted so that the tissue is secured in a desired position.
[0006] Delivery of a suture anchor to a treatment site can be time consuming and challenging to undertake in the tight space encountered during endoscopic surgery and sometimes even in conventional open surgery. In most surgical procedures, a pilot hole is drilled at the implantation site prior to screwing in the device. In other cases a self-tapping device tip is used to screw in the device without a pilot hole. Alternatively, ultrasonic energy has been proposed in embedding bone anchors in bony tissue without pre-drilling a pilot hole. These methods of implanting a device in bone tissue, while commonly used in surgery today, are not optimal. Pre-drilling a pilot hole prior to placing the device requires the surgeon to exchange tools through the cannula and to locate the pilot hole after introducing the implant in the arthroscopic field. Self-tapping devices are limited to use at sites with the appropriate thickness of cortical bone. Ultrasonic energy based devices are susceptible to large energy losses with minor changes in device configuration, and rely on ultrasonic energy sources which can be expensive. It would therefore be desirable to provide a suture anchor system that provides easy access to the treatment site and that can easily and accurately deliver a suture anchor to a desired location.
[0007] In a particular application, treating musculoskeletal disease in a hip joint can be especially challenging. The hip joint is a deep joint surrounded by a blanket of ligaments and tendons that cover the joint, forming a sealed capsule. The capsule is very tight thereby making it difficult to advance surgical instruments past the capsule into the joint space. Also, because the hip joint is a deep joint, delivery of surgical instruments far into the joint space while still allowing control of the working portions of the instrument from outside the body can be challenging. Additionally, the working space in the joint itself is very small and thus there is little room for repairing the joint, such as when reattaching a torn labrum to the acetabular rim. Thus, the suture anchor tool must be small enough to fit in the limited space. Moreover, when treating a torn labrum, the suture anchor must be small enough to be inserted into the healthy rim of bone with adequate purchase, and the anchor also must be short enough so that it does not protrude through the bone into the articular surface of the joint (e.g. the acetabulum). Thus, the anchor delivery instrument must also be able to hold and deliver suture anchors having a small diameter and small length.
[0008] Therefore, it would be desirable to provide improved suture anchors and suture anchor delivery instruments that overcome some of the aforementioned challenges. Such suture anchors and delivery instruments are preferably suited to arthroscopic procedures, and in particular labral repair in the hip. At least some of these objectives will be met by the disclosure described below.
[0009] 2. Description of the Background Art
[0010] Patents disclosing suture anchoring devices and related technologies include U.S. Pat. Nos. 7,566,339; 7,390,329; 7,309,337; 7,144,415; 7,083,638; 6,986,781; 6,855,157; 6,770,076; 6,767,037; 6,656,183; 6,652,561; 6,066,160; 6,045,574; 5,810,848; 5,728,136; 5,702,397; 5,683,419; 5,647,874; 5,630,824; 5,601,557; 5,584,835; 5,569,306; 5,520,700; 5,486,197; 5,464,427; 5,417,691; and 5,383,905. Patent publications disclosing such devices include U.S. Patent Publication Nos. 2009/0069845; 2008/0188854; and 2008/0054814.
BRIEF SUMMARY OF THE INVENTION
[0011] The current invention comprises surgical devices and methods to treat various soft tissue and joint diseases, and more specifically relates to suture anchors and suture anchor delivery instruments used in the treatment of bone, cartilage, muscle, ligament, tendon and other musculoskeletal structures.
[0012] In a first aspect of the present invention, a method for impacting a suture anchor into bone comprises providing an implantable suture anchor, and providing an impactor device for impacting the suture anchor into the bone. The suture anchor is coupled to a distal portion of the impactor device. Positioning the suture anchor engages the suture anchor with the bone at an implantation site, and powering the impactor device impacts the suture anchor thereby implanting the suture anchor into the bone. The frequency of impaction is less than 20 KHz. The impactor device is decoupled from the suture anchor and then the impactor device is removed from the implantation site.
[0013] The suture anchor may pass through adjacent musculoskeletal tissues and may attach the adjacent musculoskeletal tissues to the bone. The adjacent musculoskeletal tissues may comprise bony tissues or soft tissues. The suture anchor may include one or more lengths of suture. Powering of the impactor device may comprise pneumatically, electrically, mechanically, or magnetically actuating the impactor device. The impactor device may impact the anchor when powered so as to linearly, rotationally, or linearly and rotationally drive the suture anchor into the bone. The frequency of impaction may be less than 1 KHz. The impaction may have an amplitude of 1,000 micrometers or less per impact.
[0014] The method may further comprise expanding a portion of the suture anchor radially outward so as to firmly engage the suture anchor with the bone. The suture anchor may comprise a plurality of fingers, and expanding a portion of the suture anchor may comprise releasing a constraint from the fingers so as to allow the fingers to radially expand outward. The impactor device may comprise an elongate tubular shaft and the step of decoupling may comprise advancing the suture anchor axially away from a distal portion of the shaft. The method may also comprise cooling the suture anchor or the implantation site with a fluid.
[0015] In another aspect of the present invention, a suture anchor delivery system comprises an implantable suture anchor having a longitudinal axis and a plurality of fingers circumferentially disposed therearound. The fingers have a constrained configuration and an unconstrained configuration. In the constrained configuration the fingers are substantially parallel with the longitudinal axis, and in the unconstrained configuration, the fingers expand radially outward. The system also includes an impactor device for impacting the suture anchor into bone. The suture anchor is releasably coupled to a distal portion of the impactor device.
[0016] In a further aspect, the invention provides a suture anchor formed of shape memory material and having an unbiased configuration adapted to securely fix the anchor in bone or other tissue. The suture anchor is deformable into a configuration adapted for delivery into the bone or tissue, from which it may be released so that it returns toward its unbiased configuration thereby anchoring the anchor in the bone or tissue. In various embodiments, the anchor may have in its unbiased configuration a plurality of resilient fingers that extend radially outward, a curved shape formed around a transverse axis, two or more wings that flare outwardly in the proximal direction, or two or more longitudinal divisions defining a plurality of axial elements that bow or deflect outwardly. Other structures are disclosed herein.
[0017] In another aspect, the invention provides a suture anchor having a tapered tip adapted for being driven into bone, with or without a pre-drilled hole, a shaft extending proximally from the tip, and a means for attaching a suture to the shaft. The tip, the shaft, or both are cross-shaped in cross section.
[0018] The suture anchor may comprise a textured outer surface to allow for bone ingrowth. The suture anchor may also comprise a length of suture coupled thereto. The impactor device may impact the suture anchor at a frequency of less than 20 KHz, or at a frequency of less than 1 KHz. the impactor device may comprise an actuation mechanism for impacting the suture anchor that is pneumatically, electrically, magnetically, or mechanically actuated. The impactor device may impact the suture anchor and drive the anchor into the bone or other tissue in a linear, rotational, or linear and rotational manner. The impactor device may impact the suture anchor with an impaction having an amplitude of 1,000 micrometers or less per impact. The system may further comprise a cooling system for cooling the impactor device and suture anchor during impaction. The cooling system may comprise a cooling fluid.
[0019] These and other embodiments are described in further detail in the following description related to the appended drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a sectional view of an anchor loaded in the distal end of an anchor driver and placed through a cannula.
[0021] FIG. 2 is a sectional view of a flat anchor loaded into the distal end of an anchor driver with a stabilization sleeve.
[0022] FIG. 3 is a sectional view of a round anchor loaded into the distal end of an anchor driver with a tubular profile.
[0023] FIG. 4 is a sectional view of the body of a pneumatic powered impactor.
[0024] FIG. 5 is a sectional view of the body of a electromechanically powered impactor.
[0025] FIG. 6 is a sectional view of the body of an impactor with a rotary mechanism.
[0026] FIG. 7 is an example of an anchor.
[0027] FIGS. 8A-8D are examples of anchors.
[0028] FIGS. 9A-9B are examples of anchor in a constrained and deployed configuration.
[0029] FIGS. 10A-10B are examples of a device for sutureless attachment of tissue to bone in a constrained and deployed configuration.
[0030] FIGS. 11A-11B are examples of a curved anchor in a constrained and deployed configuration.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The devices and methods disclosed herein address at least some of the limitations of current methods of implanting devices into bony tissue. The method involves driving the device into bony tissue by impaction whereby, an impactor drives the implant into bone at frequencies between 10 and 20 KHz, preferably between 20 and 1000 Hz, most preferably between 30 and 500 Hz; and at amplitudes of 100 to 1000μ, preferably 200-750μ, most preferably 300-500μ. The implantable device may be loaded into the distal end of the impactor such that the distal end of the impactor and the attached device may be introduced into an arthroscopic field through a cannula.
[0032] FIG. 1 , shows a sectional view of implant 103 loaded into an impactor 102 and introduced through a cannula 103 . Implant 101 is located at the distal end of impactor assembly 102 . The assembly 102 is introduced down the bore of cannula 103 and placed in the proximity of bony structure 104 . Having been placed at the surface of bony structure 104 the impactor 102 is energized and the implant 101 is driven into the bone. Channel 105 extends transversely through the implant 103 and allows a suture to be secured thereto. During the impaction period, contact between the tip of the device and the bony tissue is maintained manually by the surgeon.
[0033] In one exemplary embodiment the implant is impacted into the bone by application of force onto the proximal surface of the implant. Referring to FIG. 2 , implant 201 is impacted by impactor member 202 . This allows the implant 201 to be constructed with substantially consistent cross sections. Sleeve 203 can move relative to the implant 201 and impactor member 202 while remaining concentric and serves to stabilize and guide the implant 201 while the implant 201 is being impacted into the bone.
[0034] In another embodiment the implant is configured with a stepped shoulder region 303 along the length of the body suitable for applying impaction force. FIG. 3 shows a cross sectional view of anchor 301 which has a round cross section and interfaces with the distal end of the impactor 302 . The distal end of the impactor 302 is generally round and hollow. The distal end of the impactor 302 which interfaces with the anchor device 301 could be of varying length to enable introduction through cannulas used to access joint spaces in the shoulder, knee, hip etc. The impactor 302 may also be loaded with multiple devices.
[0035] At the frequencies utilized during deployment of anchors, the amount of energy loss by heat dissipation is low. However, the distal end of the impactor may optionally be designed to circulate cold fluid to regulate the temperature of the impactor tip and the implant. Other forms of cooling well know in the art may also be used in conjunction with the impactor.
[0036] The frequency and amplitude of the impactor may be adjusted to optimize the implantation process depending on the size of the implant, the design of the implant, as well as the properties of bone at the implant site, etc.
[0037] In another embodiment, the impactor is powered by compressed gas which is commonly available in operating rooms. FIG. 4 shows a cutaway view of one embodiment of a pneumatic driver used for placing devices in bony tissue. Shuttle element 401 is cycled back and forth based on air pressure by selectively pressurizing and releasing pressure in chamber 402 through the cyclic motion of shuttle 401 relative to ports 403 and 404 . As the shuttle moves port 403 is selectively covered or uncovered causing the shuttle to reverse direction based on the action of spring 405 which rebounds shuttle 401 back into the depressurized chamber 402 . At one end of the shuttle travel, the shuttle impacts active element 406 which is in contact with the proximal end of the device 407 thereby transmitting the energy from the shuttle 401 to the device 407 with each cycle. At the end of the cycle, the spring 408 returns the active element 406 back to its original position. Those skilled in the art will appreciate that the system shown in FIG. 4 is an exemplary system and the same effect could be accomplished with a variety of pressured driving mechanisms.
[0038] In another embodiment, the impactor could be designed to operate using a mechanical shuttle mechanism driven by an electromagnetic field. FIG. 5 shows a sectional view of an instrument used for driving devices into bony tissue. Shuttle element 501 may be composed of any ferromagnetic material and is cycled back and forth based on the magnetic field created by a coil 502 which is connected to a signal generator capable of generating alternating current. At one end of the shuttle travel, the shuttle impacts active element 503 which is in contact with the proximal end of the device 504 thereby transmitting the energy from the shuttle to the device with each cycle. Those skilled in the art will appreciate this system shown in FIG. 5 is an exemplary system and the same effect could be accomplished with a variety of electromechanical driving mechanisms.
[0039] In another embodiment, the impactor could be designed to operate using mechanical means whereby rotary motion is converted to linear motion. FIG. 6 shows a sectional view of an instrument used for driving devices into bony tissue. Cable driven cam 601 is designed with a circular ramp 602 that interfaces with mating ramp 603 that is part of shuttle 605 that does not rotate due to pin 604 and slot in 603 . Rotation of ramp 602 causes mating ramp 603 to move in a reciprocating fashion which is transmitted to the active element 606 which in turn imparts its energy to implant 608 . Shuttle 605 returns to its original position once ramps 602 and 603 have disengaged via the force applied by spring 607 . This allows active element 606 to return due to the force applied by spring 608 . Those skilled in the art will appreciate this system shown in FIG. 6 is an exemplary system and the same effect could be accomplished with a variety of mechanisms that convert rotational motion into reciprocating motion.
[0040] In all the embodiments described above, by altering the pressure, current, rotational speed etc., the frequency and amplitude of the impactor can be varied to enable the surgeon to select settings that are appropriate for various tissue properties (e.g.; cortical bone, cancellous bone, etc.)
[0041] In addition to the embodiments described above, the impactor may have linear and rotational motion combined to create a reciprocating twisting motion. By creating a reciprocating twisting motion, devices may be driven in more securely into bony tissue, thereby increasing the stability of the implanted device. The amount of twisting motion may be varied based on the specific design and dimensions of the device. FIG. 7 illustrates an exemplary embodiment of a suture anchor device 702 having a pointed distal tip 706 and a main shaft 704 . Both the main shaft 704 and the distal tip 706 have a twisted, helical-like configuration so that the anchor will rotate as it is being driven into the bone by an impactor having a reciprocating twisting motion.
[0042] The impaction method has advantages that are not limited to a particular device design. For example, the implant may be cylindrical, flat, or a have a variety of other cross sections. Additionally the cross section may change along the length of the implant. FIGS. 8A-8D show a variety of anchor devices that may be useful in this application. The implant may be threaded or plain. FIG. 8A shows an anchor with a tip 801 which has a triangular pointed tip while the shank 802 has a substantially round cross section. Shank 802 has a hole 803 that passes through the shank allowing for attachment of a suture. FIG. 8B shows an anchor 810 having a rectangular cross section 812 resulting in a generally flat configuration. FIG. 8C shows an anchor 816 with a cross section generally described as a hollow tube and a suture S coupled thereto. In the embodiment shown in FIG. 8C , wings or fingers 804 and 805 are active elements that deploy once the implant is released from the delivery instrument. For example wings or fingers 804 , 805 may be fabricated from a superelastic material like Nitinol, spring temper stainless steel, a resilient polymer, or the wings may be fabricated from a shape memory alloy, such that once the anchor 816 is advanced from the delivery instrument and the wings 804 , 805 become unconstrained, they spring open, radially outward. The wings help secure the anchor 816 into bone or other tissue. In alternative embodiments, the wings 804 , 805 may be deformed into the flared radially outward position to help secure the anchor into the bone. For example, a plunger may be advanced into the center of the anchor thereby causing the wings 804 , 805 to flare outward. FIG. 8D shows an anchor 814 with a tip 814 A and a shank 814 B having a generally X-shaped or cross-shaped cross section that may inserted into bone using the techniques described herein. In the embodiment shown, both the tip and the shank of anchor 814 have a cross-shape cross-section, although in other embodiments just the tip or just the shank may have a cross-shape. Shank 814 B has a transverse hole through which a suture may be threaded. Other means of attachment of the suture to the shank may also be used.
[0043] Additionally, the implant and driver could be designed such that a loaded implant constrained by the driver is placed at the implantation site. Following placement, the implant recovers to a pre-determined shape that enhances the anchoring of the implant in the bony tissue. FIG. 9A shows a cylindrically shaped tubular expandable anchor 906 in its loaded (constrained) condition. The anchor comprises a plurality of axially oriented slits 905 that form a plurality of axially oriented elements 901 . Element 901 is an active element that can be constrained to the profile of the non active portion of the implant 902 . Element 901 is replicated in a circular pattern around the periphery of the implant 906 . Conically shaped nosecone 903 is distal to the end of the driver instrument (not illustrated) while the shank is composed of active elements and non active portions 901 and 902 respectively. The anchor 906 is constrained in the delivery instrument. FIG. 9B shows the same anchor 906 in its deployed configuration after being released and unconstrained from the delivery instrument (not illustrated). Elements 901 are self-expanding and thus have moved to an expanded position to lock the anchor into the bony tissue. The elements 901 may be fabricated from self-expanding materials such as superelastic nitinol, shape memory alloys, spring temper metals, resilient polymers, or other resilient materials. Expansion element 901 causes a shortening of the overall anchor 906 length. In the case where there is a preloaded suture or soft tissue fixation element attached to 901 , this shortening of the anchoring element can be used as a tensioning means for the soft tissue fixation element. Tensioning the soft tissue fixation would provide improved coaptation of the soft tissue to the bone, and improve the repair. The degree of foreshortening can be programmed into the device by modifying one or a combination of the diameter of the distal driving (pointed) element of 901 , the length of the shaft of 901 , the diameter of the shaft of 901 , and the specific design of the cutouts 905 of 901 .
[0044] Change in the implant after implantation could be based on the expansion of the body of the anchor as shown in FIG. 9B or by deployment of a fixation member from the body of the anchor as shown in FIG. 8C . A combination of the expansion of the body of the anchor and deployment of members from the body could also be used. Expansion of the anchor could include mechanical means of expanding the anchor from a first configuration to a second configuration based on the malleability of the material or could be achieved through the use of self-expanding or shape memory materials. Deployment of fixation members may be achieved through various means including shape memory and mechanical means. The implants may include one or more sutures. The body of the implant may have holes to allow for bony in-growth into or across the implant. The surface of the implant may be textured or porous to allow for bone in-growth to enhance long term anchoring of the implant. The implant may be hollow to allow for bony in-growth within the implant. An advantage of using a hollow implant is the entrapment of the bone particles from the implantation site within the implant during impaction.
[0045] An additional embodiment of the current invention is an anchor configured to provide for fixation of tissue directly to the bone adjacent to the anchor location. FIG. 10A shows the anchor in a constrained configuration for delivery. Active elements 1001 are constrained in this undeployed state in the distal end of the driver (not illustrated) while nosecone 1002 may be exposed beyond the distal end of the driver. FIG. 10B shows the same anchor after it has been placed in bony tissue and the anchor has been deployed from the delivery instrument so that it is unconstrained. Active elements 1001 include a plurality of fingers that are axially aligned with the longitudinal axis of the anchor when constrained, and expand radially outward when unconstrained. The elements spread out and allow for the capture of tissue between the fingers and the bone or other tissue into which the anchor is disposed. Nosecone 1002 is affixed into bony tissue. By varying different parameters of element 1001 which may include but are not limited to the thickness, material, heat treating, and radius of curvature of the deployed device, it will be possible to change the force of apposition between the two tissues to be fixed. This design also provides a degree of self-adjustment, allowing different tissue thicknesses to be attached to underlying bone by a single device without requiring a suture. By having a radius of curvature which changes along the length of the active elements 1001 rather than a constant radius of curvature, the device can be programmed to provide approximately the same force of apposition for a range of tissue thicknesses to the underlying bone with the same device design. This allows a surgeon to use a single cartridge-loaded device to place a number of anchors without device exchange.
[0046] Element 1001 may be made from a resorbable material such as PLLA, collagen, highly crosslinked hyaluronic acid or the like. While some of these materials may be processed and formed to self-deploy as described above, many require secondary steps after placement to deform them into a fixation shape. As an example, when element 1001 is made from PLLA, a secondary step may include application of heat to element 1001 to plastically deform it into the desired final configuration. Once the heat source is removed, the PLLA or other plastically deformable material remains in its final shape and position. In other embodiments, the elements 1001 may be fabricated from self-expanding material like nitinol, spring temper metals, or resilient polymers. The elements may also be made from shape memory materials including metal alloys like nitinol or shape memory polymers.
[0047] Additionally, elements 1001 and 1002 may be two separate elements, with element 1001 being placed on top of the tissue to be fixed, and 1002 being driven down through element 1001 and into the underlying bone, fixing element 1001 and tissue to be fixed. In this embodiment, element 1001 may be slotted as shown, or it may be configured more like a washer or grommet shape.
[0048] In another embodiment both the portion of the anchor located in bony tissue and the anchor portion in the adjacent tissue may be configured with both elements being active.
[0049] In yet another embodiment, an anchor 1102 may be constructed with a generally curved profile as shown in FIG. 11A . FIG. 11B shows the anchor 1102 once it is loaded into a delivery system 1103 which constrains it to a generally straight profile within a constraining sleeve 1101 that is part of the driver. As the anchor 1102 is deployed from the constraining sleeve 1101 into the bone, it advances along a curved profile into the implantation site.
[0050] The implants described in this invention could be made from metals like stainless steel, titanium, nitinol, etc., as well as resorbable and non-resorbable polymers like PLLA, PEEK etc. Implants may also be composites of two or more materials.
[0051] The method, devices and implants described above could be used in a variety of applications including any application that requires an implant to be anchored into bony tissue. For example, placement of bone anchors in the humeral head for reattachment of a torn rotator cuff, placement of bone anchors in the acetabular or glenoid rim for reattachment of the torn labrum, placement of tacks to attach labral tissue to the glenoid rim, placement of screws in the vertebral bodies to attach cervical plates for spinal fusion, placement of screws in small joint bones for stabilizing reduced fractures, for treating stress urinary incontinence with a bone-anchored pubovaginal sling, placement of plates in cranio-facial reconstruction, fixation of fractures, etc.
[0052] While the device and implants are designed to be used preferably in arthroscopic or minimally invasive procedures, they could also be utilized in open or mini-open surgical procedures.
[0053] The implants in this invention may be loaded into a delivery device (e.g. a tube) which can be attached to the distal end of the impactor. The loaded delivery device may be designed to be introduced through a standard arthroscopic cannula and may contain one or more implants, thereby enabling the implantation of multiple implants without removing the delivery tool from the arthroscopic field. The delivery device may have features like a slit to enable manipulation of sutures attached to the implant. Alternatively, the sutures may pass through the body of the delivery device and be accessible through the proximal end of the cannula.
Example 1
[0054] An impactor device was fabricated similar to the device shown in FIG. 4 . Air pressure was used to cycle a metal shuttle that impacts the active member at the distal end of the impactor. A cylindrical anchor (proximal diameter=1.5 mm, body diameter=2 mm) with a conical distal tip (length of anchor=6 mm), was loaded into the distal tip of the impactor. A #2 braided polyester suture was attached to the anchor via a hole through the minor diameter of the anchor. The distal tip of the active member had an OD of 2 mm and ID of 1.5 mm, and a slit to allow for egress of the suture. The impactor anchor assembly was connected to 90 psi compressed air. The distal end of the assembly was placed in contact with fresh cadaveric bovine cortical and cancellous bone. An air supply valve was opened and the anchors were driven into the bony tissue with ease. The pullout strength of the anchors were assessed subjectively and indicated good fixation of the anchors. The anchors were then carved out of the bony tissue and the surrounding tissue was examined for gross damage. There was no sign of thermal necrosis or other damage at the implantation site.
[0055] While the above detailed description and figures are a complete description of the preferred embodiments of the invention, various alternatives, modifications, and equivalents may be used. The various features of the embodiments disclosed herein may be combined or substituted with one another. Therefore, the above description should not be taken as limiting in scope of the invention which is defined by the appended claims.
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A method for impacting a suture anchor into bone comprises providing an implantable suture anchor and providing an impactor device for impacting the suture anchor into the bone. The suture anchor is coupled to a distal portion of the impactor device. Positioning the suture anchor engages the anchor with the bone at an implantation site, and powering the impactor device impacts the suture anchor thereby implanting the suture anchor into the bone. The frequency of impaction is less than 20 KHz. The impactor device is then decoupled from the suture anchor, and the impactor device may be removed from the implantation site.
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BACKGROUND OF THE INVENTION
The present invention relates to a multimedia interface of a diagnostic test instrument and, more particularly, to automated testing, including multimedia-derived instructions, test monitoring, and error response, by an audiometer or other medical or diagnostic test instrument.
A wide variety of medical and diagnostic test instrumentation is known. An example of such instrumentation is an audiometer. The audiometer is an electrically activated generator of test tones for evaluation of hearing. Other medical and diagnostic instrumentations include a spirometer for measuring lung capacity, vision testing equipment, blood alcohol testing equipment, and occupational health industry maintenance testing equipment, such as blood pressure, EKG, and other wellness testing equipment. Generally, these and other prior testing instrumentations require one or more individuals to administer the test by operating the equipment and giving instructions to the test subject.
The trend in testing, however, appears to be toward automation. Through automation, reduced numbers of test administrators may be required and increased accuracy of testing, with lack of deviation caused by human administrator error, may be possible. Although certain limited automation has previously been possible, that automation has been directed primarily to the automated compilation, organization, and reporting of data in desirable formats. Processing units, such as, for example, personal computers, have previously been employed to achieve the automation of the compilation, organization, and reporting finctions. Little automation, if any, has previously been achieved, however, in connection with the actual administration of the test. Administration of such tests has typically been performed almost wholly by one or more human test administrators.
Hearing testing has for several decades been performed utilizing an instrument called an audiometer. Prior to the audiometer, tuning forks and other tone generating devices were employed. In the early testing, a test subject responded directly to a test administrator who recorded test results based on the administrator's subjective determinations. The advent of the audiometer, an electronic instrument that generates tones, provided a degree of standardization in hearing testing because uniform tones and proper calibrations are better achieved.
Even after the invention of the audiometer, however, hearing testing was far from standardized, as testing varied in both procedures and determinations. A standardized procedure, still followed today, was then developed for hearing testing. That procedure is referred to as the "Hughson-Westlake" procedure. Other procedures are followed in some instances, but the Hughson-Westlake procedure is probably the most common.
In the Hughson-Westlake procedure, tones at a level audible to the test subject, such as, for example, 30 dB, are first presented to the subject. The test subject responds that the tones are heard, and then the level of the tones are reduced by 10 dB. This is repeated with the test subject responding that the tones are heard followed by 10 dB reductions until the test subject's response (or lack of response) indicates that the tones are not heard. When the test subject so responds that the tones are not heard, the tone level is raised 5 dB. If the test subject does not then respond, the level is raised another 5 dB, and this is repeated until the subject signals that the tone is heard. This entire process is repeated until the test subject has three ascending positive responses at the same level. In order to make comparison of hearing quality over time, a first test is administered to establish a base line hearing level and later testing, undertaken at subsequent time intervals, provides results for comparison to base line. The comparison indicates any hearing loss or other changes over time.
As with diagnostic and industrial health testing instruments, generally, audiometers have progressed towards more automation. Also as with other instruments, however, automation of audiometers has typically focused on compilation, organization, and reporting of test results. The automation has not been directed to replacement of a human test administrator (or at least the traditional functions of such an administrator) by a machine automated process.
As previously mentioned, automation, particularly by a machine such as a computer, achieves certain advantages. In particular, the testing may be more uniform among subjects and test periods, whereas testing is subject to variation when a human test administrator administers and grades the test. Also, supplying human test administrators to conduct tests is rather costly. Reducing the required number of test administrators through further automation of testing procedures may reduce or eliminate those costs. Furthermore, test presentation and determined results may vary among human test administrators. More standardized and accurate testing may be possible if intervention of a human test administrator is reduced through further automation. In addition to those advantages, certain automation may provide added advantages, for example, multilingual test administration, multiple simultaneous different tests, multiple simultaneous test subjects, visual features, and other possibilities.
Embodiments of the present invention provide advantages of multimedia automation in diagnostic testing employing electronic or other instrumentation. The embodiments are particularly suited in the case of an audiometer, however, numerous other applications of the embodiments are possible. The above-described advantages, as well as other advantages, are achieved through the embodiments. The present invention is, thus, a significant improvement in the art and technology.
SUMMARY OF THE INVENTION
An embodiment of the invention is a method for automatedly administering an audiometric test. The method comprises the steps of controlling an audiometer to selectively switch the audiometer output between test tones generated by the audiometer and sound signals generated from digital information, first switching the audiometer output to sound signals when the step of controlling indicates a beginning of a new test, a completion of a current test, or a test error, outputting sound representative of the sound signals after the step of first switching, second switching the audiometer output to test tones after the step of outputting, and outputting test tones until the next step of first switching.
Another embodiment of the invention is a multimedia audiometer. The multimedia audiometer comprises means for outputting sound signals generated from digital information, means for outputting test tones, means for switching between the means for outputting sound signals and the means for outputting test tones, and means for controlling the means for switching, the means for controlling being communicatingly connected with the means for switching. The means for switching is communicatingly connected with the means for outputting sound signals and the means for outputting test tones.
Yet another embodiment of the invention is a multimedia audiometer. The multimedia audiometer comprises a computer, a tone generator, and a switch connected with the computer and the tone generator. The switch selectively causes either the tone generator or the computer to output sound waves, and the computer controls the switch.
Another embodiment of the invention is an audiometer. The audiometer comprises a processor, a memory, communicatingly connected with the processor, for storing digital data, a sound wave generator, for generating analog sound signals in respect of digital data, electrically connected with the processor, a test tone generator electrically connected with the processor, and a switch connected with the sound wave generator, the test tone generator, and the processor. The switch is controlled by the processor to selectively cause either the sound wave generator or the test tone generator to output sound waves.
A further embodiment of the invention is an instrument that conducts a test protocol on a test subject. The test protocol comprises an output by the instrument followed by an input to the instrument. The test subject determines the input, which input may be positive, negative, or null. The instrument comprises an output generator, an input detector for detecting the input, a digital data storage for storing a digital data, a multimedia converter, the multimedia converter converts the digital data to an analog signal, and logic circuitry connected to the input detector, the digital data storage, the multimedia converter, and the output generator, for logically operating on the input, reading the digital data, delivering the digital data to the multimedia converter, and controlling the output generator.
Yet another embodiment of the invention is a multimedia audiometer. The multimedia audiometer comprises a basic audiometer, a computer, a multimedia input interface communicatingly connecting the computer and the basic audiometer, and a communications interface communicatingly connecting the computer and the basic audiometer.
Another embodiment of the invention is a diagnostic instrument. The diagnostic instrument comprises means for outputting an audible sound,means for generating a test tone, means for storing a digital data, means for generating an analog signal derived from the digital data, means for switching an output of the means for outputting between the test tone and the analog signal, the means for switching being electrically connected to the means for generating a test tone and the means for generating an analog signal, means for processing, means for inputting, the means for inputting connects the means for processing to the means for outputting, and means for communicating, the means for communicating connects the means for processing to the means for outputting, the means for generating the test tone, the means for storing the digital data, the means for generating the analog signal, the means for switching, and the means for inputting.
Yet another embodiment of the invention is a method of performing a diagnostic test protocol. The method comprises the steps of outputting an audible sound, generating a test tone, storing a digital data, generating an analog sound derived from the digital data, switching the audible sound from the step of outputting between the test tone and the analog signal, processing the digital data, and controlling the steps of outputting, generating the test tone, storing, generating the analog sound, and switching.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a functional block diagram of a conventional audiometer;
FIG. 2 is a detailed schematic of a typical audiometer, corresponding to the functional block diagram of FIG. 1;
FIG. 3 is a schematic of a talkover card for use with the audiometer of FIG. 2;
FIG. 4 is a block diagram of an audiometer interfaced with a personal computer for multimedia automation of audiometer testing;
FIG. 5 is a functional block diagram of an audiometer interfaced with a multimedia personal computer;
FIG. 6 is a schematic of the personal computer connection with the talkover card of FIG. 3, to provide multimedia automation of audiometer testing; and
FIG. 7 is a flow diagram of a protocol for audiometric testing utilizing the multimedia features of the embodiments of the present invention to automate the test process.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a functional block diagram of a conventional audiometer 2 may be described. Although the following discussion primarily addresses embodiments of the present invention employed for an audiometer, the embodiments have varied application in a wide variety of medical and diagnostic instrumentation. All those applications are intended as included within the scope of the invention. Also, the following describes various embodiments of the present invention as particularly employed with the conventional audiometer 2. It is to be understood that the conventional audiometer 2 is detailed only for example purposes, and all other alternative audiometer configurations, as well as other instrumentation and configurations thereof, are also applications for the invention in accordance with the principles herein.
Conventional Audiometer
The conventional audiometer 2 is generally comprised of three parts: microprocessor circuitry 4, audio circuitry 6, and certain optional elements 8. In addition to those three parts, the conventional audiometer 2 includes a power supply and related elements not shown in the functional block diagram. One example of the conventional audiometer 2 is the RA250 Microprocessor Audiometer available from TREMETRICS, Inc., Austin, Tex. Of course, as previously mentioned, the conventional audiometer 2 illustrated is shown only for purposes of illustration and example. Other audiometers and other types of medical and diagnostic instrumentation are also within the scope of the invention.
Microprocessor Circuitry
The microprocessor circuitry 4 of the conventional audiometer 2 may include a processing unit (CPU) 12, such as, for example, an Intel™ 8085 microprocessor or another microprocessor. The CPU 12 serves to coordinate and control operations and functions of the conventional audiometer 2. The CPU 12 conductively connects with various memory, such as, for example, erasable programmable read only memory (EPROM) 14 and random access memory (RAM) 16. The memory 14, 16 may serve to store a software protocol which controls the CPU 12 to cause the conventional audiometer 2 to provide audiometric functions. The memory 14, 16 may also serve to maintain certain variables to achieve desired operations and calibration of the conventional audiometer 2, or simply to provide storage for values made available to and from the CPU 12.
In addition to the memory 14, 16, the CPU 12 conductively connects with various input and output ports and peripherals. Input and output ports may include a serial I/O port 22 and a parallel interface 24. The serial I/O port 22 may provide connections for certain optional elements 8, as hereinafter discussed. The parallel interface 24 may connect with an input device, for example, a keyboard 20. The parallel interface 24 may also connect with the audio circuitry 6, as later explained. Another input device, such as a display 18, for example, may connect with the memory 14, 16, CPU 12, and other features of the microprocessor circuitry 4. Such other features of the microprocessor circuitry 4 may include, for example, certain programmable registers 26 and other elements.
Audio Circuitry
Now discussing the audio circuitry 6 of the conventional audiometer 2, the audio circuitry 6 interfaces with the microprocessor circuitry 4 in several ways. The programmable registers 26 may serve as ports that connect with an oscillator (also "frequency generator") 30. The oscillator 30 may provide timing for a sine wave generator 32 that produces a digitally synthesized sine wave from which audible test tones are derived. Because the sine wave generator 32 produces a digitally synthesized wave, the wave may be smoothed by a low pass filter 34.
The low pass filter 34 may connectively interface with the parallel interface 24 of the microprocessor circuitry 4. Other elements of the audio circuitry 6, such as a frequency selector 36, an electronic attenuator 38, a pulse control 40, a relay control attenuator 42, and a handswitch jack 44, may conductively connect with the parallel interface 24 to complete the interface of the audio circuitry 6 with the microprocessor circuitry 4 of the conventional audiometer. Pursuant to this interface arrangement, the audio circuitry 6 and the microprocessor circuitry 4 may communicate signals for control and other purposes.
In addition to the connection of the low pass filter 34 with the parallel interface 24, the low pass filter 34 may conductively connect with frequency compensation circuitry, such as, for example, a frequency selector 36 that, together with the control provided through the parallel interface 24, helps compensate for attenuation. Other elements, such as the electronic attenuator 38 which connects with the frequency selector 36, also provide compensation for attenuation. The sine wave generator 32 feeds the pulse control 40 which, together with input to the pulse control 40 from the electronic attenuator 38, delivers signals representative of desired test tones to a power amplifier 46. The power amplifier 46 feeds the relay control attenuator 42 for left and right earphone signals. The relay control attenuator 42 is conductively connected with an earphone jack 48.
In order to allow a test subject to interface with the audio circuitry 6, earphone speakers 50 and a handswitch 52 may be provided. The earphone speakers 50 may plug into the earphone jack 48. The test subject wearing the earphone speakers 50 will then receive test tones generated by the conventional audiometer 2. The handswitch 52 may plug into the handswitch jack 44. The handswitch 52 provides means for the test subject to interface with the conventional audiometer 2 in order to signal to the conventional audiometer 2 that the test subject either does or does not correctly receive test tones through the earphone speakers 50.
Options
In addition to the basic elements just described, the conventional audiometer 2 may include certain optional elements 8. Various optional elements 8 are possible, depending upon desired operations and functions. Two common optional elements 8 of the conventional audiometer 2 have been an RS232 port 8a and a talkover card 8b. The RS232 port 8a may conductively connect to the serial I/O port 22 to allow communications of the microprocessor circuitry 4 with external peripherals (not shown) connected with the RS232 port 8a. Examples of external peripherals which may connect to the RS232 port 8a may include printers, terminals, and modems. The RS232 standard and suitable connections to ports conforming thereto are generally known.
The other of the common optional elements 8, the talkover card 8b, is of particular significance in embodiments of the present invention. The talkover card 8b is conductively connected with the audio circuitry 6 of the conventional audiometer 2 between the relay control attenuator 42 and the earphone jack 48. In effect, the talkover card 8b serves as a switch to divert input to the earphone jack 48 when desired by a human test administrator (not shown). The human test administrator may selectively "throw" the switch and cause the input to the earphone jack 48 to switch from signals from the relay control attenuator 42 representative of test tones to signals representative of the human test administrator's instructions then being voiced. Details of the talkover card 8b are hereinafter more fully discussed with respect to FIG. 3.
Referring now to FIG. 2, a detailed schematic of the conventional audiometer 2 of FIG. 1 is shown. Those skilled in the art will understand and appreciate the electrical elements and connectivities of the detailed schematic.
Referring now to FIG. 3, a detailed schematic is provided of the talkover card 8b of the conventional audiometer 2. The talkover card 8b comprises a fixed gain operational amplifier 60. A voice microphone 62 is an input to the amplifier 60. Other common electronic elements, such as, for example, resistors, capacitors, and others, may be included in the circuitry of the talkover card 8b. The amplifier 60 is connected to the input to the earphone jack 48 of the audio circuitry 6 of the conventional audiometer 2 (shown in FIG. 1) by a relay 64a. When a human test administrator wishes to deliver voice sounds, rather than test tones, to a test subject wearing the earphone speakers 50 plugged into the earphone jack 48 (shown in FIG. 1), the test administrator causes the relay 64a to be thrown. The test administrator, by such action, simultaneously causes the conventional audiometer 2 to interrupt the test then in progress, discontinuing test tone generation.
Referring to FIGS. 1-3, in conjunction, the relay 64a when so thrown connects the amplifier 60, across switches 66a, to the input to the earphone jack 48. In particular, electrical connector 68 passes the voice signals from the amplifier 60 to the earphone jack 48 for delivery through the right ear speaker of the earphone speakers 50 and electrical connector 70 similarly passes the voice signals to the left ear speaker. When relay 64a results in closure of its switches 66a, relay 64b results in opening of its switches 66b, and vice versa. In this manner, either voice signals through the talkover card 8b or test tone signals through the audio circuitry 6 at any instant, but not both simultaneously, is delivered through the earphone speakers 50. As those skilled in the art will understand and appreciate, this design of the conventional audiometer 2 has allowed a human test administrator to interrupt test tone testing to give instructions, error messages, and other voice commands. The conventional audiometer 2 has required intervention of a human test administrator, however, by selectively throwing relays 64a,b and speaking into the microphone 62 of the talkover card 8b, in order to conduct hearing test with intermittent instructions and messages.
Multimedia Embodiments
Referring now to FIG. 4, a multimedia audiometer 100, according to embodiments of the present invention, may be described. The multimedia audiometer 100 includes a basic audiometer 200 having the basic elements of the conventional audiometer 2 (shown in FIG. 1). That is, the multimedia audiometer 100 is also comprised of the microprocessor circuitry 4 and the audio circuitry 6 (or other similar processing and audio electronics and circuits) of the conventional audiometer 2 (shown in FIG. 1). The earphone speakers 50 and the handswitch 52 are also interfaced with the basic audiometer 200.
Although the multimedia audiometer 100 and the conventional audiometer 2 share these similar basic elements, the basic audiometer 200 is merely a subset of the entire multimedia audiometer 100, as is apparent in FIG. 4. In addition to the elements of the basic audiometer 200, 2, the multimedia audiometer 100 includes a computer 102, such as a personal computer, another type of computer, or some other processing and storage device. The computer 102 may be equipped and connected with peripherals, such as a keyboard 106 and a display monitor 104, as well other known input/output, communications, printing, and peripheral equipment. In any event, the computer 102 should have multimedia capabilities, that is, the computer 102 should be capable of producing sound waves and/or visual images from representative digital information stored, generated, and/or manipulated within or by the computer 102.
The computer 102 may be conductively connected with the basic audiometer 200 through two interfaces: a communications interface 108 and a multimedia input interface 110. The communications interface 108 may allow for serial, parallel, or other communications. If communications are serial, the communications interface 108 may connect the computer 102 with the RS232 port 8a (shown in FIG. 1) in standard manner, as though the basic audiometer 200 is a peripheral to the computer 102. The multimedia input interface 110 requires, however, that the conventional audiometer 2 be modified in certain respects to provide the basic audiometer 200 for multimedia automation of testing, as hereafter described.
Referring now to FIG. 5, the communications interface 108 and the multimedia input interface 110 connect the computer 102 with the basic audiometer 200 to form the multimedia audiometer 100, as shown in functional block form. A serial input/output port (not shown in detail) of the computer 102 may directly connect via the communications interface 108 with the RS232 port 8a of the basic audiometer 200. A multimedia output port (not shown in detail) of the computer 102 may directly connect via the multimedia input interface 110 with a multimedia talkover card 118b, similar to the talkover cord 8b (shown in FIG. 3) of the conventional audiometer 2. The multimedia output port of the computer 102 may, for example, be a port of a sound card (not shown in detail) from which sound signals are output by the computer 102. Alternatively or additionally, other multimedia outputs (not shown) of the computer 102, for example, graphical image or video outputs, may connect with the multimedia input interface 110 in similar manner. The talkover card 8b (shown in FIG. 3) of the conventional audiometer 2 configuration has not previously provided a port for connection of the multimedia input interface 110. The conventional audiometer 2 may, therefore, be adapted to provide such port. The adapted conventional audiometer 2 is the basic audiometer 200.
Referring now to FIG. 6, a sound port 120 of a multimedia talkover card 118b for multimedia input to the basic audiometer 200 may be described. The sound port 120 connects with the multimedia input interface 110, so that multimedia outputs of the computer 2 are input to the multimedia talkover card 118b. The sound port 120 may include a connector 120a to which the multimedia input interface 110 may be plugged. The connector 120a may be attached with two input leads 120b. The input leads 120 a,b may be attached with an audio jack plug 121. The audio jack plug 121 is insertable in an audio jack 122 connected to the amplifier 60 output. When the audio jack plug 121 is not inserted in the audio jack 122, the output of the amplifier 60 is shorted prior to the switches 66a. When the audio jack plug 121 is inserted in the audio jack 122, however, the circuit is completed and the computer 102 connected to the sound port 120 may supply multimedia input to the switches 66a. In effect, the microphone 62 is substituted with the multimedia input via the sound port 120. All other features of the multimedia talkover card 118b are substantially the same as the features of the talkover card 8b of the prior technology.
Although the input leads 120b of the sound port 120 are shown as connected with an output of the amplifier 60 in the Figure, alternatively, the input leads 120b could in similar manner connect with inputs to the amplifier 60 or at some other location prior to or after the amplifier 60. Furthermore, although the multimedia talkover card 118b is expressly described as a "card" to the basic audiometer 200, it is to be understood that any other functional elements and circuitry that perform similarly, such as, for example, a relay circuit that switches between the tone generator of the basic audiometer 200 and the multimedia output from the computer 102, as well as other possibilities, are all within the scope of the invention. Now referring to FIG. 7, in conjunction with FIGS. 4-6, operations 300 of the multimedia audiometer 100 and the software driving those operations 300 are discussed. When power is supplied to the multimedia audiometer 100, the basic audiometer 200, as well as the computer 102, may perform various set-up functions 302. Those set-up finctions 302 of the multimedia audiometer 100, for example, boot-up and initialization of the computer 102 and start-up and initialization of the basic audiometer 200, are conventional. The start-up and initialization of the basic audiometer 200 may be substantially the same as that of the conventional audiometer 2 (shown in FIG. 1).
Generally, this start-up and initialization of the basic audiometer 200 may proceed, for example, as follows:
At turn-on, the basic audiometer 200 presents a first tone and a message appears on the display 18. The basic audiometer 200 is now ready for operation. If a processing error by the CPU 12 is discovered during the turn-on, an appropriate message is displayed.
The following example illustrates an initialization procedure for the basic audiometer 200. Keys of the keyboard 20 are indicated by ! and messages in quotes. To begin, press:
______________________________________KEYBOARD DISPLAY______________________________________ SPECIAL! SPC00 ENTER! MM DD YY______________________________________
______________________________________KEYBOARD DISPLAY COMMENT______________________________________ 04 30 96! OM DD YY______________________________________
The message "mode pulsed" then appears on the display 18. Press NO! to switch to continuous mode. "Continuous Mode" will be displayed. Press ENTER! when the desired code is displayed. The display should now read "1 KL AA AUTO" and then displays "PRESS NEW TEST!". Other parameters which may be selected include the test other ear first and delete 8000 Hz. To do this, press:
______________________________________KEYBOARD DISPLAY COMMENT______________________________________ SPECIAL! SPC 04 04! SPC 04______________________________________ ENTER! LEFT EAR FIRST NO! RIGHT EAR FIRST ENTER! 1KR AA AUTO (Now testing right ear first) SPECIAL! SPC 06 06! SPC 06 ENTER! 8KR SEL AUTO NO! 8KR DEL AUTO ENTER! 1KR AA AUTO (8 Khz is deleted)______________________________________
The basic audiometer 200 is now initialized.
Any or all of the above-mentioned parameters can be changed at any time by entering a desired special routine. Various "Special" codes that may be possible with the basic audiometer 200 of the multimedia audiometer 100 may, for example, include the following:
______________________________________SPECIAL FUNCTION______________________________________00 Initialization of audiometer01 Enter date and time02 Mode Pulsed/Continuous03 Enter Examiner ID04 Invent runtable to test better ear first05 Select Printer Format06 Select or Delete 8K07 Select Baud rate08 Turn on or off audio feedback for key pushes09 Accelerated listening check10 Check calibration date11 Call Ram Rom check12 Calibration mode and program calibration eeprom13 Printer text14 Not used15 Display routine for time and date (no entry)16 Not used17 Display selected audiogram18 Print selected audiogram or audiograms19 Display and/or enter serial number20 Not used______________________________________
Software protocols to accomplish the start-up and initialization of the basic audiometer 200 may be stored in the memory 14, 16 of the basic audiometer elsewhere. Processing and control for the start-up and initialization of the set-up finctions 302 are performed by the CPU 12 of the basic audiometer 200. Alternatively, the basic audiometer 200 could be computer 102 to perform the start-up and initialization, or start-up and initialization could be controlled manually or in some other manner.
After the set-up finctions 302, including start-up and initialization of the basic audiometer 200, are completed, the basic audiometer 200 may be ready to begin administering a new audiometric test of a test subject. A new test may be begun, for example, by pressing a key of the basic audiometer 200 or, alternatively, by a similar input to the computer 102. Upon the start of the new test, the computer 102 may control the basic audiometer 200 by communications over the communications interface 108 (shown in FIGS. 4-5).
If initial instructions to the test subject are desired, the computer 102 may control 304 the basic audiometer 200 over the communications interface 108 (shown in FIGS. 4-5). This control 304 may trigger the relay 64a and the relays 64b (shown in FIG. 2) to close the switches 66a and open the switches 66b (shown in FIG. 2), respectively. When the switches 66a are closed and the switches 66b opened in this manner, sound signals passed to the sound port 120 from the computer 102 over the multimedia input interface 110 are delivered through the amplifier 69 of the multimedia talkover card 118b and through the earphone jack 48 to the earphone speakers 50.
The particular sound signals so passed to the earphone speakers 50 may be derived from digital information stored or generated in, or read by, the computer 102. The computer 102 may select and output 306 signals representative of the particular digital information. If the testing is just beginning, the signals so selected and output 306 may be initial instructions to the test subject about the test and the testing procedure. Of course, the particular signals could be representative of virtually any type of information which is subject to derivation from digital data. Although sound is described here as being derived from digital data, those skilled in the art will know and appreciate that digital data may be manipulated and processed in a multitude of ways to derive other types of information, for example, visual graphics and images and others.
After the computer has selected and output 306 the desired sound signals to the basic audiometer 200 and signals have been delivered to the test subject as sound waves through the earphone speakers 50, the computer 102 again may control 308 the basic audiometer 200. The control 308 at this instant may trigger the relay 64a to close the switches 66a and the relays 66b (shown in FIG. 2) to open the switches 66b, respectively. The control 308, then, causes the basic audiometer 200 to generate 310 a series of test tones, such as, for example, tones in accordance with the Hughson-Westlake procedure or another testing protocol.
When the switches 66a are closed and the switches 66b are opened because of the control 308, the test tones generated 310 by the audio circuitry 6 of the basic audiometer 200 are delivered through the earphone jack 48 to the earphone speakers 50. According to the particular testing protocol, the test subject may respond to the test tones by input 312 via the handswitch 52 connected to the basic audiometer 200. The basic audiometer 200, in cooperation with the computer 102, will detect and determine any error 314 of the input 312 response.
If there is not any error 316, then the basic audiometer 200 may continue to generate successive test tones 320 according to the particular test protocol, until the test is completed 322. The successive test tones 320 are generated in the same manner as previously described. That is, the basic audiometer 200 operates to generate test tones 310 delivered to the test subject; the test subject responds with input 312 via the handswitch 52; and the audiometer 200, in conjunction with the computer 102, detects and determines 314 any error.
If an error 318 is detected and determined 314, the computer 102, based on its particular programmed logic, determines 324 whether to proceed 326 with the testing, to re-test 328, or to perform some other function (not shown). Certain errors that may be encountered during the administration of the test include, for example, the following:
No response at 1 kHz, Error Code E1, signifies that the test subject is not responding to the test tone. The test subject may receive a multimedia sound message, generated by the computer 102 and passed through the earphone speakers 50, as to how to take the test, for example, as follows:
"There has been no response for any tone in the initial test--as soon as you hear a tone cut it off by pressing and releasing the hand switch."
Then, the test may be restarted.
Failed to Establish Threshold, Error Code E2, signifies that the basic audiometer 200 is unable to establish a hearing threshold level (HTL) from the response of the test subject. The test subject may be instructed based on digital data of the computer 102, for example, as follows:
"The audiometer has been unable to establish a threshold--listen for the tone and as soon as you hear the tone cut it off by pressing and releasing the hand switch."
The test may then recommence.
Hand Switch Error, Error Code E4, signifies that the test subject is not releasing the response handswitch 52. The test subject may, for example, receive the following instructions generated from the digital data stored by computer 102:
"The audiometer is recognizing the hand switch as being on for a length of time--as soon as you hear a tone cut it off by pressing and releasing the hand switch."
The test may then recommence.
Response no tone, Error Code E5, signifies that the test subject has responded at least three times when no tone or stimulus was present. A multimedia message, for example, as follows, may be delivered through the earphone speakers 50:
"The audiometer is recognizing responses when no tone is present--as soon as you hear a tone cut it off by pressing and releasing the hand switch."
The test is, thereafter, restarted.
The foregoing error codes, multimedia messages, and operations are merely example possibilities. An example of an entire error code list is as follows:
______________________________________Error MultimediaCode Indication Audiometer Response______________________________________AA Not TestedDD Deleted FrequencyEE No Response Test ContinuesEF Test IncompleteEB 25 Presentations Test Continues No HTLE1 No Response Stops Test Repeat 1KHz InstructionsE2 1KHz 25 Stops Test Repeat Presentations No Instructions HTLE3 1KHz Retest Stops Test Repeat Error InstructionsE4 Hand Switch Stops Test Holding Error Switch MSGE5 Response No Tone Stops Test Response w/window closedE6 Error For Second Stops Test Examiner Time InterventionE7 Max. Failed Stops Test Examiner Frequencies > 6 InterventionE8 Hardware Error Only seen at Turnon and Ater EPROM Diagnostic Check______________________________________ Error Codes That Do Not Stop Test EE Error Codes that Get Instructions and Resume Testing EB Same as E2 message E1 E2 E4 E5 Error Codes That Stop Test and Pop Up Message on PC for Operator Test Does Not Restart E3 E6 E7
In the case that a re-test 328 is warranted because of an error or otherwise, the operations 300 begin anew with the computer control 304 of the basic audiometer 200 over the communications interface 108 (shown in FIGS. 4-5) to trigger the relays 64a,b. The testing thereafter proceeds through the steps of selection and output 306, computer control 308, test tone generation 310, test subject response input 312, and detection and error determination 314.
Once the entire test protocol is completed in the foregoing manner, the test is completed 322. The computer 102 may then control 330 the basic audiometer 200 to trigger the relays 64a,b to close the switches 66a and to open the switches 66b. The control 330 is accomplished in the manners previously described by communications between the computer 102 and the basic audiometer 200 over the communications interface 108.
After the control 330 so sets the switches 66a,b, the computer 102 may further select and output 340 sound signals, which sound signals are derived from digital data stored, generated or read by the computer 102. The sound signals may travel to the earphone jack 48 and the earphone speakers 50 to deliver final instructions and messages to the test subject.
Numerous alternatives and variations are possible for the multimedia audiometer 100. For example, digital data stored, generated or read by the computer 102 may be representative of a wide variety of sounds, images, video, or other multimedia features. In certain embodiments, the particular digital data may allow the test subject to select any of a number of different languages through which testing is administered. Further, digital data may be manipulated by the computer 102 in such a manner that multiple simultaneous tests may be administered. There are, of course, numerous other possibilities.
There are also many possible variations and alternatives in the configuration of the computer 102 and the basic audiometer 200 by providing the audiometer with additional memory, processing, wave sound generation, and appropriate software. Alternatively, the computer 102 could include test tone generation means and appropriate software programming to perform the functions of the basic audiometer 200. Even further, the multimedia audiometer 100 could be implemented by using a programmable digital tape player or compact disc (CD) player and allowing the basic audiometer 200 to select desired tracks to play. Other alternatives may be possible, it being understood that those skilled in the art will generally know and appreciate that the employment of computer or other control of instrumentation operations during test administration and the use of multimedia features for instruction, messages, and other herebefore required human administrative actions is possible with the incorporation of digital data, according to the embodiments of the present invention, from which are derived multimedia features.
It is to be understood that multiple variations, changes and modifications are possible in the aforementioned embodiments of the invention. Although illustrative embodiments of the invention have been shown and described, a wide range of modification, change, and substitution is contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the foregoing description be construed broadly and understood as being given by way of illustration and example only, the spirit and scope of the invention being limited only by the appended claims.
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A method for automatedly administering an audiometric test includes the steps of controlling an audiometer to selectively switch the audiometer output between test tones generated by the audiometer and sound signals generated from digital information; first switching the audiometer output to sound signals when the step of controlling indicates a beginning of a new test, a completion of a current test, or a test error; outputting sound representative of the sound signals after the step of first switching; second switching the audiometer output to test tones after the step of outputting; and outputting test tones until the next step of first switching.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 14/717,509, filed on May 20, 2015, entitled “REFRIGERATION APPLIANCE AND METHOD FOR OPERATING SUCH APPLIANCE,” which claims priority to European Patent Application No. EP14169369.7, filed on May 21, 2014, entitled “REFRIGERATION APPLIANCE AND METHOD FOR OPERATING SUCH APPLIANCE,” the disclosures of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a refrigeration appliance comprising a cavity in which an ozone generator is placed.
[0003] Interest in ozone has expanded in recent years in response to consumer demands for ‘greener’ food additives, regulatory approval and the increasing acceptance that ozone is an environmentally friendly technology. The multi functionality of ozone makes it a promising food processing agent. Excess ozone auto decomposes rapidly to produce oxygen and thus leaves no residues in foods from its decomposition. In particular, the US Food and Drug Administration (FDA)'s rulings on ozone usage in food have resulted in increased interest in potential food applications worldwide.
[0004] The effectiveness of ozone against microorganisms present in food systems depends on several factors including the amount of ozone applied, the residual ozone in the medium and various environmental factors such as medium pH, temperature, relative humidity, additives and the amount of organic matter surrounding the cells.
[0005] The use of ozone in the processing of foods has recently come to forefront, as a result of the approval by the FDA to use ozone as an antimicrobial agent for food treatment, storage, and processing.
[0006] Generally ozone is used in water treatment, sanitizing, washing and disinfection of equipment, odor removal, and fruit, vegetable, meat and seafood processing as an antioxidant.
[0007] Existing solutions on the market present the ozone device applied on the whole cavity of the refrigerator to improve air quality by odor removal and reduced microbial growth.
[0008] The main outcomes of such known solutions are related to the control and removal of ethylene for ripening fruits through the use of ozone, sterilization, implementation design, device components, and ozone device structure.
[0009] JP 06-153789 discloses a method for removing ethylene in a storehouse in which ozone is used for ethylene decomposition.
[0010] JP 2010-054092 shows a refrigerator with an ozone generating device arranged in a vegetable compartment. This document is silent about affective ozone concentration.
[0011] It is an object of the present invention to provide a refrigeration appliance with a device able to remove or reduce the residues of pesticides and microorganisms present on the surfaces of food items during storage by the ozone emission and in the meanwhile maintain their natural quality (color, ripening, freshness, and nutritional aspects) thanks to a new specific duty cycle treatment able to manage the ozone generation to allow food treatment without impacting food sensorial and nutritional quality. By using a certain ozone concentration the applicant has discovered surprising results in the maintenance of high levels of vitamin contents, particularly vitamin C content, for long storage periods in the cavity of the refrigerator.
[0012] The solution according to the invention is preferably integrated into a dedicated compartment for fresh fruits and vegetables (without packaging) in the refrigerator.
[0013] There are other additional benefits in using a certain ozone concentration, and they are related to keep food quality by microbial reduction; improve air quality by odor removal/reduce cross contamination and delay the ripening process by ethylene oxidation, while minimizing the oxidative process causing food deterioration.
BRIEF SUMMARY OF THE INVENTION
[0014] 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
[0015] The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings, certain embodiment(s) which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. Drawings are not necessary to scale. Certain features of the invention may be exaggerated in scale or shown in schematic form in the interest of clarity and conciseness.
[0016] FIG. 1 is a perspective view of a portion of a refrigerator according to the invention;
[0017] FIG. 2 is a graph showing the behavior of a function linking the ozone concentration to microbial growth and vitamin C variation;
[0018] FIG. 3 is a graph showing the results for microbial growth for strawberries in a crisper of a traditional refrigerator and in a refrigerator according to the invention;
[0019] FIG. 4 is a graph showing how the vitamin C decay in a reference fresh food (strawberries) is slowed down in a refrigerator according to the invention;
[0020] FIG. 5 shows an example of ozone generation control; and
[0021] FIG. 6 shows an example of ripening control system according to the invention.
DETAILED DESCRIPTION
[0022] Before the subject invention is described further, it is to be understood that the invention is not limited to the particular embodiments of the invention described below, as variations of the particular embodiments may be made and still fall within the scope of the appended claims. It is also to be understood that the terminology employed is for the purpose of describing particular embodiments, and is not intended to be limiting. Instead, the scope of the present invention will be established by the appended claims.
[0023] Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range, and any other stated or intervening value in that stated range, is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges, and are also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention.
[0024] In this specification and the appended claims, the singular forms “a,” “an” and “the” include plural reference unless the context clearly dictates otherwise.
[0025] With reference to the drawings, an ozone generating device 10 is placed in a specific sealed housing 12 and fixed on a rear wall 14 of an inner liner of a fresh food compartment A of a refrigerator. A consumer should not be able to remove the plastic housing 12 by hand. Such housing 12 is placed in the upper part of a crisper drawer D covered by a glass shelf S to permit a good mixing with the air in the drawer in the real time. If the drawer D isn't sealed by the upper shelf S the potential benefits are lower for food items inside. Ozone is therefore in direct contact on food surface. The ozone generating device 10 is mounted on the rear wall 14 of the liner in correspondence with a notch 13 provided in an upper rear wall of a crisper drawer D, so that the ozone generated by the ozone generating device 10 is confined in the crisper drawer D.
[0026] Besides the ozone device, the housing can be also equipped with an additional ozone sensor 16 ( FIG. 5 ) and an ethylene sensor 18 ( FIG. 6 ).
[0027] According to a specific feature of the invention, the duty cycle of the ozone device 10 produces an average of ozone concentration between 0.04 ppm and 0.12 ppm, preferably between 0.05 ppm and 0.11 ppm, with an ideal value around 0.08 ppm. At this concentration, ozone is able to act on cell membranes killing microorganisms without impact on nutritional aspects.
[0028] In tests carried out by the Applicant, the above concentration between 0.05 ppm and 0.11 ppm has shown to be the optimal one since it permits one to reach good microbial reduction and lower vitamin C reduction.
[0029] Lower ozone concentrations, i.e. <0.05 ppm, lead to no benefits: food items show the same performances as the ones stored in standard condition, the same as in absence of ozone.
[0030] With higher concentrations, i.e. higher than 0.1 ppm and particularly between 0.11 ppm and 4 ppm, consumer perceives the ozone odor and food presents fast decay in oxidative process (vitamin C, pigments . . . ), even if a reduced microbial growth is nevertheless assured.
[0031] To test the benefits of the optimal concentration of the ozone, it is necessary to drive the ozone generating device 10 with a proper duty cycle. A reference test procedure has been developed by the applicant in order to measure trade off tests on microbial and nutritional aspects considering an ozone device 10 that has been placed in the upper part of the crisper drawer D as shown in FIG. 1 ; the ozone concentration in such tests was constantly monitored using a portable ozone detector.
[0032] To define the ozone concentration, strawberry samples have been selected due to their higher perishable characteristic; they have been placed in a crisper bin inside the refrigerator at 5° C., 80% RH and endowed with the ozone device 10.
[0033] A relevant number of tests had been performed, and in particular a specific analysis had been evaluated. Microbial growth and vitamin C variation were estimated during the course of the experiment. Four different ozone concentrations have been used: reference value (without ozone activation), 0.012 ppm, 0.08 ppm, 0.12 ppm.
[0034] Generally, the higher the ozone concentration, the higher the microbial growth reduction, and the higher the vitamin C variation.
[0035] Graph of FIG. 2 summarizes the trade-off between microbial growth, vitamin C variation and ozone concentration by a specific function F:
[0000]
-
(
Vitamin
Co
-
Vitamin
C
)
^
2
δ
^
2
log
(
UFC
)
[0036] Where:
[0037] Vitamin Co=initial vitamin C concentration in strawberries (mg/100 g sample)
[0038] Vitamin C=vitamin concentration at the end of storage (mg/100 g sample)
[0039] Sigma=Vitamin C variation that could be tolerated in the search of the optimal value
[0040] Log (UFC)=Unit Formant Colonies, bacterial growth
[0041] In ideal conditions vitamin C variation is close to zero and the ideal UFC (microbial growth) is low. The mathematical function that summarizes vitamin C variation and microbial growth is shown in FIG. 2 . The above trade-off is reached at about 0.08 ppm of ozone concentration.
[0042] Other tests have been carried out by the Applicant to validate the trade-off target. In particular strawberries and tomatoes had been evaluated with a specific duty cycle that is able to generate 0.08 ppm. A comparison of performances was carried out on samples stored in the crisper bin endowed with ozone generator device 10 versus those placed into traditional crisper drawer without ozone generator. Food quality parameters have been observed for 14 days of storage in the crisper drawer.
[0043] FIG. 3 presents the results for microbial growth for strawberries after 12 days of storage in the crisper bin D with and without ozone treatment.
[0044] By applying the optimal concentration, as shown in FIG. 3 , ozone is able to reduce 2 logarithm units of the microbial growth every day of test.
[0045] In samples stored in standard conditions (no ozone), it is evident from the increase of the concentration value above 10 5 UFC/g that white mold is present. This occurs after 6 days test; the same results have been achieved in tester condition after 12 days.
[0046] On the other hand the vitamin C variation is lower in samples stored in contact with ozone treatment.
[0047] FIG. 4 shows vitamin C content in strawberries stored in a crisper bin with ozone generator 10 vs. the standard one after 12 days.
[0048] By applying the optimal concentration, ozone is able to slow down the vitamin C decay.
[0049] In samples stored in standard conditions (no ozone), it is evident there is a fast decay in terms of vitamin C content.
[0050] In this way it is possible to prolong shelf life of foodstuff, reduce bacterial growth, and maintain the same nutritional quality.
[0051] According to a preferred embodiment of the invention, the current drawer and inner liner are modified and sensors are added in the lid S.
[0052] Ozone sensor 16 and ethylene sensor 18 ( FIGS. 5 and 6 ) can be designed in a compact device (unique package) to save space and simplify cabling process.
[0053] The ozone sensor 16 is able to monitor the ozone concentration and sends an input to a control system K able to modulate the ozone generation and in case to stop it when the ozone threshold is reached.
[0054] There is no direct contact between the system (ozone generator 10 and sensors 16 , 18 are placed in the housing 12 ) and consumer; when the drawer D is open the ozone generator 10 is switched off automatically.
[0055] Ozone is a powerful oxidizer that can also remove odors molecules and ethylene prolonging the storage time. The ethylene sensor 18 is able to monitor the ethylene production. It is preferably an electrochemical sensor for ethylene monitoring and it sends an input to switches on the device 10 when the ethylene reaches a predetermined threshold. Besides controlling the ethylene concentration, ozone is also monitored. In case ozone level reaches a predetermined limit, the system is blocked even if the ethylene concentration is still high.
[0056] The ozone device 10 is switched ON during storage to slow down the ripening in fruits when the ethylene sensor achieves a predetermined threshold (this can be managed by a specific algorithm that monitors the ethylene concentration).
[0057] The user interface of the refrigerator comprises a specific button or the like to allow the user to activate the ozone control (ozone generation system), with a LED light used as a feedback to show that the ozone generation is carried out.
[0058] Even if in the above description the ozone generator 10 has been shown as confined in the space of the crisper drawer D, it can also be associated to the entire cavity of the refrigerator or to another sub-compartment thereof.
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A refrigeration appliance comprises a cavity in which an ozone generating device is placed. The ozone generating device is configured to maintain in the cavity a concentration of ozone between 0.04 and 0.12 ppm, more preferably between 0.06 and 0.1 ppm.
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FIELD OF THE INVENTION
[0001] The present invention relates to an improved locking mechanism for locking a mobile folding table in a closed position for moving and storing the table, and to an improved lift-assisting mechanism for aiding a user in folding a mobile folding table only up to a predetermined angle of the table top from the vertical direction.
BACKGROUND OF THE INVENTION
[0002] In settings where tables frequently need to be transferred between use and storage or from one use location to another, such as institutional settings, it is desirable to have mobile folding tables that are quickly convertible between a stationary, unfolded configuration for use and a mobile, folded configuration for movement and storage. As the table top sections of a mobile folding table can be quite heavy, lift assisting mechanisms which may be, for example, pressurized gas cylinders and/or torsion bars, are typically employed to assist a user in lifting the table top into a folded configuration. During movement and storage of the table, it is also advantageous to automatically retain the table top in a fully folded configuration so that the table remains compact. However, if the force provided by the lift-assisting mechanism is alone great enough to retain the table top in a fully folded configuration against the weight of the table top and/or other unintended forces, it may be unduly difficult for a user to oppose the lift-assisting force to unfold the table for use.
[0003] From present attempts to address this problem, it is known to employ a passive locking mechanism to retain the table in a fully folded configuration. Typically, the locking mechanism is selectively disengageable by a user applying a relatively small transverse force, allowing the table top to be lowered into an unfolded configuration. When the table is in the folded configuration and the locking mechanism is engaged, the engaged components of the mechanism are often located a considerable distance below the table center, to provide enough leverage to avoid undue stresses on the locking mechanism. However, it has been found that a locking mechanism located substantially below the folded table center is awkward to reach and thus difficult to disengage while at the same time controlling the lowering of the table into an unfolded position. This awkward operation unduly conveniences and could risk injuring a table user.
[0004] A need therefore exists for a mobile folding table that can be comfortably and safely disengaged from a folded and locked configuration and lowered into an unfolded configuration for use.
BRIEF SUMMARY OF THE INVENTION
[0005] In accordance with one aspect of the invention, a mobile folding table with an improved locking mechanism is provided. The table includes a first table top half and a second table top half foldably connected to the first table top half so that the table top halves are foldable about a folding axis to and from a folded configuration, wherein the table top halves are generally vertical and generally parallel, and an unfolded configuration, wherein the table top halves are generally horizontal and generally coplanar. A first locking member is movably connected to a first foldable component of the table and operably connected to a manual actuator, which may for example be a T-handle; and a second locking member is attached to a second foldable component of the table, the second locking member adapted for locking engagement with the first locking member when the table top halves are in the folded configuration to prevent relative movement of the first and second foldable components away from each other and to prevent the movement of the table top halves toward the unfolded configuration. For example, the first foldable component may be the first table top half, and the second foldable component may be a part of the table frame that is constrained to remain generally vertical in all configurations of the table, so that when two components are locked together, the table is locked in the folded configuration.
[0006] When the table top halves are in the unfolded configuration, a generally straight edge of the first table top half opposes a generally straight edge of the second table top half to define a table centerline. The folding axis is parallel to and disposed vertically downward from the table centerline, so that when the table top halves are in the folded configuration, the generally straight edge of the first table top half and the generally straight edge of the second table top half are separated by a gap, and the manual actuator is disposed proximate the gap so that the manual actuator can be manually reached from the top of the folded table and moved to disengage the locking engagement of the first and second locking members to permit the table to be unfolded.
[0007] In one embodiment, the improved folded locking mechanism described above is provided in a table that also has a lift-assisting mechanism and an unfolded locking mechanism to prevent the lift-assisting mechanism from undesirably folding the table when the table is unfolded for use. If the manual actuator is connected to the first table top half, the unfolded locking mechanism may include a center locking bar movably connected to the second table top half proximate the table centerline, the locking bar selectively engageable to a latch member that is fixed with respect to the first table top half when the table is in the unfolded configuration to prevent the table from being folded. By connecting the manual actuator and center locking bar to opposite table top halves, impingement of or obstruction of manual access to either mechanism by the other is conveniently avoided.
[0008] In accordance with another aspect of the present invention, a mobile folding table with an improved lift assisting mechanism is provided. The table includes a first table top half and a second table top half foldably connected to the first table top half so that the table top halves are foldable about a folding axis to and from a folded configuration and an unfolded configuration, the table top halves being generally horizontal and generally coplanar in the unfolded configuration and being generally vertical and generally opposed in the folded configuration. The lift assisting mechanism has a first end and a second end and is configured to provide an extending force tending to extend the ends apart from each other. The first end of the lift assisting mechanism is directly connected to a first component of a folding linkage of the table such that it is always engaged for applying the extending force to the first component. For example, the first end of the lift assisting mechanism may be pivotally attached to the first component. The second end of the lift assisting mechanism is connected to a second component of the folding table linkage via a clutch, which may comprise a slotted member slidingly retaining a pin attached to the second end of the lift assisting mechanism. The first and second components are configured so that extending the lift assisting mechanism to move the first and second components apart from each other causes the table top halves to fold toward the folded configuration. The clutch is configured so that the lift assisting mechanism transmits a force to urge the first and second components apart from each other only when the table top halves are disposed at an angle from the vertical direction that is larger than a predetermined angle.
[0009] In one embodiment, the table with improved lift assisting mechanism also includes the improved folded locking mechanism described above. Conveniently, the manual actuator of the improved folded locking mechanism being accessible at the top of the folded table permits a user to manually disengage the locking mechanism to allow the table to settle to the partially unfolded angle at which the lift-assisting pistons are engaged, while standing in an advantageous location for controlling the settling of the table to the partially unfolded angle under the weight of the table top halves.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a side view of a mobile folding table with an improved locking mechanism according to the invention.
[0011] FIG. 1 a is a side view of the mobile folding table shown in FIG. 1 , with alternative seating, shown in the folded configuration.
[0012] FIG. 1 b is a top view of the mobile folding table shown in FIG. 1 .
[0013] FIG. 1 c is a bottom perspective view of the locking mechanism shown in FIG. 1 , incorporated in a mobile folding table.
[0014] FIG. 2 is a fragmentary side schematic illustration of a locking mechanism of the present invention shown in a partially folded table configuration.
[0015] FIG. 3 is a fragmentary side schematic illustration of the camming action of a locking mechanism of the present invention just before locking engagement.
[0016] FIG. 4 is a fragmentary side schematic illustration of a locking mechanism of the present invention in locking engagement in a fully folded table configuration.
[0017] FIG. 5 is a top-side perspective fragmentary view of a mobile folding table showing the location of a manual actuator of a locking mechanism according to the invention incorporated into the table.
[0018] FIG. 6 is a fragmentary schematic side illustration of a partially folded table in which a pair of fully extended lift-assisting piston-cylinder assemblies have initially engaged a clutching mechanism according to another aspect of the invention.
[0019] FIG. 7 is a fragmentary side-bottom perspective view of a locking bar according to another aspect of the invention engaged with hinge plates to lock a folding table in an unfolded configuration.
DETAILED DESCRIPTION OF THE INVENTION
[0020] With reference to the Figures generally, a mobile folding table 10 incorporating an improved folded locking mechanism 12 according to the invention for retaining table 10 in a folded configuration is described in this section. According to another aspect of the present invention discussed in this section, table 10 includes an improved lift-assisting mechanism, which may advantageously be combined with improved folded locking mechanism 12 . According to yet another aspect of the present invention discussed in this section, table 10 additionally includes an unfolded locking mechanism 14 for retaining table 10 in an unfolded configuration.
[0021] Referring to FIGS. 1 , 1 b, and 1 c, table 10 is shown in side view, top view, and fragmentary bottom perspective view, respectively, in its unfolded configuration for use. As shown in FIGS. 1 and 1 b, table 10 includes a left table top half 16 and a right table top half 18 , hingedly connected to each other for folding into a vertical configuration for movement and storage. In the unfolded configuration, opposed, generally straight edges of table top halves 16 and 18 meet to define a centerline C. In the illustrated embodiment, a small gap g separates halves 16 and 18 in the unfolded configuration, although it should be noted that it is within the scope of the invention for halves 16 and 18 to be generally flush in the unfolded configuration. A left hinge plate 20 attached to left table top half 16 and a right hinge plate 22 attached to right table top half 18 are connected for independent pivotal motion about a center bar 24 . As shown in FIG. 1 , folded locking mechanism 12 includes a locking bar 26 pivotally connected to the bottom of left table top half 16 . Arrow A indicates the general path of locking bar 26 towards a locking latch 28 during folding. Locking latch 28 is attached to a vertical frame member 30 , which is hidden in FIG. 1 but seen in FIG. 1 c, frame member 30 itself being pivotally connected to the bottom of left table top half 16 but constrained to remain generally vertical by folding linkage 32 throughout folding and unfolding. In this manner, when bar 26 is in locking engagement with locking latch 28 , table 10 is retained in the fully folded configuration shown in FIG. 1 a. It should be noted that locking latch 28 may alternatively be attached to the bottom of right table top half 18 within the scope of the invention. However, attaching latch 28 to right table top half 18 would place it further from left table top half 16 than in the illustrated embodiment, thus requiring either latch 28 or locking bar 26 to be longer and increasing material usage and table weight, as well as making it more difficult to avoid interference between moving table parts. Therefore, attaching latch 28 to vertical frame member 30 is preferred.
[0022] With reference to FIGS. 1 and 1 c, locking mechanism 12 includes an actuator member 34 and a connecting link 36 in addition to locking bar 26 . Actuator member 34 is slidably connected to left table top half 16 within sleeve 38 , which is fixedly attached to the bottom of left table top half 16 . For example, sleeve 38 may be welded to a fixed bar as best seen in FIG. 5 . Connecting link 36 is pivotally attached to actuator member 34 and to locking bar 26 . In this manner, when table 10 is in the folded configuration, locking bar 26 may be pivotally lifted out of locking engagement with latch 28 by simply pulling on a T-handle 40 of actuator member 34 , and then table 10 may be lowered into the unfolded configuration.
[0023] On the other hand, manual actuation is not required to engage locking mechanism 12 ; rather, locking mechanism automatically engages upon folding as illustrated schematically in FIGS. 24 . Referring to FIG. 2 , locking mechanism 12 is shown in the partially folded table configuration, with fragmentary portions of left table top half 16 and vertical frame member 30 shown as context. Arrow B indicates the general arcuate path followed by locking bar 26 towards latch 28 during folding. Turning to FIGS. 3 and 4 , the camming action of locking mechanism 12 is illustrated; in particular, locking bar 26 is automatically forced upward by a camming portion 42 of latch 28 , as indicated by arrow C, and then falls into a notch 44 of latch 28 by the force of gravity, as indicated by arrows D, where locking bar 26 is held in locking engagement with latch 28 until T-handle 40 is pulled. As seen in FIG. 5 , T-handle 40 is easily accessible for manual pulling at the top of table 10 near the midpoint of center bar 24 when table 10 is in the folded configuration. This allows a user to disengage locking mechanism 12 while standing near the center of table 10 , a convenient position for stabilizing left table top half 16 as it is lowered into the unfolded configuration.
[0024] In accordance with another aspect of the present invention, with reference to FIGS. 1 c, 5 and 6 , table 10 includes an improved lift assisting mechanism for aiding a user in lifting table top halves 16 and 18 into the folded configuration and in stably lowering table top halves 16 and 18 from the folded to the unfolded configuration. The lift assisting mechanism may be any suitable mechanism to provide a lift assisting force, including, for example, spring mechanisms and pressurized piston-cylinder mechanisms. In the illustrated embodiment, cylinder assemblies 46 a and 46 b are configured to provide an upward lifting force to center bar 24 via pistons 48 a and 48 b. Pistons 48 a and 48 b are connected to a center sleeve 50 , which is disposed to be freely rotatable around center bar 24 , by sliding engagement of the ends of pistons 48 a and 48 b with clutches 52 a and 52 b, which are fixedly attached to center sleeve 50 . Preferably, cylinder assemblies 46 a and 46 b are high-speed cylinder assemblies; i.e., they are free of internal forces that oppose rapid extension of pistons 48 a and 48 b. High-speed cylinder assemblies are discussed in more detail in co-pending U.S. patent application Ser. No. 12/455,204, entitled “Mobile Folding Table with High-Speed Cylinder Lift-Assist and Stabilizer Mechanism,” the disclosure of which is hereby incorporated by reference.
[0025] During initial folding of table 10 , pressurized gas in cylinders 46 a and 46 b provides a force tending to extend pistons 48 a and 48 b, which press against the top ends of clutch slots 54 a and 54 b to provide a lifting force to center sleeve 50 . However, pistons 48 a and 48 b become fully extended before table 10 is fully folded, in a partially folded configuration in which table top halves 16 and 18 are at an angle a with respect to the vertical, as illustrated schematically in FIG. 6 . At this point, the ends of pistons 48 a and 48 b lose contact with the top ends of clutch slots 54 a and 54 b during unassisted manual folding of table 10 between the partially and fully folded configurations, and the ends of pistons 48 a and 48 b slide downward in clutch slots 54 a and 54 b, as indicated by their final positions toward the bottoms of slots 54 a and 54 b shown in FIG. 5 . The present inventors found it beneficial for pistons 48 a and 48 b to be fully extended at an angle a below which the weight of table top halves 16 and 18 provides relatively little to no downward force on center sleeve 50 , so that it is relatively easy to perform the remaining folding manually. Conversely, if pistons 48 a and 48 b remained engaged all the way to the fully folded configuration of the table, it would be relatively difficult to overcome the lifting force of pistons 48 a and 48 b when initially unfolding the table through table angles less than α, when the weight of table top halves 16 and 18 provides less lowering assistance. The preferred angle α depends on many factors, including the weight and weight distribution of table top halves 16 and 18 , but for a typical table, a may advantageously be set at about 25-30 degrees.
[0026] Given that the initial lowering of table top halves 16 and 18 to angle α is unopposed by lift assisting forces according to the present invention, a synergistic relationship exists between the improved locking mechanism 12 and the improved lift assisting and clutch mechanism of the present invention. That is, the placement of T-handle 40 near the top and center of folded table 10 permits a user to disengage locking mechanism 12 while standing in a convenient position for controlling the initial free fall of table 10 into the unfolded configuration, prior to engagement of pistons 48 a and 48 b with clutch slots 54 a and 54 b.
[0027] In yet another aspect of the present invention, table 10 may further include unfolded locking mechanism 14 in addition to improved folded locking mechanism 12 and any suitable lift assisting mechanism. Unfolded locking mechanisms are typically used in conjunction with lift assisting mechanisms, to retain folding tables in the unfolded configuration during use and to prevent undesired folding of the table by the lift assisting mechanisms. In the illustrated embodiment, unfolded locking mechanism 14 includes a center locking bar 56 that is pivotally mounted to right table top half 18 and configured to selectively engage a slot in left hinge plate 20 to prevent rotational movement of left table top half 16 with respect to right table top half 18 toward the folded configuration from being undesirably caused by the lift assisting mechanism when the table is unfolded for use. According to the present invention, center locking bar 56 and T-handle 40 are advantageously connected to opposite halves of table 10 to avoid impingement of either mechanism by the other.
[0028] While the invention has been described with respect to certain preferred embodiments, as will be appreciated by those skilled in the art, it is to be understood that the invention is capable of numerous changes, modifications and rearrangements, and such changes, modifications and rearrangements are intended to be covered by the following claims.
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In one aspect of the present invention, an improved locking mechanism for a mobile folding table is provided, permitting convenient access near the top of the folded table to a manual actuator for unlocking the table from a folded configuration. In another aspect of the present invention, an improved lift-assisting mechanism for a mobile folding table is provided, with a clutch that engages the lift-assisting mechanism only when the table top halves are at an angle from the vertical that is equal to or larger than a predetermined angle. These two aspects of the invention may be advantageously and synergistically combined in the same mobile folding table.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of forming a thin oxysulfide film and more particularly to a method of forming a thin oxysulfide film having a good crystallinity suitable for use as a fluorescent film in thin film EL (electroluminescence) devices and CRTs.
2. Description of the Related Art
Because of many problems in respect of luminance, a dispersive type EL device which uses zinc sulfide (ZnS) fluorescent powder has been deterred its development as a light source for illumination. In its place, a thin film EL device using a thin film phosphor layer has drawn attention recently because it can generate high luminance.
In the thin film EL device, since the luminescent layer is made of a thin transparent film, halation and oozing due to scattering of light incident into the luminescent layer and light generated within the luminescent layer do not occur to any great degree, the thin film EL device exhibits clear and high-contrast display performances. Therefore, the thin film EL device is suitable for display units of vehicle-mounted type and for computer terminals, etc. as well as a light source for illumination.
The thin film EL device is generally of a layered structure comprising a transparent substrate, a transparent electrode made of a tin oxide (SnO 2 ) layer, a first dielectric layer, a luminescent layer made of a host material layer with luminescent center impurities being added thereto, a second dielectric layer, and a rear electrode made of an aluminum layer, sequentially laminated in this order.
The luminescence process of the thin film EL device is as follows. When a required voltage is applied across the transparent and rear electrodes, an electric field is created within the luminescent layer by which electrons trapped in the interface state are drawn out and accelerated to have sufficient energy and collide with orbital electrons of the luminescent center substance, for example, Eu, to excite the orbital electrons. When the excited luminescent center substance returns to its ground state, it emits light.
In a conventional thin film EL device, a luminescent layer comprising, for example, a host material of Y 2 O 2 S containing Eu as a luminescent center impurity (hereinafter expressed as Y 2 O 2 S:Eu) is formed by the process of sputtering or electron beam deposition.
In the sputtering process, for example, a sintered pellet made of a mixture of Y 2 O 2 S:Eu fluorescent powder and sulfur is sputtered, thereby to deposit the sputtered mixture on a substrate.
According to the conventional method of forming the luminescent layer, when the substrate temperature and the sulfur density are low, Y 2 O 3 :Eu is produced while when the substrate temperature is increased to about 200°-400° C., Y 2 O 2 S:Eu is produced. The resulting Y 2 O 2 S:Eu, however, exhibits a low orientation characteristic and has a granular multi-crystalline structure or a structure containing a so-called dead layer in which many small crystalline grains is produced at the early stage of growth. When the substrate temperature is further increased, orientation characteristics are improved, but sulfur is eliminated, thereby producing Y 2 O 3 :Eu, the undesirable.
When a luminescent layer contains a dead layer, electrons in the luminescent layer accelerated by an externally applied electric field are scattered by a crystalline granular interface before they collide with luminescent center impurities so as to emit light. Thus, the externally applied electric field does not contribute effectively to the light emission.
For a CRT display, Y 2 O 2 S:Eu is used which is produced by sintering for several hours at a temperature of about 1000° C. However, crystallinity is low unless it is sintered at high temperature and the resulting grain size is large, for example, larger than several μm. Therefore, it is disadvantageous when used as a thin film luminescent material.
This problem applies not only to Y 2 O 2 S:Eu, but also to other thin oxysulfide films.
As described above, in the conventional method, a film having high crystallinity cannot be obtained at low temperature while if the substrate temperature is increased, sulfur is eliminated, so that a thin excellent oxysulfide film cannot be obtained in this manner either.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a thin oxysulfide film excellent in crystallinity and suitable for a luminescent layer of thin film EL devices or a fluorescent film for CRTs.
According to the present invention, a thin oxysulfide film is formed by evaporating a metal element within a chamber in which an oxygen gas and a sulfur gas are introduced to combine them chemically on a substrate to form a thin metal oxysulfide film on a surface of the substrate.
Preferably, at least one of impurities of Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm and Yb is evaporated from an independent evaporation source to be added to the film when the film is formed.
According to the method of the present invention, evaporation of a metal element and supplying of sulfur and oxygen are independently controlled such that these substances are chemically combined on a substrate to form a luminescent layer whose composition is stoichiometric. Thus, a thin oxysulfide film having high crystallinity is produced.
Even if the temperature of the substrate is raised for the purpose of improving the crystallinity, since sulfur is supplied into the chamber in the form of gas, the sulfur will not be eliminated and the quantity of sulfur is appropriately controlled. Therefore, a thin rare earth oxysulfide film having a good stoichiometric composition can be produced.
It is preferable to add at least one of Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb as the luminescent center impurity at the time of the film formation. Then, a thin luminescent layer having uniform distribution of luminescent center impurity and excellent crystallinity can be produced.
This is because the process of growth takes place as follows.
Assume that substance A is evaporated from an evaporation source, and substances B and C are supplied in a vapor phase to form a substance ABC on the substrate. Let the substances A, B and C be a metal, oxygen and sulfur, respectively. If the metal A is an element in Group IIa of the periodic table such as Ca or Sr or an element in Group IIb such as Zn or Cd, and the temperature Ts of the substrate is relatively low (for example, lower than 600° C.), it is possible to establish the following conditions: P O <<P A , P O <<P B and P O <<P C where P O is degree of vacuum (pressure) of the chamber and P A , P B and P C are the vapor pressures of the substances A, B and C, respectively. Under such conditions, the substances A, B and C by themselves do not substantially stick to the substrate, so that the compound ABC alone grows selectively.
In the case where the metal A is an element in Group IIIa such as La or Y, P A does not become very large so that the metal A alone sticks to the substrate. However, it is considered that the compound ABC may also grow selectively probably for the following reason. Taking Y 2 O 2 S for example, the process: 2Y+O 2 +1/2S 2 Y 2 O 2 S is an exothermic reaction and the elements A, B and C are very active on the surface of the thin film. Therefore, these elements, particularly the element A, can have kinetic energy sufficient for settling themselves in the most stable position. As a result, a thin film excellent in flatness and crystallinity will be formed even at a low substrate temperature.
This applies to a case where luminescent center impurities are added. As a result, although a thin fluorescent film, for example, of Y 2 O 2 S:Eu, does not generally exhibit sufficient luminous efficiency unless heat treatment is carried out at a temperature above 1000° C., the film forming method according to the present invention provides a thin fluorescent film having a satisfactory high luminous efficiency even at a temperature lower than 600° C.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates a thin film EL device of an embodiment of the present invention;
FIG. 2(a)-(e) illustrates a process for manufacturing the thin film EL device of FIG. 1;
FIG. 3 schematically illustrates a device for forming a thin film in carrying out a method according to the present invention;
FIG. 4 is a graph illustrating a result of X-ray diffraction of a luminescent layer of a thin film EL device formed by the inventive method; and
FIG. 5 shows an X-ray fluorescent plate in a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Embodiments of the present invention will be described below in detail with reference to the drawings.
Referring to FIG. 1, a thin film EL device of a first embodiment has a double dielectric layer structure in which a luminescent layer 1 is made of a host material of Y 2 O 2 S containing Eu as a luminescent center impurity (Y 2 O 2 S: Eu) and has a thickness of 500 nm.
More particularly, the EL device comprises a transparent glass substrate 2 having a thickness of 1 mm, a transparent electrode 3 made of tin oxide (SnO 2 ) having a thickness of 0.3 μm formed on substrate 2, a first dielectric layer 4 made of tantalum oxide (Ta 2 O 5 ) having a thickness of 0.5 μm, the luminescent layer 1 as described above, a second dielectric layer 5 made of tantalum oxide (Ta 2 O 5 ) having a thickness of 0.5 μm, and rear electrodes 6 made of aluminum having a thickness of 0.5 μm, disposed in this order.
A method of producing such a thin film EL device will be described by referring to FIGS. 2(a)-(e).
First, the transparent electrode 3 made of SnO 2 is formed on a transparent glass substrate 2 by sputtering process (FIG. 2(a)), and the first dielectric layer 4 made of tantalum oxide is formed by sputtering process (FIG. 2(b)).
Subsequently, the luminescent layer 1 is formed using a thin film growth device shown in FIG. 3. The device comprises a vacuum chamber 10 in which a crucible 11 for containing yttrium (Y), a crucible 12 for containing luminescent center impurity of Eu, a sulfur gas introducing tube 13 for supplying sulfur gas, an oxygen gas introducing tube 14 for supplying oxygen gas, a substrate support 16 for supporting a substrate and a heater 15 for heating the temperature of the substrate. Temperatures of crucible 11 and 12, quantities of sulfur gas supplied from the sulfur gas introducing tube 13 and oxygen gas supplied from the oxygen gas introducing tube 14 are controlled independently. The sulfur gas is supplied by heating sulfur 18 by means of a heater 17. The supply of the sulfur gas and the oxygen gas is controlled by valves 19a and 19b and a mass-flow controller 20.
In the formation of the film, the vapor pressure within the vacuum chamber 10 is first set at 10 -5 Torr. Then, setting the temperature T s of glass substrate 2 at 565° C., sulfur gas and oxygen gas are supplied while controlling the temperatures of crucible 11 and 12 and, the quantities of supplied sulfur gas and oxygen gas independently such that the composition of the luminescent layer is stoichiometric.
The luminescent layer 1 having grown in the above manner is made of a thin Y 2 O 2 S: Eu film having a thickness of 300 nm where the luminescent center impurities of Eu are uniformly distributed and having excellent crystallinity (FIG. 2(c)). The partial pressures of oxygen and sulfur gases are 3.0×10 -4 Torr and 1.5×10 -4 Torr, respectively.
FIG. 4 shows the result of X-ray diffraction of Y 2 O 2 S: Eu thus obtained. The result shows that Y 2 O 2 S: Eu has excellent crystallinity and orientation (100).
Then, as shown in FIG. 2(d), the second dielectric layer 5 made of a tantalum oxide layer is formed by sputtering process.
Finally, as shown in FIG. 2(e), an aluminum film is formed by vacuum deposition and then patterned to form the rear electrode 6 by photolithography process.
The thin film EL device is operable by applying an alternating electric field across the transparent and the rear electrodes. The device has a high luminance performance at a low voltage.
While the luminescent layer is made of a thin Y 2 O 2 S: Eu film in the above embodiment, the present invention is not limited to this. Same effects can be achieved by using other metal oxysulfide as host material and at least one of Ce, Pr, Nd, Pm, Sm, Gd, Tb, Dy, Ho, Er, Tm and Yb as a luminescent center impurity which is added to the host material when the film is formed.
Thin metal oxysulfide film is usable not only in thin film EL devices, but also in fluorescent films for CRTs and X-ray intensifying screens.
In addition, the present invention is applicable to the formation of thin ZnO x S 1-x films in addition to the formation of thin films of oxysulfides of rare earth elements.
A method of making an X-ray fluorescent plate as a second embodiment of the present invention will be described referring to FIG. 5. The X-ray fluorescent plate is characterized by a sensitized fluorescent layer 13 formed by the thin film forming process of the present invention. As shown in FIG. 5, the X-ray fluorescent plate comprises a reflective tungsten layer 22 having a thickness of 0.5 μm formed on a transparent glass substrate 21, a sensitized fluorescent layer 23 made of Gd 2 O 2 S: Tb and having a thickness of 3 μm formed on reflective layer 22, an X-ray film stuck to the layer 23 and a photo-preventive cover which covers the whole of the product thus formed.
The process of making the X-ray fluorescent plate is as follows.
A thin tungsten film 22 is formed on the glass substrate 21 having a thickness of 1 mm by electron beam vapor deposition.
Then, the sensitized fluorescent layer 23 is formed using a thin film growing device shown in FIG. 3 in which the crucible 11 contains gadolinium (Gd) and the crucible 12 contains luminescent center impurity Tb.
In the formation of the film, the vapor pressure within the vacuum chamber 10 is first set at 10 -5 Torr. Then, setting the temperature T s of the glass substrate 21 at 580° C., sulfur gas and oxygen gas are suplied while controlling the temperatures of crucible 11 and 12, the quantities of supplied sulfur gas and oxygen gas independently such that the composition of the sensitized fluorescent layer is stoichiometric.
The thin sensitized fluorescent layer 23 having grown in the above manner is made of a thin Gd 2 O 2 S: Tb film having a thickness of 3 μm where the luminescent center impurities of Tb are uniformly distributed and having excellent crystallinity. The partial pressures of oxygen and sulfur gases are 3.0×10 -4 Torr and 1.5×10 -4 Torr, respectively.
An X-ray film 24 is stuck to the sensitized fluorescent layer 23 thus obtained, and a cover 25 which prevents the film from being exposed is mounted on the whole of the product thus obtained.
The conventional X-ray fluorescent plate has a structure in which a sensitized sheet is stuck to each side of an X-ray film. According to the present invention, the sensitized fluorescent layer 23 is made of Gd 2 O 2 S: Tb with Tb being added uniformly. Since the sensitized fluorescent layer has an excellent performance, it is required to be formed on only one side of the X-ray film. Therefore, the X-ray fluorescent plate can be made with a simple structure and can detect X-rays with very high sensitivity. Therefore, productivity of the plate is improved and the production cost is reduced.
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In order to provide a thin oxysulfide film excellent in crystallinity and suitable for use as a luminescent layer of a thin film EL device and a thin fluorescent film for a CRT, a metal element is evaporated from an evaporation source provided in a chamber in which a sulfur gas and an oxygen gas have been introduced to combine those substances chemically on a substrate provided in the chamber to form a thin oxysulfide film on a surface of the substrate.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and system for treating a semiconductor material. More specifically, the present invention relates to a method and system for preheating a semiconductor material and reducing the amount of laser radiation required to achieve downstream surface melting on at least one side while also enabling controlled recrystallization and cooling.
2. Description of the Related Art
The ion implantation process, which introduces impurity atoms or dopants into surface region of a semiconductor wafer leaves dopant atoms in interstitial sites where they electronically inactive. In order to move the dopant atoms into substitutional sites in the lattice to render them active and otherwise to repair process damage an annealing of the surface region is performed by heating to high temperature, typically in a tube furnace or with a rapid thermal process (RPT) furnace.
The absorption depth of a given wavelength of light in a material decreases as temperature of the material increases. An example is the absorption of silicon as a function of temperature as is shown in FIG. 1 , provided by Thomas R. Harris, “ Optical Properties of Si, Ge, GaAs, InAs, and InP at elevated Temperatures , Thesis AFIT/GAP/ENP/10-M08, Air Force Institute of Technology, Wright-Patterson Air Force Base, Ohio, 2010 the contents of which are incorporated by reference, Also for review by the public is U.S. Pat. No. 7,494,942 and U.S. Pat. No. 7,399,945, the contents of which are also incorporated by reference.
Necessarily, for the purpose of annealing ion implanted semiconductor wafers having a crystal lattice structure using an JR laser, much of the laser radiation is used to heat the wafer to a point where most of the laser radiation is absorbed close to the surface of the wafer facing the incident beam (incident side). Ultimately the material reaches a temperature where most of the radiation is absorbed near the surface and a thin layer of the material near the surface melts further changing the absorption rate therein.
Conventionally, an incident laser beam impinges on only a tiny part of a wafer on an incident side at any moment in time resulting in substantial localized thermal gradients, localized large stress gradients, and wafer fracture.
The amount of incident laser radiation required to achieve surface melting can be significantly reduced if the wafer is preheated, prior to heating the surface to a higher desired melting temperature. There are several methods available for wafer preheating, including; conductive source heating via resistance, conduction from a susceptor heated by RF (Radio Frequency), and radiative heating by JR (Infra Red) light source (non-laser).
The process using ion implantation to generate a semiconductor junction provides for a two-step process; a first step of “ion implantation” at a specific ion energy and dose (so-called pre-deposition) and a second step of “annealing” (also drive-in diffusion). The later is performed in two ways: (A) heating of an ion-implanted wafer in a furnace to a temperature of >1000° C. for a time period of >0.50 hr (allowing implanted species to migrate), and (B) rapidly heating a surface of an implanted waver with a heat source (allowing rapid migration to active sites), often in a process called rapid thermal processing (RTP)).
In a process referred to as GILD (Gaseous Immersion Laser Doping), laser heating (surface melting) by laser energy when performed in an appropriate gaseous environment containing a desired doping species (including but not limited to Arsine (AsH 3 ), Phosphine (PH 3 ), and/or Boron Triflouride (BF 3 ) or others as is known in the art) was found to result in high quality semiconductor junctions and eliminated ion implantation and lowering capital equipment cost substantially. It was essential to the GILD process to employ short pulsed and short wavelengths lasers operating in the UV spectrum (Excimers). This was essential due to the short absorption depth of UV radiation in silicon.
Accordingly, there is a need for an improved method and system for preheating of semiconductor materials for laser annealing and gas immersion laser doping so that the amount of laser radiation required to achieve further processing is significantly reduced with enhanced processing economics. There is also a need to eliminate material fracture arising during localized heating by a scanned laser beam during processing.
ASPECTS AND SUMMARY OF THE INVENTION
In response it is now recognized that longer wavelength radiation above 1.0 microns (such as 1.06 and 10.2 microns) provided by a single fiber laser source (including, Yb-doped, CO 2 , ruby, near IR lasers, or other doped high wavelength fibers, LEDs, or operative diode lasers or diode arrangements) operating at any operative power range, including above 100W, or above 1.0 kW, or more may be used for improved processing economics. Such processing may include preheating to temperatures over 400° C. and up to approximately 600° C., to create free carriers during preheating, or at higher temperatures to activate implanted doping atoms, or to anneal or to conduct GILD processes. Preheating may be done by a preheat beam derived from the same laser source as an exposing laser, through beam splitting or differently proportioned beams split by optics, or by providing a second laser source. It is now recognized that the preheating laser is not limited to the particular illustration here, but may be provided by any other suitable laser beam arrangement.
It is recognized that long wavelength radiation causes material heating thereby further changing the absorption depth of the radiation so that resulting surface melting has been largely neglected. If the material is undergoing melting at the surface in a partial vacuum containing a dopant gas the dopant will rapidly diffuse to the liquid solidus interface forming junctions down to the melt depth.
It is recognized that the temperature gradient arising during processing must not exceed a critical value that results in fracture or other damages within the crystal structure.
It is also now recognized that the use of a long wavelength in a ribbon beam having a width and a tailored Gaussian or similar profile can be scanned orthogonally to a long dimension of the ribbon over a full width of a wafer during a process, such that via the beam profile, the beam provides, respectively, a leading edge and a trailing edge, such that the distribution of radiation power (width and intensity of the profile) over a scan rate factor dictates a melt depth on an incident surface. See for example FIG. 2 which illustrates this profile concept. This treatment may be used to scan a complete wafer at a beam scanning rate of about 15 cm/sec., or more, to meet throughput requirements. This process may be used to treat a wafer of any dimension. This process may be used to control surface melting to a desired junction depth, for example 0.23 μm. If the wafer is preheated by some means other than the exposing laser, the magnitude of the temperature gradients can also be reduced and less laser power is required.
A fiber laser system enables a method for treating a semiconductor material by preheating, by annealing of an ion implanted wafer, or by GILD type wafer treatment. A longer wave length fiber laser having a Gaussian profile operating in any suitable mode is applied in a ribbon beam across an incident wafer. Preferably the laser wavelength is greater than 1 μm (micron) and preferably a Yb-doped fiber laser of multi kW is used. The method is performed in a gaseous environment which may further comprise a doping species.
An aspect of the present invention provides an improved method and system for preheating semiconductor material for laser annealing and gas immersion laser doping so that an amount of laser energy power is reduced and the temperature gradients are easily controlled.
The preheating steps may be performed in any suitable environment, including a fully evacuated, partial pressure, and/or over pressure environment. Where an atmosphere is employed, the atmosphere may be any suitable working atmosphere, including for example, a noble gas or non-reactive gas (H 2 , He 2 , N 2 , Ar, etc.) or any combination or mixture of gases or any suitable doping species and/or any combination of dopant gases.
The above, and other aspects, features and advantages of the present invention will become apparent from the following description read in conjunction with the accompanying drawings, in which like reference numerals designate the same elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph of the infrared transmission of photon energy for Si as a function of temperature.
FIG. 2 is a graphical representation of a ribbon beam profile relative to a scan direction; e.g., preheating, melt zone, and recrystallization and cooling.
FIG. 3 is an exemplary process system for preheating, or treating, a semiconductor material.
FIG. 4 is an exemplary process illustration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to several embodiments of the invention that are illustrated in the accompanying drawings. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps. The drawings are in simplified form and are not to precise scale. For purposes of convenience and clarity only, directional terms, such as top, bottom, up, down, over, above, and below may be used with respect to the drawings. These and similar directional terms should not be construed to limit the scope of the invention in any manner.
It will also be recognized herein that various techniques of preheating a semiconductor material are recognized in the art, and may be optionally used in the proposed process, but are not required. These techniques include preheating by conduction from a heat source, heating by conduction from a susceptor heated by RF power, radiative heating by IR light sources other than a laser, such that the proposed process may be adapted to also include any of these preheating process easily without departing from the scope or spirit of the invention.
Any of the preheating methods can be applied, alone, in sequence, or simultaneously, to reduce the amount of laser power required for later final processing, annealing and/or GILD treatment and/or to reduce thermal stresses within the wafer.
FIG. 3 is a simplified exemplary system of an optional process flow of one alternative embodiment of the present invention. A laser source system 200 is selected based upon desired wavelength and Gaussian or similar profile, and could be any one of: an Yb fiber laser; a CW laser; or other known fiber laser suitable for the purpose. Laser source system 200 may be optionally any known laser source, including optionally fiber laser, disk lasers, gas lasers, or others known in the art. Laser source 200 may optionally include a square fiber, round fiber, or other laser diode sources, including operative laser system components including collimator optics, homogenizer optics, optics, and other elements known to those of skill in the art to generate a desired beam. The beam is directed to an optical splitter system 202 which splits the initial beam into a preheating beam 204 and a non-preheating process beam 206 for process annealing or GILD, etc. Optical splitter system 202 is quipped with suitable optics to both split the initial beam and optionally to selectively determine an intensity proportion of the split beam between preheat beam 204 and non-preheat or process beam 206 .
Beam 204 can be utilized as an annealing pre-laser while beam 206 can also be directed to perform optionally, a second preheating step or the actual processing step. It is to be understood that the semiconductor material, shown as a wafer 210 is operative relative to a supporting system 208 . Therefore, while one embodiment may involve preheating a semiconductor material a related process may vary by time and intensity (power), or beam profile (Gaussian or other profile) and may be used to further preheat (e.g., a second pre-heat), to anneal (following ion implantation). It will be recognized from this paragraph, that the teachings of the proposed invention may be adaptively employed to manage the preheating, melting, recrystallization, and cooling of a semiconductor material.
It will also be recognized, that optionally, beams 204 , 206 may follow-each other in close proximity, even very close proximity, on a single wafer 210 , possibly sufficiently close that the beam distribution profiles overlap.
It will also be recognized, that alternatively and optionally, a single long wavelength beam having a suitable Gaussian or similar profile and formed into a ribbon form and scanned on wafer 210 orthogonal to a long dimension of the ribbon form may conduct both preheating and treating processing as noted in FIG. 2 in a single scan that extends beyond both wafer edges.
Supporting system 208 may be any operative moving stage system to process wafers 210 along direction D relative to beams 204 , 206 , or optionally a single beam as discussed in the above paragraph. Such an operative system may include an Electrostatic Chuck (not shown) for each wafer 210 with a gold or other reflective coating. Where a form of preheating uses diodes the preheating may be of high intensity and short exposure (resulting in partial-thickness heating) or longer treatment to provide uniform (isothermal) preheating through the thickness of the wafer, depending upon user preference. The electrostatic force attracts the wafer into immediate contact with the chuck thereby providing uniform temperature across the surface of the wafer after laser annealing.
A computerized process controller system 215 containing an operational process control program, memory systems, and process control (all not shown) is in operative communication with laser source system 200 , laser beam processing optics and beam splitter system 202 , an optional reflectivity measurement system apparatus 216 for measuring the reflectivity of reflected laser light for process control. Based upon readings from reflectivity measurement system apparatus 216 , operative instructions may be issued by process controller 215 to vary a processing variable (speed, intensity, power, split ratio or otherwise).
Additionally referring now to FIG. 4 an illustrative treatment shown in situ (in an instant process moment), where a semiconductor material (wafer) 210 is supporting on supporting system 208 moving in direction D. This motion direction provides a leading edge 231 and a trailing edge 230 for wafer 210 . Region 232 is a ribbon beam from preheating beam 204 (See FIG. 3 ) extending beyond both edges of the scanning direction of the wafer (normal to the narrow axis of the annealing laser beam of the wafer). The ribbon beam fully extends the width of wafer 210 before contacting and after full treatment. In this manner, there is a full scanning over the complete wafer to manage the temperature gradient during processing. It will be understood that optical splitter system 202 may contain optics sufficient to shape the beam to fully scan the wafer. It will be also understood that optical splitter system 202 may also operate to control an intensity ratio between the split beams so that preheating beam 204 operates a different intensity than processing beam 206 Similarly, controller 215 may provide different duration times of the split beams, and may also optionally be used to manage the Gaussian profile so that it may be expanded in the narrow direction of a ribbon beam to effect the temperature gradient for preheating and cooling of a surface.
It will also be understood by those of skill in the art that the preheating method and system discussed herein may employ laser diode preheating, laser diode or direct laser diode preheating, and laser beam preheating without departing from the scope herein, such that the use of the term laser preheating, laser diode and/or laser diode or direct laser diode may be adaptively used but readily understood within the scope of the disclosure. It is further understood, that based upon intensity and absorption factors, the thermal temperature during preheating or annealing/GILD treatment may be above 400° C.
Having described at least one of the preferred embodiments of the present invention with reference to the accompanying drawings, it will be apparent to those skills that the invention is not limited to those precise embodiments, and that various modifications and variations can be made in the presently disclosed method and system for preheating of semiconductor material for laser annealing and gas immersion laser doping without departing from the scope or spirit of the invention. Thus, it is intended that the present disclosure cover the modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents.
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A fiber laser system enables a method for treating a semiconductor material by preheating a wafer for laser annealing and gas immersion laser doping by a laser source. A long wave length fiber laser having a Gaussian or similar profile is applied in a full-width ribbon beam across an incident wafer. Preferably the wavelength is greater than 1 μm (micron) and preferably a Yb doped fiber laser is used. The process is performed in a suitable environment which may include doping species. The process ensures the temperature gradient arising during processing does not exceed a value that results in fracture of the wafer while also reducing the amount of laser radiation required to achieve controlled surface melting, recrystallization and cooling.
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This is a divisional of application Ser. No. 08/209,204, filed Mar. 8, 1994 now U.S. Pat. No. 7,115,554, which is a continuation-in-part of application Ser. No. 08/059,022, filed May 6, 1993, abandoned.
BACKGROUND OF THE INVENTION
The invention relates to prophylactic or affirmative treatment of diseases and disorders of the musculature by administering polypeptides found in vertebrate species, which polypeptides are growth, differentiation and survival factors for muscle cells.
Muscle tissue in adult vertebrates will regenerate from reserve myoblasts called satellite cells. Satellite cells are distributed throughout muscle tissue and are mitotically quiescent in the absence of injury or disease. Following muscle injury or during recovery from disease, satellite cells will reenter the cell cycle, proliferate and 1) enter existing muscle fibers or 2) undergo differentiation into mulinucleate myotubes which form new muscle fiber. The myoblasts ultimately yield replacement muscle fibers or fuse into existing muscle fibers, thereby increasing fiber girth by the synthesis of contractile apparatus components. This process is illustrated, for example, by the nearly complete regeneration which occurs in mammals following induced muscle fiber degeneration; the muscle progenitor cells proliferate and fuse together regenerating muscle fibers.
Several growth factors which regulate the proliferation and differentiation of adult (and embryonic) myoblasts in vitro have been identified. Fibroblast growth factor (FGF) is mitogenic for muscle cells and is an inhibitor of muscle differentiation. Transforming growth factor β (TGFβ) has no effect on myoblast proliferation, but is an inhibitor of muscle differentiation. Insulin-like growth factors (IGFs) have been shown to stimulate both myoblast proliferation and differentiation in rodents. Platelet derived growth factor (PDGF) is also mitogenic for myoblasts and is a potent inhibitor of muscle cell differentiation. (For a review of myoblast division and differentiation see: Florini and Magri, 1989:256:C701-C711).
In vertebrate species both muscle tissue and neurons are potential sources of factors which stimulate myoblast proliferation and differentiation. In diseases affecting the neuromuscular system which are neural in origin (i.e., neurogenic), the muscle tissue innervated by the affected nerve becomes paralyzed and wastes progressively. During peripheral nerve regeneration and recovery from neurologic and myopathic disease, neurons may provide a source of growth factors which elicit the muscle regeneration described above and provide a mechanism for muscle recovery from wasting and atrophy.
A recently described family of growth factors, the neuregulins, are synthesized by motor neurons (Marchioni et al. Nature 362:313, 1993) and inflammatory cells (Tarakhovsky et al., Oncogene 6:2187-2196 (1991)). The neuregulins and related p185 erbB2 binding factors have been purified, cloned and expressed (Benveniste et al., PNAS 82:3930-3934, 1985; Kimura et al., Nature 348:257-260, 1990; Davis and Stroobant, J. Cell. Biol. 110:1353-1360, 1990; Wen et al., Cell 69:559, 1992; Yarden and Ullrich, Ann. Rev. Biochem. 57:443, 1988; Holmes et al., Science 256:1205, 1992; Dobashi et al., Proc. Natl. Acad. Sci. 88:8582, 1991; Lupu et al., Proc. Natl. Acad. Sci. 89:2287, 1992). Recombinant neuregulins have been shown to be mitogenic for peripheral glia (Marchionni et al., Nature 362:313, 1993) and have been shown to influence the formation of the neuromuscular junction (Falls et al., Cell 72:801, 1993). Thus the regenerating neuron and the inflammatory cells associated with the recovery from neurogenic disease and nerve injury provide a source of factors which coordinate the remyelination of motor neurons and their ability to form the appropriate connection with their target. After muscle has been reinnervated the motor neuron may provide factors to muscle, stimulating muscle growth and survival.
Currently, there is no useful therapy for the promotion of muscle differentiation and survival. Such a therapy would be useful for treatment of a variety of neural and muscular diseases and disorders.
SUMMARY OF THE INVENTION
We have discovered that increased mitogenesis differentiation and survival of muscle cells may be achieved using proteins heretofore described as glial growth factors, acetylcholine receptor inducing activity (ARIA), heregulins, neu differentiation factor, and, more generally, neuregulins. We have discovered that these compounds are capable of inducing both the proliferation of muscle cells and the differentiation and survival of myotubes. These phenomena may occur in cardiac and smooth muscle tissues in addition to skeletal muscle tissues. Thus, the above compounds, regulatory compounds which induce synthesis of these compounds, and small molecules which mimic these compounds by binding to the receptors on muscle or by stimulating through other means the second messenger systems activated by the ligand-receptor complex are all extremely useful as prophylactic and affirmative therapies for muscle diseases.
A novel aspect of the invention involves the use of the above named proteins as growth factors to induce the mitogenesis, survival, growth and differentiation of muscle cells. Treating of the muscle cells to achieve these effects may be achieved by contacting muscle cells with a polypeptide described herein. The treatments may be provided to slow or halt net muscle loss or to increase the amount or quality of muscle present in the vertebrate.
These factors may be used to produce muscle cell mitogenesis, differentiation, and survival in a vertebrate (preferably a mammal, more preferably a human) by administering to the vertebrate an effective amount of a polypeptide or a related compound. Neuregulin effects on muscle may occur, for example, by causing an increase in muscle performance by inducing the synthesis of particular isoforms of the contractile apparatus such as the myosin heavy chain slow and fast isoforms; by promoting muscle fiber survival via the induction of synthesis of protective molecules such as, but not limited to, dystrophin; and/or by increasing muscle innervation by, for example, increasing acetylcholine receptor molecules at the neuromuscular junction.
The term muscle cell as used herein refers to any cell which contributes to muscle tissue. Myoblasts, satellite cells, myotubes, and myofibril tissues are all included in the term “muscle cells” and may all be treated using the methods of the invention. Muscle cell effects may be induced within skeletal, cardiac and smooth muscles.
Mitogenesis may be induced in muscle cells, including myoblasts or satellite cells, of skeletal muscle, smooth muscle or cardiac muscle. Mitogenesis as used herein refers to any cell division which results in the production of new muscle cells in the patient. More specifically, mitogenesis in vitro is defined as an increase in mitotic index relative to untreated cells of 50%, more preferably 100%, and most preferably 300%, when the cells are exposed to labelling agent for a time equivalent to two doubling times. The mitotic index is the fraction of cells in the culture which have labelled nuclei when grown in the presence of a tracer which only incorporates during S phase (i.e., BrdU) and the doubling time is defined as the average time required for the number of cells in the culture to increase by a factor of two.
An effect on mitogenesis in vivo is defined as an increase in satellite cell activation as measured by the appearance of labelled satellite cells in the muscle tissue of a mammal exposed to a tracer which only incorporates during S phase (i.e., BrdU). The useful therapeutic is defined in vivo as a compound which increases satellite cell activation relative to a control mammal by at least 10%, more preferably by at least 50%, and most preferably by more than 200% when the mammal is exposed to labelling agent for a period of greater than 15 minutes and tissues are assayed between 10 hours and 24 hours after administration of the mitogen at the therapeutic dose. Alternatively, satellite cell activation in vivo may be detected by monitoring the appearance of the intermediate filament vimentin by immunological or RNA analysis methods. When vimentin is assayed, the useful mitogen is defined as one which causes expression of detectable levels of vimentin in the muscle tissue when the therapeutically useful dosage is provided.
Myogenesis as used herein refers to any fusion of myoblasts to yield myotubes. Most preferably, an effect on myogenesis is defined as an increase in the fusion of myoblasts and the enablement of the muscle differentiation program. The useful myogenic therapeutic is defined as a compound which confers any increase in the fusion index in vitro. More preferably, the compound confers at least a 2.0-fold increase and, most preferably, the compound confers a 3-fold or greater increase in the fusion index relative to the control. The fusion index is defined as the fraction of nuclei present in multinucleated cells in the culture relative to the total number of nuclei present in the culture. The percentages provided above are for cells assayed after 6 days of exposure to the myogenic compound and are relative to an untreated control. Myogenesis may also be determined by assaying the number of nuclei per area in myotubes or by measurement of the levels of muscle specific protein by Western analysis. Preferably, the compound confers at least a 2.0-fold increase in the density of myotubes using the assay provided, for example, herein, and, most preferably, the compound confers a 3-fold or greater increase.
The growth of muscle may occur by the increase in the fiber size and/or by increasing the number of fibers. The growth of muscle as used herein may be measured by A) an increase in wet weight, B) an increase in protein content, C) an increase in the number of muscle fibers, or D) an increase in muscle fiber diameter. An increase in growth of a muscle fiber can be defined as an increase in the diameter where the diameter is defined as the minor axis of ellipsis of the cross section. The useful therapeutic is one which increases the wet weight, protein content and/or diameter by 10% or more, more preferably by more than 50% and most preferably by more than 100% in an animal whose muscles have been previously degenerated by at least 10% and relative to a similarly treated control animal (i.e., an animal with degenerated muscle tissue which is not treated with the muscle growth compound). A compound which increases growth by increasing the number of muscle fibers is useful as a therapeutic when it increases the number of fibers in the diseased tissue by at least 1%, more preferably at least 20%, and most preferably, by at least 50%. These percentages are determined relative to the basal level in a comparable untreated undiseased mammal or in the contralateral undiseased muscle when the compound is administered and acts locally.
The survival of muscle fibers as used herein refers to the prevention of loss of muscle fibers as evidenced by necrosis or apoptosis or the prevention of other mechanisms of muscle fiber loss. Survival as used herein indicates an decrease in the rate of cell death of at least 10%, more preferably by at least 50%, and most preferably by at least 300% relative to an untreated control. The rate of survival may be measured by counting cells stainable with a dye specific for dead cells (such as propidium iodide) in culture when the cells are 8 days post-differentiation (i.e., 8 days after the media is changed from 20% to 0.5% serum).
Muscle regeneration as used herein refers to the process by which new muscle fibers form from muscle progenitor cells. The useful therapeutic for regeneration confers an increase in the number of new fibers by at least 1%, more preferably by at least 20%, and most preferably by at least 50%, as defined above.
The differentiation of muscle cells as used herein refers to the induction of a muscle developmental program which specifies the components of the muscle fiber such as the contractile apparatus (the myofibril). The therapeutic useful for differentiation increases the quantity of any component of the muscle fiber in the diseased tissue by at least 10% or more, more preferably by 50% or more, and most preferably by more than 100% relative to the equivalent tissue in a similarly treated control animal.
Atrophy of muscle as used herein refers to a significant loss in muscle fiber girth. By significant atrophy is meant a reduction of muscle fiber diameter in diseased, injured or unused muscle tissue of at least 10% relative to undiseased, uninjured, or normally utilized tissue.
Methods for treatment of diseases or disorders using the polypeptides or other compounds described herein are also part of the invention. Examples of muscular disorders which may be treated include skeletal muscle diseases and disorders such as myopathies, dystrophies, myoneural conductive diseases, traumatic muscle injury, and nerve injury. Cardiac muscle pathologies such as cardiomyopathies, ischemic damage, congenital disease, and traumatic injury may also be treated using the methods of the invention, as may smooth muscle diseases and disorders such as arterial sclerosis, vascular lesions, and congenital vascular diseases. For example, Duchenne's muscular dystrophy, Becker's dystrophy, and Myasthenia gravis are but three of the diseases which may be treated using the methods of the invention.
The invention also includes methods for the prophylaxis or treatment of a tumor of muscle cell origin such as rhabdomyosarcoma. These methods include administration of an effective amount of a substance which inhibits the binding of one or more of the polypeptides described herein and inhibiting the proliferation of the cells which contribute to the tumor.
The methods of the invention may also be used to treat a patient suffering from a disease caused by a lack of a neurotrophic factor. By lacking a neurotrophic factor is meant a decreased amount of neurotrophic factor relative to an unaffected individual sufficient to cause detectable decrease in neuromuscular connections and/or muscular strength. The neurotrophic factor may be present at levels 10% below those observed in unaffected individuals. More preferably, the factor is present at levels 20% lower than are observed in unaffected individuals, and most preferably the levels are lowered by 80% relative to unaffected individuals under similar circumstances.
The methods of the invention make use of the fact that the neuregulin proteins are encoded by the same gene. A variety of messenger RNA splicing variants (and their resultant proteins) are derived from this gene and many of these products show binding to P185 erbB2 and activation of the same. Products of this gene have been used to show muscle cell mitogenic activity (see Examples 1 and 2, below), differentiation (Examples 3 and 6), and survival (Examples 4 and 5). This invention provides a use for all of the known products of the neuregulin gene (described herein and in the references listed above) which have the stated activities as muscle cell mitogens, differentiation factors, and survival factors. Most preferably, recombinant human GGF2 (rhGGF2) is used in these methods.
The invention also relates to the use of other, not yet naturally isolated, splicing variants of the neuregulin gene. FIG. 29 shows the known patterns of splicing. These patterns are derived from polymerase chain reaction experiments (on reverse transcribed RNA), analysis of cDNA clones (as presented within), and analysis of published sequences encoding neuregulins (Peles et al., Cell 69:205 (1992) and Wen et al., Cell 69:559 (1992)). These patterns, as well as additional patterns disclosed herein, represent probable splicing variants which exist. The splicing variants are fully described in Goodearl et al., U.S. Ser. No. 08/036,555, filed Mar. 24, 1993, incorporated herein by reference.
More specifically, cell division, survival, differentiation and growth of muscle cells may be achieved by contacting muscle cells with a polypeptide defined by the formula
WYBAZCX (SEQ ID NOS: 212-385)
wherein WYBAZCX is composed of the polypeptide segments shown in FIG. 30 (SEQ ID NOS: 185-211) wherein W comprises the polypeptide segment F (SEQ ID NO: 206), or is absent wherein Y comprises the polypeptide segment E (SEQ ID NO: 207), or is absent; wherein Z comprises the polypeptide segment G (SEQ ID NO: 210) or is absent; wherein X comprises the polypeptide segment C/D HKL (SEQ ID NO: 185), C/D H (SEQ ID NO: 186), C/D HL (SEQ ID NO: 187), C/D D (SEQ ID NO: 188), C/D′HL (SEQ ID NO: 189), C/D′HKL (SEQ ID NO: 190), C/D′H (SEQ ID NO: 191), C/D′D (SEQ ID NO: 192), C/D C/D′HKL (SEQ ID NO: 193), C/D C/D′H (SEQ ID NO: 194), C/D C/D′HL (SEQ ID NO: 195), C/D C/D′D (SEQ ID NO: 196), C/D D′H (SEQ ID NO: 197), C/D D′HL (SEQ ID NO: 198), C/D D′HKL (SEQ ID NO: 199), C/D′D′H (SEQ ID NO: 200), C/D′D′HL (SEQ ID NO: 201), C/D′D′HKL (SEQ ID NO: 202), C/D C/D′D′H (SEQ ID NO: 203), C/D C/D′D′HL (SEQ ID NO: 204), or C/D′D′HKL (SEQ ID NO: 205).
Furthermore, the invention includes a method of treating muscle cells by the application to the muscle cell of a
30 kD polypeptide factor isolated from the MDA-MB 231 human breast cell line; or 35 kD polypeptide factor isolated from the rat I-EJ transformed fibroblast cell line to the glial cell or 75 kD polypeptide factor isolated from the SKBR-3 human breast cell line; or 44 kD polypeptide factor isolated from the rat I-EJ transformed fibroblast cell line; or 25 kD polypeptide factor isolated from activated mouse peritoneal macrophages; or 45 kD polypeptide factor isolated from the MDA-MB 231 human breast cell; or 7 to 14 kD polypeptide factor isolated from the ATL-2 human T-cell line to the glial cell; or 25 kD polypeptide factor isolated from the bovine kidney cells; or 42 kD ARIA polypeptide factor isolated from brain; 46-47 kD polypeptide factor which stimulates 0-2A glial progenitor cells; or 43-45 kD polypeptide factor, GGFIII, 175 U.S. patent application Ser. No. 07/931,041, filed Aug. 17, 1992, incorporated herein by reference.
The invention further includes methods for the use of the EGFL1, EGFL2, EGFL3, EGFL4, EGFL5, and EGFL6 polypeptides, FIG. 37 to 42 and SEQ ID Nos. 150 to 155, respectively, for the treatment of muscle cells in vivo and in vitro.
Also included in the invention is the administration of the GGF2 polypeptide whose sequence is shown in FIG. 44 for the treatment of muscle cells.
An additional important aspect of the invention are methods for treating muscle cells using:
(a) a basic polypeptide factor also known to have glial cell mitogenic activity, in the presence of fetal calf plasma, a molecular weight of from about 30 kD to about 36 kD, and including within its amino acid sequence any one or more of the following peptide sequences:
F K G D A H T E (SEQ ID NO: 1)
A S L A D E Y E Y M X K (SEQ ID NO: 2)
T E T S S S G L X L K (SEQ ID NO: 3)
A S L A D E Y E Y M R K (SEQ ID NO: 7)
A G Y F A E X A R (SEQ ID NO: 11)
T T E M A S E Q G A (SEQ ID NO:13)
A K E A L A A L K (SEQ ID NO: 14)
F V L Q A K K (SEQ ID NO: 15)
E T Q P D P G Q I L K K V P M V I G A Y T (SEQ ID NO: 165)
E Y K C L K F K W F K K A T V M (SEQ ID NO: 17)
E X K F Y V P (SEQ ID NO: 19)
K L E F L X A K (SEQ ID NO: 32); and
(b) a basic polypeptide factor for use in treating muscle cells which is also known to stimulate glial cell mitogenesis in the presence of fetal calf plasma, has a molecular weight of from about 55 kD to about 63 kD, and including within its amino acid sequence any one or more of the following peptide sequences:
V H Q V W A A K (SEQ ID NO: 45)
Y I F F M E P E A X S S G (SEQ ID NO: 46)
L G A W G P P A F P V X Y (SEQ ID NO: 47)
W F V V I E G K (SEQ ID NO: 48)
A S P V S V G S V Q E L Q R (SEQ ID NO: 49)
V C L L T V A A L P P T (SEQ ID NO: 50)
K V H Q V W A A K (SEQ ID NO: 48)
K A S L A D S G E Y M X K (SEQ ID NO: 49)
D L L L X V (SEQ ID NO: 53)
Methods for the use of the peptide sequences set out above, derived from the smaller molecular weight polypeptide factor, and from the larger molecular weight polypeptide factor, are also aspects of this invention. Monoclonal antibodies to the above peptides are themselves useful investigative tools and therapeutics.
Thus, the invention further embraces methods of using a polypeptide factor having activities useful for treating muscle cells and including an amino acid sequence encoded by:
(a) a DNA sequence shown in any one of FIG. 27A , 27 B or 27 C, SEQ ID Nos. 129-131, respectively;
(b) a DNA sequence shown in FIG. 21 , SEQ ID No. 85;
(c) the DNA sequence represented by nucleotides 281-557 of the sequence shown in FIG. 27A , SEQ ID No. 129; or
(d) a DNA sequence hybridizable to any one of the DNA sequences according to (a), (b) or (c).
Following factors as muscle cell mitogens:
(a) a basic polypeptide factor which has, if obtained from bovine pituitary material, an observed molecular weight, whether in reducing conditions or not, of from about 30 kD to about 36 kD on SDS-polyacrylamide gel electrophoresis which factor has muscle cell mitogenic activity including stimulating the division of myoblasts, and when isolated using reversed-phase HPLC retains at least 50% of said activity after 10 weeks incubation in 0.1% trifluoroacetic acid at 4° C.; and
(b) a basic polypeptide factor which has, if obtained from bovine pituitary material, an observed molecular weight, under non-reducing conditions, of from about 55 kD to about 63 Kd on SDS-polyacrylamide gel electrophoresis which factor the human equivalent of which is encoded by DNA clone GGF2HBS5 and which factor has muscle cell mitogenic activity and when isolated using reversed-phase HPLC retains at least 50% of the activity after 4 days incubation in 0.1% trifluoroacetic acid at 4° C.
Thus other important aspects of the invention are the use of:
(a) A series of human and bovine polypeptide factors having cell mitogenic activity including stimulating the division of muscle cells. These peptide sequences are shown in FIGS. 30 , 31 , 32 and 33 , SEQ ID Nos. 132-133 respectively.
(b) A series of polypeptide factors having cell mitogenic activity including stimulating the division of muscle cells and purified and characterized according to the procedures outlined by Lupu et al. Science 249: 1552 (1990); Lupu et al. Proc. Natl. Acad. Sci. USA 89: 2287 (1992); Holmes et al. Science 256: 1205 (1992); Peles et al. 69: 205 (1992); Yarden and Peles Biochemistry 30: 3543 (1991); Dobashi et al. Proc. Natl. Acad. Sci. 88: 8582 (1991); Davis et al. Biochem. Biophys. Res. Commun. 179: 1536 (1991); Beaumont et al., patent application PCT/US91/03443 (1990); Bottenstein, U.S. Pat. No. 5,276,145, issued Jan. 4, 1994; and Greene et al. patent application PCT/US91/02331 (1990).
(c) A polypeptide factor (GGFBPP5) having glial cell mitogenic activity including stimulating the division of muscle cells. The amino acid sequence is shown in FIG. 31 , SEQ ID No. 144.
Methods for stimulating mitogenesis of a myoblast by contacting the myoblast cell with a polypeptide defined above as a muscle cell mitogen in vivo or in vitro are included as features of the invention.
Muscle cell treatments may also be achieved by administering DNA encoding the polypeptide compounds described above in an expressible genetic construction. DNA encoding the polypeptide may be administered to the patient using techniques known in the art for delivering DNA to the cells. For example, retroviral vectors, electroporation or liposomes may be used to deliver DNA.
The invention includes the use of the above named family of proteins as extracted from natural sources (tissues or cell lines) or as prepared by recombinant means.
Other compounds in particular, peptides, which bind specifically to the p185 erbB2 receptor can also be used according to the invention as muscle cell mitogens. A candidate compound can be routinely screened for p185 erbB2 binding, and, if it binds, can then be screened for glial cell mitogenic activity using the methods described herein.
The invention includes use of any modifications or equivalents of the above polypeptide factors which do not exhibit a significantly reduced activity. For example, modifications in which amino acid content or sequence is altered without substantially adversely affecting activity are included. The statements of effect and use contained herein are therefore to be construed accordingly, with such uses and effects employing modified or equivalent factors being part of the invention.
The human peptide sequences described above and 46 presented in FIGS. 30 , 31 , 32 and 33 , (SEQ ID Nos. 386, 388, 389, 391-413) respectively, represent a series of splicing variants which can be isolated as full length complementary DNAs (cDNAS) from natural sources (cDNA libraries prepared from the appropriate tissues) or can be assembled as DNA constructs with individual exons (e.g., derived as separate exons) by someone skilled in the art.
The invention also includes a method of making a medicament for treating muscle cells, i.e., for inducing muscular mitogenesis, myogenesis, differentiation, or survival, by administering an effective amount of a polypeptide as defined above. Such a medicament is made by administering the polypeptide with a pharmaceutically effective carrier.
Another aspect of the invention is the use of a pharmaceutical or veterinary formulation comprising any factor as defined above formulated for pharmaceutical or veterinary use, respectively, optionally together with an acceptable diluent, carrier or excipient and/or in unit dosage form. In using the factors of the invention, conventional pharmaceutical or veterinary practice may be employed to provide suitable formulations or compositions.
Thus, the formulations to be used as a part of the invention can be applied to parenteral administration, for example, intravenous, subcutaneous, intramuscular, intraorbital, ophthalmic, intraventricular, intracranial, intracapsular, intraspinal, intracisternal, intraperitoneal, topical, intranasal, aerosol, scarification, and also oral, buccal, rectal or vaginal administration.
The formulations of this invention may also be administered by the transplantation into the patient of host cells expressing the DNA encoding polypeptides which are effective for the methods of the invention or by the use of surgical implants which release the formulations of the invention.
Parenteral formulations may be in the form of liquid solutions or suspensions; for oral administration, formulations may be in the form of tablets or capsules; and for intranasal formulations, in the form of powders, nasal drops, or aerosols.
Methods well known in the art for making formulations are to be found in, for example, “Remington's Pharmaceutical Sciences.” Formulations for parenteral administration may, for example, contain as excipients sterile water or saline, polyalkylene glycols such as polyethylene glycol, oils of vegetable origin, or hydrogenated naphthalenes, biocompatible, biodegradable lactide polymer, or polyoxyethylene-polyoxypropylene copolymers may be used to control the release of the present factors. Other potentially useful parenteral delivery systems for the factors include ethylene-vinyl acetate copolymer particles, osmotic pumps, implantable infusion systems, and liposomes. Formulations for inhalation may contain as excipients, for example, lactose, or may be aqueous solutions containing, for example, polyoxyethylene-9-lauryl ether, glycocholate and deoxycholate, or may be oily solutions for administration in the form of nasal drops, or as a gel to be applied intranasally. Formulations for parenteral administration may also include glycocholate for buccal administration, methoxysalicylate for rectal administration, or citric acid for vaginal administration.
The present factors can be used as the sole active agents, or can be used in combination with other active ingredients, e.g., other growth factors which could facilitate neuronal survival in neurological diseases, or peptidase or protease inhibitors.
The concentration of the present factors in the formulations of the invention will vary depending upon a number of issues, including the dosage to be administered, and the route of administration.
In general terms, the factors of this invention may be provided in an aqueous physiological buffer solution containing about 0.1 to 10% w/v compound for parenteral administration. General dose ranges are from about 1 mg/kg to about 1 g/kg of body weight per day; a preferred dose range is from about 0.01 mg/kg to 100 mg/kg of body weight per day. The preferred dosage to be administered is likely to depend upon the type and extent of progression of the pathophysiological condition being addressed, the overall health of the patient, the make up of the formulation, and the route of administration.
The polypeptide factors utilized in the methods of the invention can also be used as immunogens for making antibodies, such as monoclonal antibodies, following standard techniques. These antibodies can, in turn, be used for therapeutic or diagnostic purposes. Thus, conditions perhaps associated with muscle diseases resulting from abnormal levels of the factor may be tracked by using such antibodies. In vitro techniques can be used, employing assays on isolated samples using standard methods. Imaging methods in which the antibodies are, for example, tagged with radioactive isotopes which can be imaged outside the body using techniques for the art of tumor imaging may also be employed.
A further general aspect of the invention is the use of a factor of the invention in the manufacture of a medicament, preferably for the treatment of a muscular disease or disorder. The “GGF2” designation is used for all clones which were previously isolated with peptide sequence data derived from GGF-II protein (i.e., GGF2HBS5, GGF2BPP3) and, when present alone (i.e., GGF2 or rhGGF2), to indicate recombinant human protein encoded by plasmids isolated with peptide sequence data derived from the GGF-II protein (i.e., as produced in insect cells from the plasmid HBS5). Recombinant human GGF from the GGFHBS5 clone is called GGF2, rhGGF2 and GGF2HBS5 polypeptide.
Treating as used herein means any administration of the compounds described herein for the purpose of increasing muscle cell mitogenesis, survival, and/or differentiation, and/or decreasing muscle atrophy and degeneration. Most preferably, the treating is for the purpose of reducing or diminishing the symptoms or progression of a disease or disorder of the muscle cells. Treating as used herein also means the administration of the compounds for increasing or altering the muscle cells in healthy individuals. The treating may be brought about by the contacing of the muscle cells which are sensitive or responsive to the compounds described herein with an effective amount of the compound, as described above. Inhibitors of the compounds described herein may also be used to halt or slow diseases of muscle cell proliferation.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings will first be described.
DRAWINGS
FIG. 1 is a graph showing the results of rhGGF2 in a myoblast mitogenesis assay.
FIG. 2 is a graph showing the effect of rhGGF2 on the number of nuclei in myotubes.
FIG. 3 is a graph of a survival assay showing the effect of rhGGF2 on survival of differentiated myotubes.
FIG. 4 is a graph of survival assays showing the effect of rhGGF2 on differentiated myotubes relative to human platelet derived growth factor, human fibroblast growth factor, human epidermal growth factor, human leucocyte inhibitory factor, and human insulin-like growth factors I and II.
FIG. 5 is a graph showing the increased survival on Duchenne muscular dystrophy cells in the presence of rhGGF2.
FIG. 6 is a graph of increasing human growth hormone (hGH) expression in C2 cells from an hGH reporter gene under control of the AchR delta subunit transcriptional control elements. This increase is tied to the addition of GGF2 to the media.
FIG. 7 is a graph of increasing hGH reporter synthesis and bungarotoxin (BTX) binding to AchR5 following the addition of increasing amounts of GGF2 to C2 cells.
FIGS. 8 , 9 , 10 and 11 are the peptide sequences derived from GGF-I and GGF-II, SEQ ID Nos. 1-20, 22-29, 32-50 and 165, (see Examples 11-13 hereinafter).
FIG. 8 shows the 21 peptide sequences (SEQ ID Nos 1-20, and 169) obtained from lysyl endopeptidase and protease V8 digestion of purified bovine pituitary GGF-I.
FIG. 9 , Panel A, is the sequences of GGF-I peptides used to design degenerate oligonucleotide probes and degenerate PCR primers are listed (SEQ ID Nos. 1, 17 and 22-29). Some of the sequences in Panel A were also used to design synthetic peptides. Panel B is a listing of the sequences of novel peptides that were too short (less than 6 amino acids) for the design of degenerate probes or degenerate PCR primers (SEQ ID Nos. 17 and 32);
FIG. 10 shows various trypsin and lysyl endopeptidase C are peptide sequences derived from GGF-II, SEQ ID Nos. 33-39, 164-166, 51-52.
FIG. 11 , Panel A, is a listing of the sequences of GGF-II peptides used to design degenerate oligonucleotide probes and degenerate PCR primers (SEQ ID Nos. 45-52). Some of the sequences in Panel A were used to design synthetic peptides. Panel B is a listing of the novel peptide that was too short (less than 6 amino acids) for the design of degenerate probes or degenerate PCR primers (SEQ ID No. 53);
FIGS. 12 , 13 A, 13 B, 14 , 15 , 16 , 17 , 18 , and 19 relate to Example 8, below, and depict the mitogenic activity of factors of the invention;
FIG. 12 shows a graph comparing BrUdR-ELISA and [ 125 I]UdR counting methods for the DNA synthesis assay in Schwann cell cultures.
FIGS. 13A and 13B show graphs comparing Br-UdR immunoreactivity with the number of Br-UdR labeled cells.
FIG. 14 shows the mitogenic response of rat sciatic nerve Schwann cells to GGFs.
FIG. 15 shows a graph quantifying DNA synthesis in rat sciatic nerve Schwann cells and 3T3 fibroblasts in the presence of GGFs.
FIG. 16 shows a graph of the mitogenic response of BHK 21 C13 cells to FCS and GGFs.
FIG. 17 shows a graph of survival and proliferation of BH 21 C13 cell micro cultures after 48 hours in the presence of GGFs.
FIG. 18 shows a graph of the mitogenic response of C6 cells to FCS.
FIGS. 19A and 19B are graphs showing the mitogenic response of C6 cells to aFGF and GGFs.
FIGS. 20 , 21 , 22 , 23 , 24 , 25 , 26 , and 27 relate to Example 10, below and are briefly described below
FIG. 20 is a listing of the degenerate oligonucleotide probes (SEQ ID Nos. 54-76, 78-88) designed from the novel peptide sequences in FIG. 7 , Panel A and FIG. 9 , Panel A;
FIG. 21 depicts a stretch of the putative bovine GGF-II gene sequence from the recombinant bovine genomic phage GGF2BG1, containing the binding site of degenerate oligonucleotide probes 609 and 650 (see FIG. 20 , SEQ ID NOs. 66 and 69, respectively). The figure is the coding strand of the DNA sequence (SEQ ID NO. 89) educed amino acid sequence (SEQ. ID NO: 385) in the third reading frame. The sequence of peptide 12 from factor 2 (bold) is part of a 66 amino acid open reading frame (nucleotides 75272);
FIG. 22A shows the degenerate PCR primers (SEQ ID Nos. 86-124) and FIG. 22B shows the unique PCR primers (SEQ ID Nos. 105-115) used in experiments to isolate segments of the bovine GGF-II coding sequences present in RNA from posterior pituitary;
FIG. 23 depicts of the nine distinct contiguous bovine GGF-II cDNA structures and sequences that were obtained in PCR amplification experiments. The top line of the Figure is a schematic of the coding sequences which contribute to the cDNA structures that were characterized;
FIG. 24 is a physical map of bovine recombinant phage of GGF2BG1. The bovine fragment is roughly 20 kb in length and contains two exons (bold) of the bovine GGF-II gene. Restriction sites for the enzymes Xbal, SpeI, Ndel, EcoRI, Kpnl, and SstI have been placed on this physical map. Shaded portions correspond to fragments which were subcloned for sequencing;
FIG. 25 is a schematic of the structure of three alternative gene products of the putative bovine GGF-II gene. Exons are listed A through E in the order of their discovery. The alternative splicing patterns 1, 2 and 3 generate three overlapping deduced protein structures (GGF2BPP1, 2, and 3), which are displayed in the various FIGS. 27A , 27 B, 27 C (described below)
FIG. 26 (SEQ ID Nos. 116-128, 45, 52, and 53 is a comparison of the GGF-I and GGF-II sequences identified in the deduced protein sequences shown in FIGS. 27A , 27 B, 27 C (described below) with the novel peptide sequences listed in FIGS. 9 and 11 . The Figure shows that six of the nine novel GGF-II peptide sequences are accounted for in these deduced protein sequences. Two peptide sequences similar to GGF-I sequences are also found;
FIG. 27A is a listing of the coding strand DNA sequence (SEQ ID No:133) and deduced amino acid sequence (SEQ ID No:384) cDNA obtained from splicing pattern number 1 in FIG. 25 . This partial cDNA of the putative bovine GGF-II gene encodes a protein of 206 amino acids in length. Peptides in bold were those identified from the lists presented in FIGS. 9 and 11 . Potential glycosylation sites are underlined (along with polyadenylation signal AATAAA (SEQ ID No: 420);
FIG. 27(B-C) is a listing of the coding strand DNA sequence (SEQ ID NO:134) and deduced amino acid sequence “SEQ ID No:385” cDNA obtained from splicing pattern number 2 in FIG. 25 . This partial cDNA of the putative bovine GGF-II gene encodes a protein of 281 amino acids in length. Peptides in bold are those identified from the lists presented in FIGS. 7 and 9 . Potential glycosylation sites are underlined (along with polyadenylation signal AATAAA SEQ ID NO:420);
FIG. 27(D-E) is a listing of the coding strand DNA sequence (SEQ ID NO:135) and deduced amino acid sequence SEQ ID NO:387 cDNA obtained from splicing pattern number 3 in FIG. 25 . This partial cDNA of the putative bovine GGF-II gene encodes a protein of 257 amino acids in length. Peptides in bold are those identified from the lists in FIGS. 9 and 11 . Potential glycosylation sites are underlined (along with polyadenylation signal AATAAA SEQ ID NO:420).
FIG. 28 , which relates to Example 15 hereinafter, is an autoradiogram of a cross hybridization analysis of putative bovine GGF-II gene sequences to a variety of mammalian DNAs on a southern blot. The filter contains lanes of EcoRI-digested DNA (5 μg per lane) from the species listed in the Figure. The probe detects a single strong band in each DNA sample, including a four kilobase fragment in the bovine DNA as anticipated by the physical map in FIG. 24 . Bands of relatively minor intensity are observed as well, which could represent related DNA sequences. The strong hybridizing band from each of the other mammalian DNA samples presumably represents the GGF-II homologue of those species.
FIG. 29 is a diagram of representative splicing variants. The coding segments are represented by F, E, B, A, G, C, C/D, C/D′, D, D′, H, K and L. The location of the peptide sequences derived from purified protein are indicated by “o”.
FIG. 30(A-R) is a listing of the DNA sequences (SEQ ID Nos: 77, 136-147, 160, 161, 173-182, 388-411) sequences (SEQ ID NOS: 391-413) of the coding segments of GGF. Line 1 is a listing of the predicted amino acid sequences of bovine GGF, line 2 is a listing of the nucleotide sequences of bovine GGF, line 3 is a listing of the nucleotide sequences of human GGF (heregulin) (nucleotide base matches are indicated with a vertical line) and line 4 is a listing of the predicted amino acid sequences of human GGF/heregulin where it differs from the predicted bovine sequence. Coding segments E, A′ and K represent only the bovine sequences. Coding segment D′ represents only the human (heregulin) sequence.
FIG. 31(A-B) is the predicted GGF2 amino acid sequence and nucleotide sequence of BPP5 (SEQ ID Nos:389 and SEQ ID No: 148, respectively) line is the nucleotide sequence and the lower line is the predicted amino acid sequence.
FIG. 32(A-B) is the predicted amino acid sequence and nucleotide sequence of GGF2BPP2 (SEQ ID No:149 and SEQ ID No:386, respectively) line is the nucleotide sequence and the lower line is the predicted amino acid sequence.
FIG. 33(A-C) is the predicted amino acid sequence and nucleotide sequence of GGF2BPP4(SEQ ID No:388 and SEQ ID No:150 respectively). The upper line is the nucleotide sequence and the lower line is the predicted amino acid sequence.
FIG. 34 (SEQ ID Nos. 147-149) depicts the alignment of two GGF peptide sequences (GGF2BPP4 and GGF2BPP5) with the human EGF (hEGF). Asterisks indicate positions of conserved cysteines.
FIG. 35 depicts the level of GGF activity (Schwann cell mitogenic assay) and tyrosine phosphorylation of a ca. 200 kD protein (intensity of a 200 kD band on an autoradiogram of a Western blot developed with an antiphosphotyrosine polyclonal antibody) in response to increasing amounts of GGF.
FIG. 36(A-B) is a list of splicing variants derived from the sequences shown in FIG. 30(A-R) .
FIG. 37 is the predicted amino acid sequence, bottom, (SEQ ID No:414) and nucleic sequence, top, of EGFL1 (SEQ ID No. 150).
FIG. 38 is the predicted amino acid sequence, bottom, (SEQ ID NO:415) and nucleic sequence, top, of EGFL2 (SEQ ID No. 151).
FIG. 39 is the predicted amino acid sequence, bottom, (SEQ ID NO:416) sequence, top, of EGFL3 (SEQ ID No. 152).
FIG. 40 is the predicted amino acid sequence, bottom, (SEQ ID NO:417) and nucleic sequence, top, of EGFL4 (SEQ ID No. 153).
FIG. 41 the predicted amino acid sequence, bottom, (SEQ ID NO:418) and nucleic sequence, top, of EGFL5 (SEQ ID No. 154).
FIG. 42 is the predicted amino acid sequence, bottom, (SEQ ID No:419) and nucleic sequence, top, of EGFL6 (SEQ ID No:155).
FIG. 43 is a scale coding segment map of the clone. T3 refers to the bacteriophage promoter used to produce mRNA from the clone. R=flanking EcoRI restriction enzyme sites. 5′ UT refers to the 5′ untranslated region. E, B, A, C, C/D′, and D refer to the coding segments. O=the translation start site. Λ=the 5′ limit of the region homologous to the bovine E segment (see Example 16) and 3′ UT refers to the 3′ untranslated region.
FIG. 44(A-D) is the predicted amino acid sequence (middle) (SEQ ID No: 170) and nucleic sequence (top) of GGF2HBS5 (SEQ ID No. 21). The bottom (intermittent) sequence represents peptide sequences derived from GGF-II preparations (see FIGS. 8 , 9 ).
FIG. 45 (A) is a graph showing the purification of rGGF on cation exchange column by fraction; FIG. 45(B-C) is a photograph of a Western blot using fractions as depicted in (A) and a GGFII specific antibody.
FIG. 46 is the sequence of the GGFHBS5, GGFHFB1 and GGFBPP5 polypeptides (SEQ ID NOS: 166, 167, and 168, respectively).
FIG. 47 is a map of the plasmid pcDHRFpolyA.
DETAILED DESCRIPTION
The invention pertains to the use of isolated and purified neuregulin factors and DNA sequences encoding these factors, regulatory compounds which increase the extramuscular concentrations of these factors, and compounds which are mimetics of these factors for the induction of muscle cell mitogenesis, differentiation, and survival of the muscle cells in vivo and in vitro.
It is evident that the gene encoding GGF/p185 erbB2 binding neuregulin proteins produces a number of variably-sized, differentially-spliced RNA transcripts that give rise to a series of proteins. These proteins are of different lengths and contain some common peptide sequences and some unique peptide sequences. The conclusion that these factors are encoded by a single gene is supported by the differentially-spliced RNA sequences which are recoverable from bovine posterior pituitary and human breast cancer cells (MDA-MB-231)). Further support for this conclusion derives from the size range of proteins which act as both mitogens for muscle tissue (as disclosed herein) and as ligands for the p185 erbB2 receptor (see below).
Further evidence to support the fact that the genes encoding GGF/p185 erbB2 binding proteins are homologous comes from nucleotide sequence comparison. Holmes et al., (Science 256:1205-1210, 1992) demonstrate the purification of a 45-kilodalton human protein (Heregulin-α) which specifically interacts with the receptor protein p185 erbB2 . Peles et al. (Cell 69:205 (1992)) and Wen et al. (Cell 69:559 (1992)) describe a complementary DNA isolated from rat cells encoding a protein called “neu differentiation factor” (NDF). The translation product of the NDF cDNA has p185 erbB2 binding activity. Several other groups have reported the purification of proteins of various molecular weights with p185 erbB2 binding activity. These groups include Lupu et al. ((1992) Proc. Natl. Acad. Sci. USA 89:2287); Yarden and Peles ((1991) Biochemistry 30:3543); Lupu et al. ((1990) Science 249:1552)); Dobashi et al. ((1991) Biochem. Biophys. Res. Comm. 179:1536); and Huang et al. ((1992) J. Biol. Chem. 257:11508-11512).
We have found that p185 erbB2 receptor binding proteins stimulate muscle cell mitogenesis and hence, stimulates myotube formation (myogenesis). This stimulation results in increased formation of myoblasts and increased formation of myotubes (myogenesis). The compounds described herein also stimulate increased muscle growth, differentiation, and survival of muscle cells. These ligands include, but are not limited to the GGF's, the neuregulins, the heregulins, NDF, and ARIA. As a result of this mitogenic activity, these proteins, DNA encoding these proteins, and related compounds may be administered to patients suffering from traumatic damage or diseases of the muscle tissue. It is understood that all methods provided for the purpose of mitogenesis are useful for the purpose of myogenesis. Inhibitors of these ligands (such as antibodies or peptide fragments) may be administered for the treatment of muscle derived tumors.
These compounds may be obtained using the protocols described herein (Examples 9-17) and in Holmes et al., Science 256: 1205 (1992); Peles et al., Cell 69:205 (1992); Wen et al., Cell 69:559 (1992); Lupu et al., Proc. Natl. Acad. Sci. USA 89:2287 (1992); Yarden and Peles, Biochemistry 30:3543 (1991); Lupu et al., Science 249:1552 (1990); Dobashi et al., Biochem. Biophys. Res. Comm. 179:1536 (1991); Huang et al., J. Biol. Chem. 257:11508-11512 (1992); Marchionai et. al., Nature 362:313, (1993); and in the GGF-III application (U.S. Ser. No. 07/931,041) of which are incorporated herein by reference. The sequences are provided and the characteristics described for many of these compounds. For sequences see FIGS. 8-11 , 20 - 27 C, 29 - 34 , 36 - 44 , and 46 . For protein characteristics see FIGS. 12-19 , 28 - 35 , 45 A and 45 B.
Compounds may be assayed for their usefulness in vitro using the methods provided in the examples below. In vivo testing may be performed as described in Example 1 and in Sklar et al., In Vitro Cellular and Developmental Biology 27A:433-434, 1991.
OTHER EMBODIMENTS
The invention includes methods for the use of any protein which is substantia homologous to the coding segments in FIG. 30 (SEQ ID Nos: 132-143, 156, and 157) as well as other naturally occurring GGF polypeptides for the purpose of inducing muscle mitogenesis. Also included are the use of: allelic variations; natural mutants; induced mutants; proteins encoded by DNA that hybridizes under high or low stringency conditions to a nucleic acid naturally occurring (for definitions of high and low stringency see Current Protocols in Molecular Biology, John Wiley & Sons, New York, 1989, 6.3.1-6.3.6, hereby incorporated by reference); and the use of polypeptides or proteins specifically bound by antisera to GGF polypeptides. The term also includes the use of chimeric polypeptides that include the GGF polypeptides comprising sequences from FIG. 28 for the induction of muscle mitogenesis.
As will be seen from Example 8, below, the present factors exhibit mitogenic activity on a range of cell types. The general statements of invention above in relation to formulations and/or medicaments and their manufacture should clearly be construed to include appropriate products and uses.
A series of experiments follow which provide additional basis for the claims described herein. The following examples relating to the present invention should not be construed as specifically limiting the invention, or such variations of the invention, now known or later developed.
The examples illustrate our discovery that recombinant human GGF2 (rhGGF2) confers several effects on primary human muscle culture. rhGGF2 has significant effects in three independent biological activity assays on muscle cultures. The polypeptide increased mitogenesis as measured by proliferation of subconfluent quiescent myoblasts, increased differentiation by confluent myoblasts in the presence of growth factor, and increased survival of differentiated myotubes as measured by loss of dye exclusion and increased acetylcholine receptor synthesis. These activities indicate efficacy of GGF2 and other neuregulins in inducing muscle repair, regeneration, and prophylactic effects on muscle degeneration.
EXAMPLE 1
Mitogenic Activity of rhGGF on Myoblasts
Clone GGF2HBS5 was expressed in recombinant Baculovirus infected insect cells as described in Example 13, infra, and the resultant recombinant human GGF2 was added to myoblasts in culture (conditioned medium added at 40 μl/ml). Myoblasts (057A cells) were grown to preconfluence in a 24 well dish. Medium was removed and replaced with DMEM containing 0.5% fetal calf serum with or without GGF2 conditioned medium at a concentration of 40 μl/ml. Medium was changed after 2 days and cells were fixed and stained after 5 days. Total nuclei were counted as were the number of nuclei in myoblasts (Table 1).
TABLE 1 Total Number Nuclei in Fusion Treatment of Nuclei/mm 2 Myotubes Index Control 395 ± 28.3 204 ± 9.19 0.515 ± 0.01 GGF 40 μl/ml 636 ± 8.5 381 ± 82.7 0.591 ± 0.15
GGF treated myoblasts showed an increased number of total nuclei (636 nuclei) over untreated controls (395 nuclei) indicating mitogenic activity. rhGGF2 treated myotubes had a greater number of nuclei (381 nuclei) than untreated controls (204 nuclei). Thus, rhGGF2 enhances the total number of nuclei through proliferation and increased cell survival. rhGGF2 is also likely to enhance the formation of myotubes.
The mitogenic activity of rhGGF2 may be measured in vivo by giving a continuous supply of GGF2 and [ 3 H]thymidine to rat muscle via an osmotic mini pump. The muscle bulk is determined by wet weight after one and two weeks of treatment. DNA replication is measured by counting labeled nuclei in sections after coating for autoradiography (Sklar et al., In Vitro Cellular and Developmental Biology 27A:433-434, 1991) in sham and rhGGF2-treated muscle. Denervated muscle is also examined in this rat animal model via these methods and this method allows the assessment of the role of rhGGF2 in muscle atrophy and repair. Mean fiber diameter can also be used for assessing effects of FGF on prevention of atrophy.
EXAMPLE 2
Effect of rhGGF2 on Muscle Cell Mitogenesis
Quiescent primary clonal human myoblasts were prepared as previously described (Sklar, R., Hudson, A., Brown, R., In vitro Cellular and Developmental Biology 1991; 27A:433-434). The quiescent cells were treated with the indicated agents (rhGGF2 conditioned media, PDGF with and without methylprednisolone, and control media) in the presence of 10 μM BrdU, 0.5% FCS in DMEM. After two days the cells were fixed in 4% paraformaldehyde in PBS for 30 minutes, and washed with 70% ethanol. The cells were then incubated with an anti-BrdU antibody, washed, and antibody binding was visualized with a peroxidase reaction. The number of staining nuclei were then quantified per area. The results show that GGF2 induces an increase in the number of labelled nuclei per area over controls (see Table 2).
TABLE 2 Mitogenic Effects of GGF on Human Myoblasts Labelled T-Test Treatment Nuclei/cm 2 p value Control 120 ± 22.4 Infected Control 103 ± 11.9 GGF 5 μl/ml 223 ± 33.8 0.019 PDGF 20 ng/ml 418 ± 45.8 0.0005 IGFI 30 ng/ml 280 ± 109.6 0.068 Methylprednisolone 1.0 μM 142 ± 20.7 0.293
Platelet derived growth factor (PDGF) was used as a positive control. Methylprednisolone (a corticosteroid) was also used in addition to rhGGF2 and showed no significant increase in labelling of DNA.
rhGGF2 purified to homogeneity (>95% pure) is also mitogenic for human myoblasts ( FIG. 1 ).
Recombinant human GGF2 also causes mitogenesis of primary human myoblasts (see Table 2 and FIG. 1 ). The mitogenesis assay is performed as described above. The mitotic index is then calculated by dividing the number of BrdU positive cells by the total number of cells.
EXAMPLE 3
Effect of rhGGF2 on Muscle Cell Differentiation
The effects of purified rhGGF2 (95% pure) on muscle culture differentiation were examined ( FIG. 2 ). Confluent myoblast cultures were induced to differentiate by lowering the serum content of the culture medium from 20% to 0.5%. The test cultures were treated with the indicated concentration of rhGGF2 for six days, refreshing the culture medium every 2 days. The cultures were then fixed, stained, and the number of nuclei counted per millimeter. The data in FIG. 2 demonstrate a large increase in the number of nuclei in myotubes when rhGGF2 is present, relative to controls.
EXAMPLE 4
Effect of rhGGF2 on the Survival of Differentiated Myotubes
The survival of differentiated myotubes was significantly increased by rhGGF2 treatment. Muscle cultures were differentiated in the presence of rhGGF2 and at various times the number of dead myotubes were counted by propidium iodide staining. As can be seen in FIG. 3 , the number of dead myotubes is lower in the rhGGF2 treated culture at 4, 5, 6, and 8 days of differentiation. The number of nuclei in myotubes was significantly increased by GGF2 treatment compared to untreated cultures after 8 days of differentiation. Specifically, the control showed 8.6 myonuclei/mm 2 , while rhGGF2 treated cultures showed 57.2 myonuclei/mm 2 (p=0.035) when counted on the same plates after geimsa staining.
The survival assay was also performed with other growth factors which have known effects on muscle culture. The rhGGF2 effect was unique among the growth factors tested ( FIG. 4 ). In this experiment cultures were treated in parallel with the rhGGF2 treated plates with the indicated concentrations of the various growth factors. Survival of myotubes was measured as above at 8 days of differentiation of 057A myoblast cells. Concentrations of factors were as follows: rhGGF2: 100 ng/ml; human platelet derived growth factor: 20 ng/ml; human basic fibroblast growth factor: 25 ng/ml; human epidermal growth factor: 30 ng/ml; human leucocyte inhibitory factor: 10 ng/ml; human insulin like growth factor I: 30 ng/ml; human insulin like growth factor II: 25 ng/ml.
The observed protection of differentiated myotubes from death indicates that rhGGF2 has promise as a therapy for intervention of muscle degeneration characterized by numerous muscle diseases. Thus, agents which increase the extramuscular concentration of neuregulins may have a prophylactic effect or slow the progress of muscle-wasting disorders and increase rates of muscle differentiation, repair, conditioning, and regeneration.
EXAMPLE 5
rhGGF2 Promotes Survival of Differentiated Myotubes with a Genetic Defect at the Duchenne Muscular Dystrophy Locus
The positive effects of rhGGF2 on myotube survival could reflect potential efficacy in degenerative disorders. These effects on myotube survival were tested on a clonally-derived primary Duchenne myoblast to determine if the response observed in normal muscle culture could also be demonstrated in cultures derived from diseased individuals. The data presented in FIG. 5 was obtained using the same muscle culture conditions (Example 4, above) used for normal individual. rhGGF2 significantly decreased the number of dead myotubes in the differentiated Duchenne muscle culture, compared to controls (p=0.032). Concentrations were as follows: GGF2: 100 ng/ml; human platelet derived growth factor: 20 ng/ml; human insulin like growth factor I: 30 ng/ml.
This example demonstrates that rhGGF2 can also promote survival of differentiated Duchenne myotubes and provides strong evidence that rhGGF2 may slow or prevent the course of muscle degeneration and wasting in mammals.
EXAMPLE 6
rhGGF2 Effect on the Differentiation Program: Induction of MHC Slow and Dystrophin Proteins
The effects of purified rhGGF2 on muscle culture differentiation was also examined by Western analysis of culture lysates. The levels of muscle specific proteins were determined in triplicate treated and untreated cultures. These cultures were prepared and treated as above except that the plate size was increased to 150 mm and the muscle culture layer was scraped off for Western analysis as described in Sklar, R., and Brown, R. ( J. Neurol. Sci. 101:73-81, 1991). The results presented in Table A indicate that rhGGF2 treatment increases the levels of several muscle specific proteins, including dystrophin, myosin heavy chain (MHC, adult slow and fast isoforms), but does not increase the levels of HSP72 or MHC neonate isoform to a similar level per amount of protein loaded on the Western. The levels of muscle specific proteins induced by rhGGF2 were similar to the quantitative increases in the number of myonuclei/mm 2 (Table 3).
TABLE 3
Control ±
rhGGF2 Treat-
p-
SD
ment ± SD
value
Total Protein (μg)
554 ± 38.4
798 ± 73.6
0.007
Myonuclei/mm 2
29.0 ± 12.2
106 ± 24.1
0.008
MHC fast/μg protein
1.22 ± 0.47
4.00 ± 0.40
0.001
MHC slow/μg protein
0.17 ± 0.13
1.66 ± 0.27
0.001
MHC neonate/μg protein
0.30 ± 0.27
0.55 ± 0.04
0.199
dystrophin/μg protein
6.67 ± 0.37
25.5 ± 11.0
0.042
HSP 72/μg protein
3.30 ± 0.42
4.54 ± 0.08
0.008
The rhGGF2 dependent increase in the adult myosin heavy chain isoforms (slow is found in type I human muscle fibers; fast is found in type 2A and 2B human muscle fibers) may represent a maturation of the myotubes, as the neonatal isoform was not significantly increased by rhGGF2 treatment.
During rat muscle development MHC isoforms switch from fetal to neonatal forms followed by a switch to mature adult slow and fast MHC isoforms (Periasamy et al. J. Biol. Chem. 259:13573-13578, 1984; Periasamy et al. J. Biol. Chem. 260:15856-15862, 1985; Wieczorek et al. J. Cell Biol. 101:618-629, 1985). While muscle can autonomously undergo some of these isoform transitions in the absence of neural cells or tissue, mouse muscle explants express the adult fast MHC isoform only when cultured in the presence of mouse spinal cord (Ecob-Prince et al. J. Cell Biol. 103:995-1005, 1986). Additional evidence that MHC isoform transitions are influenced by nerve was established by Whalen et al. ( Deve. Biol. 141:24-40, 1990); after regeneration of notexin treated rat soleus muscles only the adult fast MHC isoform was produced in the new denervated muscle, but innervated regenerated muscle made both fast and slow adult MHC isoforms. Thus the demonstration in Table 3 that rhGGF2 increases the synthesis of adult MHC isoforms indicates that rhGGF2 may induce a developmental maturation of muscle which may mimic neuronal innervation.
EXAMPLE 7
Neuregulins, Including rhGGF2, Induce the Synthesis of Acetylcholine Receptors in Muscle
The expression of acetylcholine receptor (AchR) subunit proteins can be induced by exposing muscle cells to neuregulins. More specifically, we have shown that contacting muscle cells with rhGGF2 can induce the synthesis of AchR subunit proteins. This induction following rhGGF2 exposure was observed in two ways: first, we detected increased expression of human growth hormone via the product of a reporter gene construct and second we detected increased binding of alpha-bungarotoxin to cells.
In the following example a mouse myoblast cell line C2 was used. C2 cells were transfected with a transgene that contained the 5′ regulatory sequences of the AChR delta subunit gene of mouse linked to a human growth hormone full-length cDNA (Baldwin and Burden, 1988. J. Cell Biol. 107:2271-2.279). This reporter construct allows the measurement of the induction of AChR delta gene expression by assaying the quantity of growth hormone secreted into the media. The line can be induced to form myotubes by lowering serum concentration in the media from 20% to 0.5%.
Specifically, mouse C2 myoblasts transfected with an AChR-human growth hormone reporter construct and were assayed for expression of hGH following treatment with rhGGF2. The results of two separate experiments are summarized in Table 4 and in FIGS. 6 (hGH expression) and 7 (hGH expression and alpha-bungarotoxin binding). Shown are the dose response curves for secreted human growth hormone and for bungarotoxin binding from muscle cultures treated with rhGGF2.
TABLE 4
Effects of rhGGF2 on the expression of AChR delta
subunit/hGH transgene and the synthesis of AChR
Exp 1
Exp 2
GGF
hGH
hGH
AChR
(ul)
(ng/ml)
(ng/ml)
(cpm/mg protein)
0
9.3 + 2.1
5.7 + 2.1
822 + 170
0.1
—
6.8 + 1.5
891 + 134
0.5
—
12.0 + 0.9
993 + 35
1.0
—
9.7 + 2.3
818 + 67
5.0
17.5 + 2.8
14.7 + 3.5
1300 + 177
10.0
14.3 + 3.2
14.1 + 3.3
1388 + 137
15.0
22.0 + 1.4
—
—
C2 myotubes were treated with cold A-BTX (20 nM) for 1 hr. at 37° C., washed with culture medium twice and then treated with GGF2. Culture medium was adjusted with bovine serum albumin at the concentration of 1 mg/ml. 24 hours later, culture medium was removed and saved for hGH assay. Muscle cultures were treated with 125 I-α-BTX (20 nM) for 1 hour at 37° C., washed and scraped in PBS containing 1% SDS. Non-specific binding was determined in the presence of cold α-BTX (40 nM). The cell homogenate was counted for radioactivity and assayed for total protein amount.
The presence of rhGGF2 led to a greater than 2-fold increase in hGH gene expression, thereby indicating that rhGGF2 induced the synthesis of the delta subunit of the acetylcholine receptor. Furthermore, increased bungarotoxin binding is consistant with assembly of these subunit proteins into functional acetylcholine receptors. To strengthen the interpretation of these data the analysis was repeated on cultures that had the hGH reporter linked to a metallothiene promoter, which should not be responsive to rhGGF2. The results of that control experiment showed that the hGH response was mediated through transcriptional activation of the AchR delta subunit gene control elements.
These results indicate that rhGGF2 could be useful in replenishing AchRs as part of the therapy for the autoimmune disease Myasthenia gravis. This activity may also be beneficial in treatment of peripheral nerve regeneration and neuropathy by stimulating a key step in re-innervation of muscle.
EXAMPLE 8
Additional Mitogenic Activities of Purified GGF-I and GGF-II
The mitogenic activity of a highly purified sample containing both GGFs I and II was studied using a quantitative method, which allows a single microculture to be examined for DNA synthesis, cell morphology, cell number and expression of cell antigens. This technique has been modified from a method previously reported by Muir et al., Analytical Biochemistry 185, 377-382, 1990. The main modifications are: 1) the use of uncoated microtiter plates, 2) the cell number per well, 3) the use of 5% Foetal Bovine Plasma (FBP) instead of 10% Foetal Calf Serum (FCS), and 4) the time of incubation in presence of mitogens and bromodeoxyuridine (BrdU), added simultaneously to the cultures. In addition the cell monolayer was not washed before fixation to avoid loss of cells, and the incubation time of monoclonal mouse anti-BrdU antibody and peroxidase conjugated goat anti-mouse immunoglobulin (IgG) antibody were doubled to increase the sensitivity of the assay. The assay, optimized for rat sciatic nerve Schwann cells, has also been used for several cell lines, after appropriate modifications to the cell culture conditions.
I. Methods of Mitogenesis Testing
On day 1, purified Schwann cells were plated onto uncoated 96 well plates in 5% FBP/Dulbecco's Modified Eagle Medium (DMEM) (5,000 cells/well). On day 2, GGFs or other test factors were added to the cultures, as well as BrdU at a final concentration of 10 μm. After 48 hours (day 4) BrdU incorporation was terminated by aspirating the medium and cells were fixed with 200 μl/well of 70% ethanol for 20 min at room temperature. Next, the cells were washed with water and the DNA denatured by incubation with 100 μl 2N HCl for 10 min at 37° C. Following aspiration, residual acid was neutralized by filling the wells with 0.1 M borate buffer, pH 9.0, and the cells were washed with phosphate buffered saline (PBS). Cells were then treated with 50 μl of blocking buffer (PBS containing 0.1% Triton X 100 and 2% normal goat serum) for 15 min at 37° C. After aspiration, monoclonal mouse anti-BrdU antibody (Dako Corp., Santa Barbara, Calif.) (50 μl/well, 1.4 μg/ml diluted in blocking buffer) was added and incubated for two hours at 37° C. Unbound antibodies were removed by three washes in PBS containing 0.1% Triton X-100 and peroxidase-conjugated goat anti-mouse IgG antibody (Dako Corp., Santa Barbara, Calif.) (50 μl/well, 2 μg/ml diluted in blocking buffer) was added and incubated for one hour at 37° C. After three washes in PBS/Triton and a final rinse in PBS, wells received 100 μl/well of 50 mM phosphate/citrate buffer, pH 5.0, containing 0.05% of the soluble chromogen o-phenylenediamine (OPD) and 0.02% H 2 O 2 . The reaction was terminated after 5-20 min at room temperature, by pipetting 80 μl from each well to a clean plate containing 40 μl/well of 2N sulfuric acid. The absorbance was recorded at 490 nm using a plate reader (Dynatech Labs). The assay plates containing the cell monolayers were washed twice with PBS and immunocytochemically stained for BrdU-DNA by adding 100 μl/well of the substrate diaminobenzidine (DAB) and 0.02% H 2 O 2 to generate an insoluble product. After 10-20 min the staining reaction was stopped by washing with water, and BrdU-positive nuclei observed and counted using an inverted microscope. Occasionally, negative nuclei were counterstained with 0.001% Toluidine blue and counted as before.
II. Cell Lines Used for Mitogenesis Assays
Swiss 3T3 Fibroblasts: Cells, from Flow Labs, were maintained in DMEM supplemented with 10% FCS, penicillin and streptomycin, at 37° C. in a humidified atmosphere of 10% CO 2 in air. Cells were fed or subcultured every two days. For mitogenic assay, cells were plated at a density of 5,000 cells/well in complete medium and incubated for a week until cells were confluent and quiescent. The serum containing medium was removed and the cell monolayer washed twice with serum free-medium. 100 μl of serum free medium containing mitogens and 10 μM of BrdU were added to each well and incubated for 48 hours. Dose responses to GGFs and serum or PDGF (as a positive control) were performed.
BHK (Baby Hamster Kidney) 21 C13 Fibroblasts: Cells from European Collection of Animal Cell Cultures (ECACC), were maintained in Glasgow Modified Eagle Medium (GMEM) supplemented with 5% tryptose phosphate broth, 5% FCS, penicillin and streptomycin, at 37° C. in a humidified atmosphere of 5% CO 2 in air. Cells were fed or subcultured every two to three days. For mitogenic assay, cells were plated at a density of 2,000 cell/well in complete medium for 24 hours. The serum containing medium was then removed and after washing with serum free medium, replaced with 100 μl of 0.1% FCS containing GMEM or GMEM alone. GGFs and FCS or bFGF as positive controls were added, coincident with 10 μM BrdU, and incubated for 48 hours. Cell cultures were then processed as described for Schwann cells.
C6 Rat Glioma Cell Line: Cells, obtained at passage 39, were maintained in DMEM containing 5% FCS, 5% Horse serum (HS), penicillin and streptomycin, at 37° C. in a humidified atmosphere of 10% CO 2 in air. Cells were fed or subcultured every three days. For mitogenic assay, cells were plated at a density of 2,000 cells/well in complete medium and incubated for 24 hours. Then medium was replaced with a mixture of 1:1 DMEM and F12 medium containing 0.1% FCS, after washing in serum free medium. Dose responses to GGFs, FCS and AFGF were then performed and cells were processed through the ELISA as previously described for the other cell types.
PC12 (Rat Adrenal Pheochromocytoma Cells): Cells from ECACC, were maintained in RPMI 1640 supplemented with 10% HS, 5% FCS, penicillin and streptomycin, in collagen coated flasks, at 37° C. in a humidified atmosphere of 5% CO 2 in air. Cells were fed every three days by replacing 80% of the medium. For mitogenic assay, cells were plated at a density of 3,000 cells/well in complete medium, on collagen coated plates (50 μl/well collagen, Vitrogen Collagen Corp., diluted 1:50, 30 min at 37° C.) and incubated for 24 hours. The medium was then placed with fresh RPMI either alone or containing 1 mM insulin or 1% FCS. Dose responses to FCS/HS (1:2) as positive control and to GGFs were performed as before. After 48 hours cells were fixed and the ELISA performed as previously described.
III. Results of Mitogenesis Assays: All the experiments presented in this Example were performed using a highly purified sample from a Sepharose 12 chromatography purification step containing a mixture of GGF-I and GGF-II (GGFs).
First, the results obtained with the BrdU incorporation assay were compared with the classical mitogenic assay for Schwann cells based on [125]I-UdR incorporation into DNA of dividing cells, described by J. P. Brockes ( Methods Enzymol. 147:217, 1987).
FIG. 12 shows the comparison of data obtained with the two assays, performed in the same cell culture conditions (5,000 cells/well, in 5% FBP/DMEM, incubated in presence of GGFs for 48 hrs). As clearly shown, the results are comparable, but BrdU incorporation assay appears to be slightly more sensitive, as suggested by the shift of the curve to the left of the graph, i.e. to lower concentrations of GGFS.
As described under the section “Methods of Mitogenesis Testing”, after the immunoreactive BrdU-DNA has been quantitated by reading the intensity of the soluble product of the OPD peroxidase reaction, the original assay plates containing cell monolayers can undergo the second reaction resulting in the insoluble DAB product, which stains the BrdU positive nuclei. The microcultures can then be examined under an inverted microscope, and cell morphology and the numbers of BrdU-positive and negative nuclei can be observed.
In FIG. 13A and FIG. 13B the BrdU-DNA immunoreactivity, evaluated by reading absorbance at 490 nm, is compared to the number of BrdU-positive nuclei and to the percentage of BrdU-positive nuclei on the total number of cells per well, counted in the same cultures. Standard deviations were less than 10%. The two evaluation methods show a very good correlation and the discrepancy between the values at the highest dose of GGFs can be explained by the different extent of DNA synthesis in cells detected as BrdU-positive.
The BrdU incorporation assay can therefore provide additional useful information about the biological activity of polypeptides on Schwann cells when compared to the (125) I-UdR incorporation assay. For example, the data reported in FIG. 15 show that GGFs can act on Schwann cells to induce DNA synthesis, but at lower doses to increase the number of negative cells present in the microculture after 48 hours.
The assay has then been used on several cell lines of different origin. In FIG. 15 the mitogenic responses of Schwann cells and Swiss 3T3 fibroblasts to GGFs are compared; despite the weak response obtained in 3T3 fibroblasts, some clearly BrdU-positive nuclei were detected in these cultures. Control cultures were run in parallel in presence of several doses of FCS or human recombinant PDGF, showing that the cells could respond to appropriate stimuli (not shown).
The ability of fibroblasts to respond to GGFs was further investigated using the BHK 21 C13 cell line. These fibroblasts, derived from kidney, do not exhibit contact inhibition or reach a quiescent state when confluent. Therefore the experimental conditions were designed to have a very low background proliferation without compromising the cell viability. GGFs have a significant mitogenic activity on BHK21 C13 cells as shown by FIG. 16 and FIG. 17 . FIG. 16 shows the Brdu incorporation into DNA by BHK 21 C13 cells stimulated by GGFS in the presence of 0.1% FCS. The good mitogenic response to FCS indicates that cell culture conditions were not limiting. In FIG. 17 the mitogenic effect of GGFs is expressed as the number of BrdU-positive and BrdU-negative cells and as the total number of cells counted per well. Data are representative of two experiments run in duplicates; at least three fields per well were counted. As observed for Schwann cells in addition to a proliferative effect at low doses, GGFs also increase the numbers of nonresponding cells surviving. The percentage of BrdU positive cells is proportional to the increasing amounts of GGFs added to the cultures. The total number of cells after 48 hours in presence of higher doses of GGFs is at least doubled, confirming that GGFs induce DNA synthesis and proliferation in BHK21 C13 cells. Under the same conditions, cells maintained for 48 hours in the presence of 2% FCS showed an increase of about six fold (not shown).
C6 glioma cells have provided a useful model to study glial cell properties. The phenotype expressed seems to be dependent on the cell passage, the cells more closely resembling an astrocyte phenotype at an early stage, and an oligodendrocyte phenotype at later stages (beyond passage 70). C6 cells used in these experiments were from passage 39 to passage 52. C6 cells are a highly proliferating population, therefore the experimental conditions were optimized to have a very low background of BrdU incorporation. The presence of 0.1% serum was necessary to maintain cell viability without significantly affecting the mitogenic responses, as shown by the dose response to FCS ( FIG. 18 ).
In FIG. 19 the mitogenic responses to aFGF (acidic Fibroblast growth factor) and GGFs are expressed as the percentages of maximal BrdU incorporation obtained in the presence of FCS (8%). Values are averages of two experiments, run in duplicates. The effect of GGFs was comparable to that of a pure preparation of aFGF. aFGF has been described as a specific growth factor for C6 cells (Lim R. et al., Cell Regulation 1:741-746, 1990) and for that reason it was used as a positive control. The direct counting of BrdU positive and negative cells was not possible because of the high cell density in the microcultures. In contrast to the cell lines so far reported, PC12 cells did not show any evident responsiveness to GGFS, when treated under culture conditions in which PC12 could respond to sera (mixture of FCS and HS as used routinely for cell maintenance). Nevertheless the number of cells plated per well seems to affect the behavior of PC12 cells, and therefore further experiments are required.
EXAMPLE 9
Amino Acid Sequences of Purified GGF-I and GGF-II
Amino acid sequence analysis studies were performed using highly purified bovine pituitary GGF-I and GGF-II. The conventional single letter code was used to describe the sequences. Peptides were obtained by lysyl endopeptidase and protease V8 digests, carried out on reduced and carboxymethylated samples, with the lysyl endopeptidase digest of GGF-II carried out on material eluted from the 55-65 RD region of a 11% SDS-PAGE (MW relative to the above-quoted markers).
A total of 21 peptide sequences (see FIG. 8 , SEQ ID Nos. 1-20, 169) were obtained for GGF-I, of which 12 peptides (see FIG. 9 , SEQ ID Nos. 1, 22-29, 17, 19, and 32) are not present in current protein databases and therefore represent unique sequences. A total of 12 peptide sequences (see FIG. 10 , SEQ ID Nos: 33-39, 51-52) where obtained for GGF-II, of which 10 peptides (see FIG. 11 , SEQ ID NOS: 42-50) are not present in current protein databases and therefore represent unique sequences (an exception is peptide GGF-II 06 which shows identical sequences in many proteins which are probably of no significance given the small number of residues). These novel sequences are extremely likely to correspond to portions of the true amino acid sequences of GGFs I and II.
Particular attention can be drawn to the sequences of GGF-I 07 and GGF-II 12, which are clearly highly related. The similarities indicate that the sequences of these peptides are almost certainly those of the assigned GGF species, and are most unlikely to be derived from contaminant proteins.
In addition, in peptide GGF-II 02, the sequence X S S is consistent with the presence of an N linked carbohydrate moiety on an asparagine at the position denoted by X.
In general, in FIGS. 8 and 10 , X represents an unknown residue denoting a sequencing cycle where a single position could not be called with certainty either because there was more than one signal of equal size in the cycle or because no signal was present. As asterisk denotes those peptides where the last amino acid called corresponds to the last amino acid present in that peptide. In the remaining peptides, the signal strength after the last amino acid called was insufficient to continue sequence calling to the end of that peptide. The right hand column indicates the results of a computer database search using the GCG package FASTA and TFASTA programs to analyze the NBRF and EMBL sequence databases. The name of a protein in this column denotes identity of a portion of its sequence with the peptide amino acid sequence called allowing a maximum of two mismatches. A question mark denotes three mismatches allowed. The abbreviations used are as follows:
HMG-1 High Mobility Group protein-1
HMG-2 High Mobility Group protein-2
LH-alpha Luteinizing hormone alpha subunit
LH-beta Luteinizing hormone beta subunit
EXAMPLE 10
Isolating and Cloning of Nucleotide Sequences Encoding Proteins Containing GGF-I and GGF-II Peptides
Isolation and cloning of the GGF-II nucleotide sequences was performed as outlined herein, using peptide sequence information and library screening, and was performed as set out below. It will be appreciated that the peptides of FIGS. 10 and 11 can be used as the starting point for isolation and cloning of GGF-I sequences by following the techniques described herein. Indeed, FIG. 20 , SEQ ID Nos: 34-76, 78-88) shows possible degenerate oligonucleotide probes for this purpose, and FIG. 22 , SEQ ID NOS: 86-115, lists possible PCR primers. DNA sequence and polypeptide sequence should be obtainable by this means as with GGF-II, and also DNA constructs and expression vectors incorporating such DNA sequence, host cells genetically altered by incorporating such constructs/vectors, and protein obtainable by cultivating such host cells. The invention envisages such subject matter.
I. Design and Synthesis of Oligonucleotide Probes and Primers
Degenerate DNA oligomer probes were designed by backtranslating the amino acid sequences (derived from the peptides generated from purified GGF protein) into nucleotide sequences. Oligomers represented either the coding strand or the non-coding strand of the DNA sequence. When serine, arginine or leucine were included in the oligomer design, then two separate syntheses were prepared to avoid ambiguities. For example, serine was encoded by either TCN or AGY as in 537 and 538 or 609 and 610. Similar codon splitting was done for arginine or leucine (e.g. 544, 545). DNA oligomers were synthesized on a Biosearch 8750 4-column DNA synthesizer using B-cyanoethyl chemistry operated at 0.2 micromole scale synthesis. Oligomers were cleaved off the column (500 angstrom CpG resins) and deprotected in concentrated ammonium hydroxide for 6-24 hours at 55-60° C. Deprotected oligomers were dried under vacuum (Speedvac) and purified by electrophoresis in gels of 15% acrylamide (20 mono:1 bis), 50 mM Tris-borate-EDTA buffer containing 7M urea. Full length oligomers were detected in the gels by UV shadowing, then the bands were excised and DNA oligomers eluted into 1.5 mls H2O for 4-16 hours with shaking. The eluate was dried, redissolved in 0.1 ml H 2 O and absorbance measurements were taken at 260 nm.
Concentrations were determined according to the following formula:
(A 260×units/ml) (60.6/length=×μM)
All oligomers were adjusted to 50 μM concentration by addition of H 2 O.
Degenerate probes designed as above are shown in FIG. 20 , SEQ ID NOS: 54-76, 78-88.
PCR primers were prepared by essentially the same procedures that were used for probes with the following modifications. Linkers of thirteen nucleotides containing restriction sites were included at the 5′ ends of the degenerate oligomers for use in cloning into vectors. DNA synthesis was performed at 1 micromole scale using 1,000 angstrom CpG resins and inosine was used at positions where all four nucleotides were incorporated normally into degenerate probes. Purifications of PCR primers included an ethanol precipitation following the gel electrophoresis purification.
II. Library Construction and Screening
A bovine genomic DNA library was purchased from Stratagene (Catalogue Number: 945701). The library contained 2×10 6 15-20 kb Sau3Al partial bovine DNA fragments cloned into the vector lambda DashII. A bovine total brain cDNA library was purchased from Clonetech (Catalogue Number: BL 10139). Complementary DNA libraries were constructed (In Vitrogen; Stratagene) from mRNA prepared from bovine total brain, from bovine pituitary and from bovine posterior pituitary. In Vitrogen prepared two cDNA libraries: one library was in the vector lambda g10, the other in vector pcDNAI (a plasmid library). The Stratagene libraries were prepared in the vector lambda unizap. Collectively, the cDNA libraries contained 14 million primary recombinant phage.
The bovine genomic library was plated on E. coli K12 host strain LE392 on 23×23 cm plates (Nunc) at 150,000 to 200,000 phage plaques per plate. Each plate represented approximately one bovine genome equivalent. Following an overnight incubation at 37° C., the plates were chilled and replicate filters were prepared-according to procedures of Maniatis et al. (2:60-81). Four plaque lifts were prepared from each plate onto uncharged nylon membranes (Pall Biodyne A or MSI Nitropure). The DNA was immobilized onto the membranes by cross-linking under UV light for 5 minutes or, by baking at 80° C. under vacuum for two hours. DNA probes were labelled using T4 polynucleotide kinase (New England Biolabs) with gamma 32 P ATP (New England Nuclear; 6500 Ci/mmol) according to the specifications of the suppliers. Briefly, 50 pmols of degenerate DNA oligomer were incubated in the presence of 600 μCi gamma 32 P-ATP and 5 units T4 polynucleotide kinase for 30 minutes at 37° C. Reactions were terminated, gel electrophoresis loading buffer was added and then radiolabelled probes were purified by electrophoresis. 32P labelled probes were excised from gel slices and eluted into water. Alternatively, DNA probes were labelled via PCR amplification by incorporation of α-32P-dATP or α-32P dCTP according to the protocol of Schowalter and Sommer, Anal. Biochem 177:90-94 (1989). Probes labelled in PCR reactions were purified by desalting on Sephadex G-150 columns.
Prehybridization and hybridization were performed in GMC buffer (0.52 M NaPi, 7% SDS, 1% BSA, 1.5 mM EDTA, 0.1 M NaCl 10 mg/ml tRNA). Washing was performed in oligowash (160 ml 1 M Na 2 HPO 4 , 200 ml 20% SDS, 8.0 ml 0.5 M EDTA, 100 ml 5M NaCl, 3632 ml H2O). Typically, 20 filters (400 sq. centimeters each) representing replicate copies of ten bovine genome equivalents were incubated in 200 ml hybridization solution with 100 pmols of degenerate oligonucleotide probe (128-512 fold degenerate). Hybridization was allowed to occur overnight at 5° C. below the minimum melting temperature calculated for the degenerate probe. The calculation of minimum melting temperature assumes 2° C. for an AT pair and 4° C. for a GC pair.
Filters were washed in repeated changes of oligowash at the hybridization temperatures four to five hours and finally, in 3.2M tetramethylammonium chloride, 1% SDS twice for 30 min at a temperature dependent on the DNA probe length. For 20mers, the final wash temperature was 60° C. Filters were mounted, then exposed to X-ray film (Kodak XAR5) using intensifying screens (Dupont Cronex Lightening Plus). Usually, a three to five day film exposure at minus 80° C. was sufficient to detect duplicate signals in these library screens. Following analysis of the results, filters could be stripped and reprobed. Filters were stripped by incubating through two successive cycles of fifteen minutes in a microwave oven at full power in a solution of 1% SDS containing 10 mM EDTA pH8. Filters were taken through at least three to four cycles of stripping and reprobing with various probes.
III. Recombinant Phage Isolation, Growth and DNA Preparation
These procedures followed standard protocol as described in Recombinant DNA (Maniatis et al 2:60-2:81).
IV. Analysis of Isolated Clones Using DNA Digestion and Southern Blots
Recombinant Phage DNA samples (2 micrograms) were digested according to conditions recommended by the restriction endonuclease supplier (New England Biolabs). Following a four hour incubation at 37° C., the reactions products were precipitated in the presence of 0.1M sodium acetate and three volumes of ethanol. Precipitated DNA was collected by centrifugation, rinsed in 75% ethanol and dried. All resuspended samples were loaded onto agarose gels (typically 1% in TAE buffer; 0.04M Tris acetate, 0.002M EDTA). Gel runs were at 1 volt per centimeter from 4 to 20 hours. Markers included lambda Hind III DNA fragments and/or ØX174HaeIII DNA fragments (New England Biolabs). The gels were stained with 0.5 micrograms/ml of ethidium bromide and photographed. For southern blotting, DNA was first depurinated in the gel by treatment with 0.125 N HCl, denatured in 0.5 N NaOH and transferred in 20×SSC (3M sodium chloride, 0.03 M sodium citrate) to uncharged nylon membranes. Blotting was done for 6 hours up to 24 hours, then the filters were neutralized in 0.5 Tris HCl pH 7.5, 0.15 M sodium chloride, then rinsed briefly in 50 mM Tris-borate EDTA.
For cross-linking, the filters were wrapped first in transparent plastic wrap, then the DNA side exposed for five minutes to an ultraviolet light. Hybridization and washing was performed as described for library screening (see section 2 of this Example). For hybridization analysis to determine whether similar genes exist in other species slight modifications were made. The DNA filter was purchased from Clonetech (Catalogue Number 7753-1) and contains 5 micrograms of EcoRI digested DNA from various species per lane. The probe was labelled by PCR amplification reactions as described in section 2 above, and hybridizations were done in 80% buffer B(2 g polyvinylpyrrolidine, 2 g Ficoll-400, 2 g bovine serum albumin, 50 ml 1M Tris-HCl (pH 7.5) 58 g NaCl, 1 g sodium pyrophosphate, 10 g sodium dodecyl sulfate, 950 ml H 2 O) containing 10% dextran sulfate. The probes were denatured by boiling for ten minutes then rapidly cooling in ice water. The probe was added to the hybridization buffer at 10 6 dpm 32 P per ml and incubated overnight at 60° C. The filters were washed at 60° C. first in buffer B followed by 2×SSC, 0.1% SDS then in 1×SSC, 0.1% SDS. For high stringency, experiments, final washes were done in 0.1×SSC, 1% SDS and the temperature raised to 65° C.
Southern blot data were used to prepare a restriction map of the genomic clone and to indicate which subfragments hybridized to the GGF probes (candidates for subcloning).
V. Subcloning of Segments of DNA Homologous to Hybridization Probes
DNA digests (e.g. 5 micrograms) were loaded onto 1% agarose gels then appropriate fragments excised from the gels following staining. The DNA was purified by adsorption onto glass beads followed by elution using the protocol described by the supplier (Bio 101). Recovered DNA fragments (100-200 ng) were ligated into linearized dephosphorylated vectors, e.g. pT3T7 (Ambion), which is a derivative of pUC18, using T4 ligase (New England Biolabs). This vector carries the E. coli β lactamase gene, hence, transformants can be selected on plates containing ampicillin. The vector also supplies β-galactosidase complementation to the host cell, therefore non-recombinants (blue) can be detected using isopropylthiogalactoside and Bluogal (Bethesda Research Labs). A portion of the ligation reactions was used to transform E. coli K12 XLl blue competent cells (Stratagene Catalogue Number: 200236) and then the transformants were selected on LB plates containing 50 micrograms per ml ampicillin. White colonies were selected and plasmid mini preps were prepared for DNA digestion and for DNA sequence analysis. Selected clones were retested to determine if their insert DNA hybridized with the GGF probes.
VI. DNA Sequencing
Double stranded plasmid DNA templates were prepared from 5 ml cultures according to standard protocols. Sequencing was by the dideoxy chain termination method using Sequenase 2.0 and a dideoxynucleotide sequencing kit (U.S. Biochemical) according to the manufacturers protocol (a modification of Sanger et al. PNAS; USA 74:5463 (1977)]. Alternatively, sequencing was done in a DNA thermal cycler (Perkin Elmer, model 4800) using a cycle sequencing kit (New England Biolabs; Bethesda Research Laboratories) and was performed according to manufacturers instructions using a 5′-end labelled primer. Sequence primers were either those supplied with the sequencing kits or were synthesized according to sequence determined from the clones. Sequencing reactions were loaded on and resolved on 0.4 mm thick sequencing gels of 6% polyacrylamide. Gels were dried and exposed to X-Ray film. Typically, 35S was incorporated when standard sequencing kits were used and a 32P end labelled primer was used for cycle sequencing reactions. Sequences were read into a DNA sequence editor from the bottom of the gel to the top (5′ direction to 3′) and data were analyzed using programs supplied by Genetics Computer Group (GCG, University of Wisconsin).
VII. RNA Preparation and PCR Amplification
Open reading frames detected in the genomic DNA and which contained sequence encoding GGF peptides were extended via PCR amplification of pituitary RNA. RNA was prepared from frozen bovine tissue (Pelfreeze) according to the guanidine neutral-CsCl procedure (Chirgwin et. al. Biochemistry 18:5294 (1979).) Polyadenylated RNA was selected by oligo-dT cellulose column chromatography (Aviv and Leder PNAS (USA) 69:1408 (1972)).
Specific DNA target sequences were amplified beginning with either total RNA or polyadenylated RNA samples that had been converted to cDNA using the Perkin Elmer PCR/RNA Kit Number: N808-0017. First strand reverse transcription reactions used 1 μg template RNA and either primers of oligo dT with restriction enzyme recognition site linkers attached or specific antisense primers determined from cloned sequences with restriction sites attached. To produce the second strand, the primers either were plus strand unique sequences as used in 3′ RACE reactions (Frohman et. al., PNAS (USA) 85:8998 (1988)) or were oligo dT primers with restriction sites attached if the second target site had been added by terminal transferase tailing first strand reaction products with dATP (e.g. 5′ race reactions, Frohman et. al., ibid). Alternatively, as in anchored PCR reactions the second strand primers were degenerate, hence, representing particular peptide sequences.
The amplification profiles followed the following general scheme: 1) five minutes soak file at 95° C.; 2) thermal cycle file of 1 minute, 95° C.; 1 minute ramped down to an annealing temperature of 45° C., 50° C. or 55° C.; maintain the annealing temperature for one minute; ramp up to 72° C. over one minute; extend at 72° C. for one minute or for one minute plus a 10 second auto extension; 3) extension cycle at 72° C., five minutes, and; 4) soak file 4° C. for infinite time. Thermal cycle files (#2) usually were run for 30 cycles. A sixteen μl sample of each 100 μl amplification reaction was analyzed by electrophoresis in 2% Nusieve 1% agarose gels run in TAE buffer at 4 volts per centimeter for three hours. The gels were stained, then blotted to uncharged nylon membranes which were probed with labelled DNA probes that were internal to the primers.
Specific sets of DNA amplification products could be identified in the blotting experiments and their positions used as a guide to purification and reamplification. When appropriate, the remaining portions of selected samples were loaded onto preparative gels, then following electrophoresis four to five slices of 0.5 mm thickness (bracketing the expected position of the specific product) were taken from the gel. The agarose was crushed, then soaked in 0.5 ml of electrophoresis buffer from 2-16 hours at 40° C. The crushed agarose was centrifuged for two minutes and the aqueous phase was transferred to fresh tubes.
Reamplification was done on five microliters (roughly 1% of the product) of the eluted material using the same sets of primers and the reaction profiles as in the original reactions. When the reamplification reactions were completed, samples were extracted with chloroform and transferred to fresh tubes. Concentrated restriction enzyme buffers and enzymes were added to the reactions in order to cleave at the restriction sites present in the linkers. The digested PCR products were purified by gel electrophoresis, then subcloned into vectors as described in the subcloning section above. DNA sequencing was done described as above.
VIII. DNA Sequence Analysis
DNA sequences were assembled using a fragment assembly program and the amino acid sequences deduced by the GCG programs GelAssemble, Map and Translate. The deduced protein sequences were used as a query sequence to search protein sequence databases using WordSearch. Analysis was done on a VAX Station 3100 workstation operating under VMS 5.1. The database search was done on SwissProt release number 21 using GCG Version 7.0.
IX. Results of Cloning and Sequencing of Genes Encoding GGF-I and GGF-II
As indicated above, to identify the DNA sequence encoding bovine GGF-II degenerate oligonucleotide probes were designed from GGF-II peptide sequences. GGF-II 12 (SEQ ID NO: 52), a peptide generated via lysyl endopeptidase digestion of a purified GGF-II preparation (see FIGS. 16 and 12 ) showed strong amino acid sequence homology with GGF-I 07 (SEQ ID No. 24), a tryptic peptide generated from a purified GGF-I preparation. GGF-II 12 was thus used to create ten degenerate oligonucleotide probes (see oligos 609, 610 and 649 to 656 in FIG. 20 , SEQ ID NOS. 66, 67, 68 and 71-79, respectively). A duplicate set of filters were probed with two sets (set 1=609, 610; set 2=649-5656) of probes encoding two overlapping portions of GGF-II 12. Hybridization signals were observed, but, only one clone hybridized to both probe sets. The clone (designated GGF2BG1) was purified.
Southern blot analysis of DNA from the phage clone GGF2BG1 confirmed that both sets of probes hybridized with that bovine DNA sequence, and showed further that both probes reacted with the same set of DNA fragments within the clone. Based on those experiments a 4 kb Eco RI sub-fragment of the original clone was identified, subcloned and partially sequenced. FIG. 21 shows the nucleotide sequence, SEQ ID 85) and the deduced amino acid sequence of the initial DNA sequence readings that included the hybridization sites of probes 609 and 650, and confirmed that a portion of this bovine genomic DNA encoded peptide 12 (KASLADSGEYM (SEQ ID No:129)).
Further sequence analysis demonstrated that GGF-II 12 resided on a 66 amino acid open reading frame (see below) which has become the starting point for the isolation of overlapping sequences representing a putative bovine GGF-II gene and a cDNA.
Several PCR procedures were used to obtain additional coding sequences for the putative bovine GGF-II gene. Total RNA and oligo dT-selected (poly A containing) RNA samples were prepared from bovine total pituitary, anterior pituitary, posterior pituitary, and hypothalamus. Using primers from the list shown in FIG. 22 , SEQ ID Nos. 105-115, one-sided PCR reactions (RACE) were used to amplify cDNA ends in both the 3′ and 5′ directions, and anchored PCR reactions were performed with degenerate oligonucleotide primers representing additional GGF-II peptides. FIG. 29 summarizes the contiguous DNA structures and sequences obtained in those experiments. From the 3′ RACE reactions, three alternatively spliced cDNA sequences were produced, which have been cloned and sequenced. A 5′ RACE reaction led to the discovery of an additional exon containing coding sequence for at least 52 amino acids. Analysis of that deduced amino acid sequence revealed peptides GGF-II-6 and a sequence similar to GGF-I-18 (see below). The anchored PCR reactions led to the identification of (cDNA) coding sequences of peptides GGF-II-1, 2, 3 and 10 contained within an additional cDNA segment of 300 bp. The 5′ limit of this segment (i.e., segment E, see FIG. 30 ) is defined by the oligonucleotide which encodes peptide GGF-II-1 and which was used in the PCR reaction (additional 5′ sequence data exists as described for the human clone in Example 11). Thus this clone contains nucleotide sequences encoding six out of the existing total of nine novel GGF-II peptide sequences.
The cloned gene was characterized first by constructing a physical map of GGF2BG1 that allowed us to position the coding sequences as they were found (see below, FIG. 30 ). DNA probes from the coding sequences described above have been used to identify further DNA fragments containing the exons on this phage clone and to identify clones that overlap in both directions. The putative bovine GGF-II gene is divided into at least 5 coding segments. Coding segments are defined as discrete lengths of DNA sequence which can be translated into polypeptide sequences using the universal genetic code. The coding segments described in FIG. 36 and referred to in the present application are: 1) particular exons present within the GGF gene (e.g. coding segment a), or 2) derived from sets of two or more exons that appear in specific sub-groups of mRNAs, where each set can be translated into the specific polypeptide segments as in the gene products shown. The polypeptide segments referred to in the claims are the translation products of the analogous DNA coding segments. Only coding segments A and B have been defined as exons and sequenced and mapped thus far. The summary of the contiguous coding sequences identified is shown in FIG. 31(A-B) . The exons are listed (alphabetically) in the order of their discovery. It is apparent from the intron/exon boundaries that exon B may be included in cDNAs that connect coding segment E and coding segment A. That is, exon B cannot be spliced out without compromising the reading frame. Therefore, we suggest that three alternative splicing patterns can produce putative bovine GGF-II cDNA sequences 1, 2 and 3. The coding sequences of these, designated GGF2BPP1.CDS, GGF2BPP2.CDS and F2BPP3.CDS, respectively, are given in FIGS. 27A (SEQ ID NO: 129), 27 (B-C), (SEQ ID No: 134) and 27 (D-E), (SEQ ID No: 135), respectively. The deduced amino acid sequence of the three cDNAs is also given in FIGS. 27 A-B(SEQ ID No: 384), 27 (B-C), (SEQ ID No: 385) and 27 (D-E), (SEQ ID No: 387).
The three deduced structures encode proteins of lengths 206, 281 and 257 amino acids. The first 183 residues of the deduced protein sequence are identical in all three gene products. At position 184 the clones differ significantly. A codon for glycine GGT in GGF2BPP1 also serves as a splice donor for GGF2BPP2 and GGF2BPP3, which alternatively add on exons C, C/D, C/D′ and D or C, C/D and D, respectively, and shown in FIG. 32(A-B) , SEQ ID NO: 145). GGFIIBPP1 is a truncated gene product which is generated by reading past the coding segment A splice junction into the following intervening sequence (intron). This represents coding segment A′ in FIG. 30E (SEQ ID No: 136). The transcript ends adjacent to a canonical AATAAA (SEQ ID No. 420) polyadenylation sequence, and we suggest that this truncated gene product represents a bona fide mature transcript. The other two longer gene products share the same 3′ untranslated sequence and polyadenylation site.
All three of these molecules contain six of the nine novel GGF-II peptide sequences (see FIG. 11 ) and another peptide is highly homologous to GGF-I-18 (see FIG. 26 ). This finding gives a high probability that this recombinant molecule encodes at least a portion of bovine GGF-II. Furthermore, the calculated isoelectric points for the three peptides are consistent with the physical properties of GGF-I and II. Since the molecular size of GGF-II is roughly 60 kD, the longest of the three cDNAs should encode a protein with nearly one-half of the predicted number of amino acids.
A probe encompassing the B and A exons was labelled via PCR amplification and used to screen a cDNA library made from RNA isolated from bovine posterior pituitary. One clone (GGF2BPP5) showed the pattern indicated in FIG. 29 and contained an additional DNA coding segment (G) between coding segments A and C. The entire nucleic acid sequence is shown in FIG. 31(A-B) (SEQ ID NO: 144). The predicted translation product from the longest open reading frame is 241 amino acids. A portion of a second cDNA (GGF2BPP4) was also isolated from the bovine posterior pituitary library using the probe described above. This clone showed the pattern indicated in FIG. 29 . This clone is incomplete at the 5′ end, but is a splicing variant in the sense that it lacks coding segments G and D. BPP4 also displays a novel 3′ end with regions H, K and L beyond region C/D. The sequence of BPP4 is shown in FIG. 33(A-C) (SEQ ID NO: 146).
EXAMPLE 11
GGF Sequences in Various Species
The GGF proteins are the members of a new superfamily of proteins. In high stringency cross hybridization studies (DNA blotting experiments) with other mammalian DNAs we have shown, clearly, that DNA probes from this bovine recombinant molecule can readily detect specific sequences in a variety of samples tested. A highly homologous sequence is also detected in human genomic DNA. The autoradiogram is shown in FIG. 28 . The signals in the lanes containing rat and human DNA represent the rat and human equivalents of the GGF gene, the sequences of several cDNA's encoded by this gene have been recently reported by Holmes et al. (Science 256: 1205 (1992)) and Wen et al. (Cell 69: 559 (1992)).
EXAMPLE 12
Isolation of a Human Sequence Encoding Human GGF2
Several human clones containing sequences from the bovine GGFII coding segment E were isolated by screening a human cDNA library prepared from brain stem (Stratagene catalog #935206). This strategy was pursued based on the strong link between most of the GGF2 peptides (unique to GGF2) and the predicted peptide sequence from clones containing the bovine E segment. This library was screened as described in Example 8, Section II using the oligonucleotide probes 914-919 listed below.
914TCGGGCTCCATGAAGAAGATGTA (SEQ ID NO: 179)
915TCCATGAAGAAGATGTACCTGCT (SEQ ID NO: 180)
916ATGTACCTGCTGTCCTCCTTGA (SEQ ID NO: 181)
917TTGAAGAAGGACTCGCTGCTCA (SEQ ID NO 182)
918AAAGCCGGGGGCTTGAAGAA (SEQ ID NO: 183)
919ATGARGTGTGGGCGGCGAAA (SEQ ID NO: 184)
Clones detected with these probes were further analyzed by hybridization. A probe derived from coding segment A (see FIG. 30 ), which was produced by labeling a polymerase chain reaction (PCR) product from segment A, was also used to screen the primary library. Several clones that hybridized with both A and E derived probes were selected and one particular clone, GGF2HBS5, was selected for further analysis. This clone is represented by the pattern of coding segments (EBACC/D′D as shown in FIG. 30 ). The E segment in this clone is the human equivalent of the truncated bovine version of E shown in FIG. 30 . GGF2HBS5 is the most likely candidate to encode GGF-II of all the “putative” GGF-II candidates described. The length of coding sequence segment E is 786 nucleotides plus 264 bases of untranslated sequence. The predicted size of the protein encoded by GGF2HBS5 is approximately 423 amino acids (approximately 45 kilodaltons, see FIG. 44 , SEQ ID NO: 170), which is similar to the size of the deglycosylated form of GGF-II (see Example 19). Additionally, seven of the GGF-II peptides listed in FIG. 26 have equivalent sequences which fall within the protein sequence predicted from region E. Peptides II-6 and II-12 are exceptions, which fall in coding segment B and coding segment A, respectively. RNA encoding the GGF2HBS5 protein was produced in an in vitro transcription system driven by the bacteriophage T7 promoter resident in the vector (Bluescript SK [Stratagene Inc.] see FIG. 47 ) containing the GGF2HBS5 insert. This RNA was translated in a cell free (rabbit reticulocyte) translation system and the size of the protein product was 45 Kd. Additionally, the cell-free product has been assayed in a Schwann cell mitogenic assay to confirm biological activity. Schwann cells treated with conditioned medium show both increased proliferation as measured by incorporation of 125 I-Uridine and phosphorylation on tyrosine of a protein in the 185 kilodalton range.
Thus the size of the product encoded by GGF2HBS5 and the presence of DNA sequences which encode human peptides highly homologous to the bovine peptides shown in FIG. 11 confirm that GGF2HBS5 encodes the human equivalent of bovine GGF2. The fact that conditioned media prepared from cells transformed with this clone elicits Schwann cell mitogenic activity confirms that the GGFIIHBS5 gene produce (unlike the BPP5 gene product) is secreted. Additionally the GGFIIBPP5 gene product seems to mediate the Schwann cell proliferation response via a receptor tyrosine kinase such as p185 erbB2 or a closely related receptor (see Example 18).
EXAMPLE 13
Expression of Human Recombinant GGF2 in Mammalian and Insect Cells
The GGF2HBS5 cDNA clone encoding human GGF2 (as described in Example 12 and also referred to herein as HBS5) was cloned into vector pcDL-SRα296 and COS-7 cells were transfected in 100 mm dishes by the DEAE-dextran method. Cell lysates or conditioned media from transiently expressing COS cells were harvested at 3 or 4 days post-transfection. To prepare lysates, cell monolayers were washed with PBS, scraped from the dishes lysed by three freeze/thaw cycles in 150 μm of 0.25 M Tris-HCl, pH8. Cell debris was pelleted and the supernatant recovered. Conditioned media samples (7 mls.) were collected, then concentrated and buffer exchanged with 10 mm Tris, pH 7.4 using Centiprep-10 and Centricon-10 units as described by the manufactures (Amicon, Beverly, Mass.). Rat nerve Schwann cells were assayed for incorporation of DNA synthesis precursors, as described. Conditioned media or cell lysate samples were tested in the Schwann cell proliferation assay as described in Marchionni et al., Nature 362:313 (1993). The cDNA, GGF2HBS5, encoding GGF2 directed the secretion of the protein product to the medium. Minimal activity was detectable inside the cells as determined by assays using cell lysates. GGF2HFB1 and GGFBPP5 cDNA's failed to direct the secretion of the product to the extracellular medium. GGF activity from these clones was detectable only in cell lysates.
Recombinant GGF2 was also expressed in CHO cells. The GGF2HBS5 cDNA encoding GGF2 was cloned into the EcoRI site of vector pcdhfrpolyA and transfected into the DHFR negative CHO cell line (GG44) by the calcium phosphate coprecipitation method. Clones were selected in nucleotide and nucleoside free a medium (Gibco) in 96-well plates. After 3 weeks, conditioned media samples from individual clones were screened for expression of GGF by the Schwann cell proliferation assay as described in Marchionni et al., Nature 362:313 (1993). Stable clones which secreted significant levels of GGF activity into the medium were identified. Schwann cell proliferation activity data from different volume aliquots of CHO cell conditioned medium were used to produce the dose response curve shown in FIG. 46 (Graham and Van Der Eb, Virology 52:456, 1973). This material was analyzed on a Western blot probed with polyclonal antisera raised against a GGF2 specific peptide. A band of approximately 65 Kd (the expected size of GGF2 extracted from pituitary) is specifically labeled ( FIG. 48 , lane 12).
Recombinant GGF2 was also expressed in insect cells using the Baculovirus expression. Sf9 insect cells were infected with baculovirus containing the GGF2HBS5 cDNA clone at a multiplicity of 3-5 (10 6 cells/ml) and cultured in Sf900-II medium. Schwann cell mitogenic activity was secreted into the extracellular medium. Different volumes of insect cell conditioned medium were tested in the Schwann cell proliferation assay in the absence of forskolin and the data used to produce a dose response curve.
This material was also analyzed on a Western blot ( FIG. 45B ) probed with the GGF II specific antibody described above.
The methods used in this example were as follows:
Schwann cell mitogenic activity of recombinant human and bovine glial growth factors was determined as follows: Mitogenic responses of cultured Schwann cells were measured in the presence of 5 μM forskolin using crude recombinant GGF preparations obtained from transient mammalian expression experiments. Incorporation of [ 125 I]-Urd was determined following an 18-24 hour exposure to materials obtained from transfected or mock transfected cos cells as described in the Methods. The mean and standard deviation of four sets of data are shown. The mitogenic response to partially purified native bovine pituitary GGF (carboxymethyl cellulose fraction; Goodearl et al., submitted) is shown (GGF) as a standard of one hundred percent activity.
cDNAs ( FIG. 46 , SEQ ID Nos: 166-168) were cloned into pcDL-SRα296 (Takebe et al., Mol. Cell. Biol. 8:466-472 (1988)), and COS-7 cells were transfected in 100 mm dishes by the DEAE-dextran method (Sambrook et al., In Molecular Cloning. A Laboratory Manual, 2nd. ed. (Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y., 1989)). Cell lysates or conditioned media were harvested at 3 or 4 days post-transfection. To prepare lysates, cell monolayers were washed with PBS, scraped from the dishes, and lysed by three freeze/than cycles in 150 μl of 0.25 M Tris-HCl, pH 8. Cell debris was pelleted and the supernate recovered. Conditioned media samples (7 mls) were collected, then concentrated and buffer exchanged with 10 mM Tris, pH 7.4 using Centriprep-10 and Centricon-10 units are described by the manufacturers (Amicon, Beverly, Mass.). Rat sciatic nerve Schwann cells were assayed for incorporation of DNA synthesis precursors, as described (Davis and Stroobant, J. Cell Biol. 110:1353-1360 (1990); Brockes et al., Brain Res. 165:105-118 (1979)).
Western blot of recombinant CHO cell conditioned medium were performed as follows: A recombinant CHO clone was cultured in MCDB302 protein-free for 3 days. 2 ml of conditioned medium was harvested, concentrated, buffered exchanged against 10 mM Tris-HCl, pH 7.4 and lyophilized to dryness. The pellet was resuspended in SDS-PAGE sample buffer, subjected to reducing SDS gel electrophoresis and analyzed by Western blotting with a GGF peptide antibody. A CHO control was done by using conditioned medium from untransfected CHO-DG44 host and the CHO HBS5 levels were assayed using conditioned medium from a recombinant clone.
EXAMPLE 14
Identification of Functional Elements of GGF
The deduced structures of the family of GGF sequences indicate that the longest forms (as represented by GGF2BPP4) encode transmembrane proteins where the extracellular part contains a domain which resembles epidermal growth factor (see Carpenter and Wahl in Peptide Growth Factors and Their Receptors I pp. 69-133, Springer-Verlag, N.Y. 1991). The positions of the cysteine residues in coding segments C and C/D or C/D′ peptide sequence are conserved with respect to the analogous residues in the spidermal growth factor (EGF) peptide sequence (see FIG. 34 , SEQ ID NOS: 147-149) This suggests that the extracellular domain functions as receptor recognition and biological activation sites. Several of the variant forms lack the H, K, and L coding segments and thus may be expressed as secreted, diffusible biologically active proteins. GGF DNA sequences encoding polypeptides which encompass the EGF-like domain (EGFL) can have full biological activity for stimulating glial cell mitogenic activity.
Membrane bound versions of this protein may induce Schwann cell proliferation if expressed on the surface of neurons during embryogenesis or during nerve regeneration (where the surfaces of neurons are intimately associated with the surfaces of proliferating Schwann cells).
Secreted (non membrane bound) GGFs may act as classically diffusible factors which can interact with Schwann cells at some distance from their point of secretion. Other forms may be released from intracells by sources via tissue injury and cell disruption. An example of a secreted GGF is the protein encoded by GGF2HBS5; this is the only GGF known which has been found to be directed to the exterior of the cell. Secretion is probably mediated via an N-terminal hydrophobic sequence found only in region E, which is the N-terminal domain contained within recombinant GGF2 encoded by GGF2HBS5.
Other GGF's appear to be non-secreted. These GGFs may be injury response forms which are released as a consequence of tissue damage.
Other regions of the predicted protein structure of GGF2 (encoded by GGF2HBS5) and other proteins containing regions B and A exhibit similarities to the human basement membrane heparan sulfate proteoglycan core protein. The peptide ADSGEY, which is located next to the second cysteine of the C2 immunoglobulin fold in these GGF's, occurs in nine of twenty-two C-2 repeats found in that basal lamina protein. This evidence strongly suggests that these proteins may associate with matrix proteins such as those associated with neurons and glia, and may suggest a method for sequestration of glial growth factors at target sites.
EXAMPLE 15
Purification of GGFs from Recombinant Cells
In order to obtain full length or portions of GGFs to assay for biological activity, the proteins can be overproduced using cloned DNA. Several approaches can be used. A recombinant E. coli cell containing the sequences described above can be constructed. Expression systems such as pNH8a or pHH16a (Stratagene, Inc.) can be used for this purpose by following manufacturers procedures. Alternatively, these sequences can be inserted in a mammalian expression vector and an overproducing cell line can be constructed. As an example, for this purpose DNA encoding a GGF, clone GGF2BPP5 has been expressed in COS cells and can be expressed in Chinese hamster ovary cells using the pMSXND expression vector (Lee and Nathans, J. Biol. Chem. 263, 3521-3527, (1981)). This vector containing GGF DNA sequences can be transfected into host cells using established procedures.
Transient expression can be examined or G418-resistant clones can be grown in the presence of methotrexate to select for cells that amplify the dhfr gene (contained on the pMSXND vector) and, in the process, co-amplify the adjacent GGF protein encoding sequence. Because CHO cells can be maintained in a totally protein-free medium (Hamilton and Ham, In Vitro 13, 537-547 (1977)), the desired protein can be purified from the medium. Western analysis using the antisera produced in Example 16 can be used to detect the presence of the desired protein in the conditioned medium of the overproducing cells.
The desired protein (rGGF2) was purified from the medium conditioned by transiently expressing cos cells as follows. rGGF II was harvested from the conditioned medium and partially purified using Cation Exchange Chromatography (POROS-HS). The column was equilibrated with 33.3 mM MES pH 6.0. Conditioned media was loaded at flow rate of 10 ml/min. The peak containing Schwann cell proliferation activity and immunoreactive (using the polyclonal antisera was against a GGF2 peptide described above) was eluted with 50 mM Tris, 1M NaCl pH 8.0.
rhGGF2 is also expressed using a stable Chinese Ovary Hamster cell line. rGGF2 from the harvested conditioned media was partially purified using Cation Exchange Chromatograph (POROS-HS). The column was equilibrated with PBS pH 7.4. Conditioned media was loaded at 10 ml/min. The peak containing the Schwann Cell Proliferative activity and immunoreactivity (using GGF2 polyclonal antisera) was eluted with 50 mM Hepes, 500 mM NaCl pH 8.0. An additional peak was observed at 50 mM Hepes, 1M NaCl pH 8.0 with both proliferation as well as immunoreactivity ( FIG. 45 ).
rhGGF2 can be further purified using Hydrophobic Interaction Chromatography as a high resolution step; Cation exchange/Reserve phase Chromatography (if needed as second high resolution step); A viral inactivation step and a DNA removal step such as Anion exchange chromatography.
Schwann Cell Proliferation Activity of recombinant GGF2 peak eluted from the Cation Exchange column was determined as follows: Mitogenic responses of the cultured Schwann cells were measured in the presence of 5 M Forskolin using the peak eluted by 50 mM Tris 1 M NaCl pH 8.0. The peak was added at 20 1, 10 1 (1:10) 10 1 and (1:100) 10 1. Incorporation of 125 I-Uridine was determined and expressed as (CPM) following an 18-24 hour exposure.
An immunoblot using polyclonal antibody raised against a peptide of GGF2 was carried out as follows: 10 1 of different fractions were ran on 4-12% gradient gels. The gels were transferred on to Nitrocellulose paper, and the nitrocellulose blots were blocked with 5% BSA and probed with GGF2-specific antibody (1:250 dilution). 125 I protein A (1:500 dilution, Specific Activity=9.0/Ci/g) was used as the secondary antibody. The immunoblots were exposed to Kodax X-Ray films for 6 hours. The peak fractions eluted with 1 M NaCl showed an immunoreactive band at 69K.
GGF2 purification on cation exchange columns was performed as follows: CHO cell conditioned media expressing rGGFII was loaded on the cation exchange column at 10 ml/min. The column was equilibrated with PBS pH 7.4. The elution was achieved with 50 mM Hepes 500 mM NaCl pH 8.0 and 50 mM Hepes 1M NaCl pH 8.0 respectively. All fractions were analyzed using the Schwann cell proliferation assay (CPM) described herein. The protein concentration (mg/ml) was determined by the Bradford assay using BSA as the standard.
A Western blot using 10 1 of each fraction was performed and immunoreactivity and the Schwann cell activity were observed to co-migrate.
The protein may be assayed at various points in the procedure using a Western blot assay. Alternatively, the Schwann cell mitogenic assay described herein may be used to assay the expressed product of the full length clone or any biologically active portions thereof. The full length clone GGF2BPP5 has been expressed transiently in COS cells. Intracellular extracts of transfected COS cells show biological activity when assayed in the Schwann cell proliferation assay described in Example 8. In addition, the full length close encoding GGF2HBS5 has been expressed transiently in COS cells. In this case both cell extract and conditioned media show biological activity in the Schwann cell proliferation assay described in Example 8. Any member of the family of splicing variant complementary DNA's derived from the GGF gene (including the Heregulins) can be expressed in this manner and assayed in the Schwann cell proliferation assay by one skilled in the art.
Alternatively, recombinant material may be isolated from other variants according to Wen et al. (Cell 69:559 (1992)) who expressed the splicing variant Neu differentiation factor (NDF) in COS-7 cells. cDNA clones inserted in the pJT-2 eukaryotic plasmid vector are under the control of the SV40 early promoter, and are 3′-flanked with the SV40 termination and polyadenylation signals. COS-7 cells were transfected with the pJT-2 plasmid DNA by electroporation as follows: 6×10 6 cells (in 0.8 ml of DMEM and 10% FEBS) were transferred to a 0.4 cm cuvette and mixed with 20 μg of plasmid DNA in 10 μl of TE solution (10 mM Tris-HCl (pH 8.0), 1 mM EDTA). Electroporation was performed at room temperature at 1600 V and 25 μF using a Bio-Rad Gene Pulser apparatus with the pulse controller unit set at 200 ohms. The cells were then diluted into 20 ml of DMEM, 10% FBS and transferred into a T75 flask (Falcon). After 14 hr. of incubation at 37° C., the medium was replaced with DMEM, 1% FBS, and the incubation continued for an additional 48 hr. Conditioned medium containing recombinant protein which was harvested from the cells demonstrated biological activity in a cell line expressing the receptor for this protein. This cell line (cultured human breast carcinoma cell line AU 565) was treated with recombinant material. The treated cells exhibited a morphology change which is characteristic of the activation of the erbB2 receptor. Conditioned medium of this type also can be tested in the Schwann cell proliferation assay.
EXAMPLE 16
Isolation of a Further Splicing Variant
Methods for updating other neuregulins described in U.S. patent application Ser. No. 07/965,173, filed Oct. 23, 1992, incorporated herein by reference, produced four closely related sequences (heregulin α, β1, β2, β3) which arise as a result of splicing variation. Peles et al. (Cell 69:205 (1992)), and Wen et al. (Cell 69:559 (1992)) have isolated another splicing variant (from rat) using a similar purification and cloning approach to that described in Examples 1-9 and 11 involving a protein which binds to p185 erbB2 . The cDNA clone was obtained as follows (via the purification and sequencing of a p185 erbB2 binding protein from a transformed rat fibroblast cell line). A p185 erbB2 binding protein was purified from conditioned medium as follows. Pooled conditioned medium from three harvests of 500 roller bottles (120 liters total) was cleared by filtration through 0.2μ filters and concentrated 31-fold with a Pelicon ultrafiltration system using membranes with a 20 kd molecular size cutoff. All the purification steps were performed by using a Pharmacia fast protein liquid chromatography system. The concentrated material was directly loaded on a column of heparin-Sepharose (150 ml, preequilibrated with phosphate-buffered saline (PBS)). The column was washed with PBS containing 0.2 M NaCl until no absorbance at 280 nm wavelength could be detected. Bound proteins were then eluted with a continuous gradient (250 ml) of NaCl (from 0.2 M to 1.0 M), and 5 ml fractions were collected. Samples (0.01 ml of the collected fractions were used for the quantitative assay of the kinase stimulatory activity. Active fractions from three column runs (total volume=360 ml) were pooled, concentrated to 25 ml by using a YM10 ultrafiltration membrane (Amicon, Danvers, Mass.), and ammonium sulfate was added to reach a concentration of 1.7 M. After clearance by centrifugation (10,000×g, 15 min.), the pooled material was loaded on a phenyl-Superose column (HR10/10, Pharmacia). The column was developed with a 45 ml gradient of (NH 4 ) 2 SO 4 (from 1.7 M to no salt) in 0.1 M Na 2 PO 4 (pH 7.4), and 2 ml fractions were collected and assayed (0.002 ml per sample) for kinase stimulation (as described in Example 18). The major peak of activity was pooled and dialyzed against 50 mM sodium phosphate buffer (pH 7.3). A Mono-S cation-exchange column (HR5/5, Pharmacia) was preequilibrated with 50 mM sodium phosphate. After loading the active material (0.884 mg of protein; 35 ml), the column was washed with the starting buffer and then developed at a rate of 1 ml/min. with a gradient of NaCl. The kinase stimulatory activity was recovered at 0.45-0.55 M salt and was spread over four fractions of 2 ml each. These were pooled and loaded directly on a Cu +2 chelating columns (1.6 ml, HR2/5 chelating Superose, Pharmacia). Most of the proteins adsorbed to the resin, but they gradually eluted with a 30 ml linear gradient of ammonium chloride (0-1 M). The activity eluted in a single peak of protein at the range of 0.05 to 0.2 M NH 4 Cl. Samples from various steps of purification were analyzed by gel electrophoresis followed by silver staining using a kit from ICN (Costa Mesa, Calif.), and their protein contents were determined with a Coomassie blue dye binding assay using a kit from Bio-Rad (Richmond, Calif.).
The p44 protein (10 μg) was reconstituted in 200 μl of 0.1 M ammonium bicarbonate buffer (pH 7.8). Digestion was conducted with L-1-tosyl-amide 2-phenylethyl chloromethyl ketone-treated trypsin (Serva) at 37° C. for 18 hr. at an enzyme-to-substrate ratio of 1:10. The resulting peptide mixture was separated by reverse-phase HPLC and monitored at 215 nm using a Vydac C4 micro column (2.1 mm i.d.×15 cm, 300 Å) and an HP 1090 liquid chromatographic system equipped with a diode-array detector and a workstation. The column was equilibrated with 0.1% trifluoroacetic acid (mobile phase A), and elution was effected with a linear gradient from 0%-55% mobile phase B (90% acetonitrile in 0.1% trifluoroacetic acid) over 70 min. The flow rate was 0.2 ml/min. and the column temperature was controlled at 25° C. One-third aliquots of the peptide peaks collected manually from the HPLC system were characterized by N-terminal sequence analysis by Edman degradation. The fraction eluted after 27.7 min. (T27.7) contained mixed amino acid sequences and was further rechromatographed after reduction as follows: A 70% aliquot of the peptide fraction was dried in vacuo and reconstituted in 100 μl of 0.2 M ammonium bicarbonate buffer (pH 7.8). DTT (final concentration 2 mM) was added to the solution, which was then incubated at 37° C. for 30 min. The reduced peptide mixture was then separated by reverse-phase HPLC using a Vydac column (2.1 mm i.d.×15 cm). Elution conditions and flow rat were identical to those described above. Amino acid sequence analysis of the peptide was performed with a Model 477 protein sequencer (Applied Biosystems, Inc., Foster City, Calif.) equipped with an on-line phenylthiohydantoin (PTH) amino acid analyzer and a Model 900 data analysis system (Hunkapiller et al. (1986) In Methods of Protein Microcharacterization , J. E. Shively, ed. (Clifton, N.J.: Humana Press p. 223-247). The protein was loaded onto a trifluoroacetic acid-treated glass fiber disc precycled with polybrene and NaCl. The PTH-amino acid analysis was performed with a micro liquid chromatography system (Model 120) using dual syringe pumps and reverse-phase (C-18) narrow bore columns (Applied Biosystems, 2.1 mm×250 mm).
RNA was isolated from Rat1-EJ cells by standard procedures (Maniatis et al., Molecular Cloning: A Laboratory Manual (Cold Spring Harbor, N.Y. (1982) and poly (A) + was selected using an mRNA Separator kit (Clontech Lab, Inc., Palo Alto, Calif.). cDNA was synthesized with the Superscript kit (from BRL Life Technologies, Inc., Bethesda, Md.). Column-fractionated double-strand cDNA was ligated into an Sal1- and Not1-digested pJT-2 plasmid vector, a derivative of the pCD-X vector (Okayama and Berg, Mol. Cell. Biol. 3: 280 (1983)) and transformed into DH10B E. coli cells by electroporation (Dower et al., Nucl. Acids Res. 16: 6127 (1988)). Approximately 5×10 5 primary transformants were screened with two oligonucleotide probes that were derived from the protein sequences of the N-terminus of NDF (residues 5-24) and the T40.4 tryptic peptide (residues 7-12). Their respective sequences were as follows (N indicates all 4 nt):
(1) 5′-ATA GGG AAG GGC GGG GCA AGG GTC NCC CTC NGC A T AGG GCC GGG CTT GCC TCT GGA GCC TCT-3′ (2) 5′-TTT ACA CAT ATA TTC NCC-3′ C G G C (1: SEQ ID NO:163; 2: SEQ ID NO:164)
The synthetic oligonucleotides were end-labeled with [γ- 32 P]ATP with T4 polynucleotide kinase and used to screen replicate sets of nitrocellulose filters. The hybridization solution contained 6×SSC, 50 mM sodium phosphate (pH 6.8), 0.1% sodium pyrophosphate, 2×Denhardt's solution, 50 μg/ml salmon sperm DNA, and 20% formamide (for probe 1) or no formamide (for probe 2). The filters were washed at either 50° C. with 0.5×SSC, 0.2% SDS, 2 mM EDTA (for probe 1) or at 37° C. with 2×SSC, 0.2% SDS, 2 mM EDTA (for probe 2). Autoradiography of the filters gave ten clones that hybridized with both probes. These clones were purified by replating and probe hybridization as described above. The cDNA clones were sequenced using an Applied Biosystems 373A automated DNA sequencer and Applied Biosystems Taq DyeDeoxy™ Terminator cycle sequencing kits following the manufacture's instructions. In some instances, sequences were obtained using [ 35 S]dATP (Amersham) and Sequenase™ kits from U.S. Biochemicals following the manufacturer's instructions. Both strands of the cDNA clone 44 were sequenced by using synthetic oligonucleotides as primers. The sequence of the most 5′ 350 nt was determined in seven independent cDNA clones. The resultant clone demonstrated the pattern shown in FIG. 27 (NDF).
EXAMPLE 17
Purification and Assay of Other Proteins which Bind p185 erbB2 Receptor
I. Purification of gp30 and P70
Lupu et al. (Science 249, 1552 (1990)) and Lippman and Lupu (patent application number PCT/US91/03443 (1990)), hereby incorporated by reference, have purified a protein from conditioned media of a human breast cancer cell line MDA-MB-231.
Lupu et al. (Proc. Natl. Acad. Sci. 89, 2287 (1992)) purified another protein which binds to the p185 erbB2 receptor. This particular protein, p75, was purified from conditioned medium used for the growth of SKBr-3 (a human breast cancer cell line) propagated in improved Eagle's medium (IMEM: GIBCO) supplemented with 10% fetal bovine serum (GIBCO).
II. Other p185 erbB2 Ligands
Peles et al. (Cell 69, 205 (1992)) have also purified a 185 erbB2 stimulating ligand from rat cells. Holmes et al. (Science 256, 1205 (1992)) have purified Heregulin α from human cells which binds and stimulates 185 erbB2 (see Example 5). Tarakovsky et al. Oncogene 6:218 (1991) have demonstrated bending of a 25 kD polypeptide isolated from activated macrophages to the Neu receptor, a p185 erbB2 homology, herein incorporated by reference.
III. NDF Isolation
Yarden and Peles (Biochemistry 30, 3543 (1991)) have identified a 35 kilodaltoh glycoprotein which will stimulate the 185 erbB2 receptor.
In other publications, Davis et al. (Biochem. Biophys. Res. Commun. 179, 1536 (1991), Proc. Natl. Acad. Sci. 88, 8582 (1991) and Greene et al., PCT patent application PCT/US91/02331 (1990)) describe the purification of a protein from conditioned medium of a human T-cell (ATL-2) cell line.
Huang et al. (1992, J. Biol. Chem. 257:11508-11512), hereby incorporated by reference, have isolated an additional neu/erb B2 ligand growth factor from bovine kidney. The 25 kD polypeptide factor was isolated by a procedure of column fractionation, followed by sequential column chromatography on DEAE/cellulose (DE52), Sulfadex (sulfated Sephadex G-50), heparin-Sepharose 4B, and Superdex 75 (fast protein liquid chromatography). The factor, NEL-GF, stimulates tyrosine-specific autophosphorylation of the neu/erb B2 gene product.
IV. Purification of Acetylcholine Receptor Inducing Activity (ARIA)
ARIA, a 42 kD protein which stimulates acetylcholine receptor synthesis, has been isolated in the laboratory of Gerald Fischbach (Falls et al., (1993) Cell 72:801-815). ARIA induces tyrosine phosphorylation of a 185 Kda muscle transmembrane protein which resembles p185 erbB2 , and stimulates acetylcholine receptor synthesis in cultured embryonic myotubes. ARIA is most likely a member of the GGF/erbB2 ligand group of proteins, and this is potentially useful in the glial cell mitogenesis stimulation and other applications of, e.g., GGF2 described herein.
EXAMPLE 18
Protein Tyrosine Phosphorylation Mediated by GGF
Rat Schwann cells, following treatment with sufficient levels of Glial Growth Factor to induce proliferation, show stimulation of protein tyrosine phosphorylation. Varying amounts of partially purified GGF were applied to a primary culture of rat Schwann cells according to the procedure outlined in Example 9. Schwann cells were grown in DMEM/10% fetal calf serum/5 μM forskolin/0.5 μg per mL GGF-CM (0.5 mL per well) in poly D-lysine coated 24 well plates. When confluent, the cells were fed with DMEM/10% fetal calf serum at 0.5 mL per well and left in the incubator overnight to quiesce. The following day, the cells were fed with 0.2 mL of DMEM/10% fetal calf serum and left in the incubator for 1 hour. Test samples were then added directly to the medium at different concentrations and for different lengths of time as required. The cells were then lysed in boiling lysis buffer (sodium phosphate, 5 mM, pH 6.8; SDS, 2%, β-mercapteothanol, 5%; dithiothreitol, 0.1M; glycerol, 10%; Bromophenol Blue, 0.4%; sodium vanadate, 10 mM), incubated in a boiling water bath for 10 minutes and then either analyzed directly or frozen at −70° C. Samples were analyzed by running on 7.5% SDS-PAGE gels and then electroblotting onto nitrocellulose using standard procedures as described by Towbin et al. (1979) Proc. Natl. Acad. Sci. USA 76:4350-4354. The blotted nitrocellulose was probed with antiphosphotyrosine antibodies using standard methods as described in Kamps and Selton (1988) Oncogene 2:305-315. The probed blots were exposed to autoradiography film overnight and developed using a standard laboratory processor. Densitometric measurements were carried out using an Ultrascan XL enhanced laser densitometer (LKB). Molecular weight assignments were made relative to prestained high molecular weight standards (Sigma). The dose responses of protein phosphorylation and Schwann cell proliferation are very similar ( FIG. 33 ). The molecular weight of the phosphorylated band is very close to the molecular weight of p185 erb2 . Similar results were obtained when Schwann cells were treated with conditioned media prepared from COS cells translates with the GGF2HBS5 clone. These results correlate well with the expected interaction of the GGFs with and activation of 185 erbB2 .
This experiment has been repeated with recombinant GGF2. Conditioned medium derived from a CHO cell line stably transformed with the GGF2 clone (GGF2HBS5) stimulates protein tyrosine phosphorylation using the assay described above. Mock transfected CHO cells fail to stimulate this activity.
EXAMPLE 19
N-glycosylation of GGF
The protein sequence predicted from the cDNA sequence of GGF-II candidate clones GGF2BPP1,2 and 3 contains a number of consensus N-glycosylation motifs. A gap in the GGFII02 peptide sequence coincides with the asparagine residue in one of these motifs, indicating that carbohydrate is probably bound at this site.
N-glycosylation of the GGFs was studied by observing mobility changes on SDS-PAGE after incubation with N-glycanase, an enzyme that cleaves the covalent linkages between carbohydrate and aspargine residues in proteins.
N-Glycanase treatment of GGF-II yielded a major band of MW 40-42 kDa and a minor band at 45-48 kDa. Activity single active deglycosylated species at ca 45-50 kDa.
Activity elution experiments with GGF-I also demonstrate an increase in electrophoretic mobility when treated with N-Glycanase, giving an active species of MW 26-28 kDa. Silver staining confirmed that there is a mobility shift, although no N-deglycosylated band could be assigned because of background staining in the sample used.
Further embodiments are within the following claims.
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The invention relates to methods of treating diseases and disorders of the muscle tissues in a vertebrate by the administration of compounds which bind the p185 erbB2 receptor. These compounds are found to cause increased differentiation and survival of cardiac, skeletal and smooth muscle.
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FIELD OF THE INVENTION
[0001] The present invention relates to certain 4-oxo-4,5-dihydro-furan-2-carboxylic acid and ester derivatives and pharmaceutically acceptable salts thereof, which exhibit useful pharmacological properties, for example as agonists for the nicotinic acid receptor, RUP25. Also provided by the present invention are pharmaceutical compositions containing one or more compounds of the invention and methods of using the compounds and compositions of the invention in the treatment of metabolic-related disorders, including dyslipidemia, atherosclerosis, coronary heart disease, insulin resistance, type 2 diabetes, Syndrome-X, and the like. In addition, the present invention also provides for the use of the compounds of the invention in combination with other active agents such as those belonging to the class of α-glucosidase inhibitors, aldose reductase inhibitors, biguanides, HMG-CoA reductase inhibitors, squalene synthesis inhibitors, fibrates, LDL catabolism enhancers, angiotensin converting enzyme (ACE) inhibitors, insulin secretion enhancers, thiazolidinedione, and the like.
BACKGROUND OF THE INVENTION
[0000] Compounds of the Invention as Antilipolytic Agents
[0002] Atherosclerosis and stroke are the numbers one and number three leading causes of death of both men and women in the United States. Type 2 diabetes is a public health problem that is serious, widespread and increasing. Elevated levels of low density lipoprotein (LDL) cholesterol or low levels of high density lipoprotein (HDL) cholesterol are, independently, risk factors for atherosclerosis and associated cardiovascular pathologies. In addition, high levels of plasma free fatty acids are associated with insulin resistance and type 2 diabetes. One strategy for decreasing LDL-cholesterol, increasing HDL-cholesterol and decreasing plasma free fatty acids is to inhibit lipolysis in adipose tissue. This approach involves regulation of hormone sensitive lipase, which is the rate-limiting enzyme in lipolysis. Lipolytic agents increase cellular levels of cAMP, which leads to activation of hormone sensitive lipase within adipocytes. Agents that lower intracellular cAMP levels, by contrast, would be antilipolytic.
[0003] It is also worth noting in passing that an increase in cellular levels of cAMP down-regulates the secretion of adiponectin from adipocytes [Delporte, M L et al. Biochem J (2002) July]. Reduced levels of plasma adiponectin have been associated with metabolic-related disorders, including atherosclerosis, coronary heart disease, insulin resistance and type 2 diabetes [Matsuda, M et al. J Biol Chem (2002) July and reviewed therein].
[0004] Nicotinic acid (niacin, pyridine-3-carboxylic acid) is a water-soluble vitamin required by the human body for health, growth and reproduction; a part of the Vitamin B complex. Nicotinic acid is also one of the oldest used drugs for the treatment of dyslipidemia. It is a valuable drug in that it favorably affects virtually all of the lipid parameters listed above [Goodman and Gilman's Pharmacological Basis of Therapeutics, editors Harmon J G and Limbird L E, Chapter 36, Mahley R W and Bersot T P (2001) pages 971-1002]. The benefits of nicotinic acid in the treatment or prevention of atherosclerotic cardiovascular disease have been documented in six major clinical trials [Guyton J R (1998) Am J Cardiol 82:18U-23U]. Nicotinic acid and related derivatives, such as, acipimox have recently been discussed [Lorenzen, A et al (2001) Molecular Pharmacology 59:349-357].
[0005] Nicotinic acid inhibits the production and release of free fatty acids from adipose tissue, likely via an inhibition of adenylyl cyclase, a decrease in intracellular cAMP levels and a concomitant decrease in hormone sensitive lipase activity. Agonists that down-regulate hormone sensitive lipase activity leading to a decrease in plasma free fatty acid levels are likely to have therapeutic value. The consequence of decreasing plasma free fatty acids is two-fold. First, it will ultimately lower LDL-cholesterol and raise HDL-cholesterol levels, independent risk factors, thereby reducing the risk of mortality due to cardiovascular incidence subsequent to atheroma formation. Second, it will provide an increase in insulin sensitivity in individuals with insulin resistance or type 2 diabetes. Unfortunately, the use of nicotinic acid as a therapeutic is partially limited by a number of associated, adverse side-effects. These include flushing, free fatty acid rebound and liver toxicity.
[0006] The rational development of novel, nicotinic acid receptor agonists that have fewer side-effects will be valuable, but to date this has been hindered by the inability to molecularly identify the nicotinic acid receptor. Furthermore, other receptors of the same class may exist on the surface of adipocytes and similarly decrease hormone sensitive lipase activity through a reduction in the level of intracellular cAMP but without the elicitation of adverse effects such as flushing, thereby representing promising novel therapeutic targets. Recent work suggests that nicotinic acid probably acts through a specific GPCR [Lorenzen A, et al. (2001) Molecular Pharmacology 59:349-357 and reviewed therein]. Further work has suggested that the effects of nicotinic acid on macrophages, spleen and probably adipocytes are mediated via this specific GPCR [Lorenzen A, et al. (2002) Biochemical Pharmacology 64:645-648 and reviewed therein].
SUMMARY OF THE INVENTION
[0007] One aspect of the present invention encompasses 4-oxo-4,5-dihydro-furan-2-carboxylic acid and ester derivatives as shown in Formula (I):
[0008] wherein:
[0009] R 1 is H or C 1-6 alkyl;
[0010] R 2 is H, halogen, C 1-4 alkyl or C 1-4 haloalkyl;
[0011] R 3 is aryl, C 3-7 cycloalkyl, C 3-7 cycloalkenyl, heteroaryl, C 3-7 heterocycloalkyl or C 3-7 heterocycloalkenyl wherein each are optionally substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, aryl, substituted aryl, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, heteroaryl, substituted heteroaryl, hydroxyl, nitro and thiol; and
[0012] R 4 is selected from the group consisting of H, C 1-6 alkyl, C 3-6 -cycloalkoxy and C 1-6 haloalkyl wherein each are optionally substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, hydroxyl, nitro and thiol; or
[0013] a pharmaceutically acceptable salt, hydrate or solvate thereof.
[0014] In some embodiments, when R 1 and R 2 are both H and R 4 is methyl, then R 3 is not phenyl or 4-chlorophenyl.
[0015] In some embodiments, when R 1 and R 2 are both H and R 4 is isopropyl, then R 3 is not phenyl.
[0016] In some embodiments, when R 1 and R 4 are both methyl and R 2 is H, then R 3 is not phenyl.
[0017] One aspect of the present invention encompasses 4-oxo-4,5-dihydro-furan-2-carboxylic acid and ester derivatives as shown in Formula (I):
or a pharmaceutically acceptable salt, hydrate or solvate thereof, wherein:
[0018] R 1 is H or C 1-6 alkyl;
[0019] R 2 is H, halogen, C 1-4 alkyl or C 1-4 haloalkyl; and
[0020] A) R 3 is aryl, C 3-7 cycloalkyl, C 3-7 cycloalkenyl, heteroaryl, C 3-7 heterocycloalkyl or C 3-7 heterocycloalkenyl wherein each are optionally substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, aryl, substituted aryl, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, heteroaryl, substituted heteroaryl, hydroxyl, nitro and thiol; and
[0021] R 4 is selected from the group consisting of H, ethyl, n-propyl, C 4-6 alkyl, C 3-6 -cycloalkyl and C 1-6 haloalkyl wherein each are optionally substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, hydroxyl, nitro and thiol; or
[0022] B) R 3 is a substituted phenyl, 2-chlorophenyl, 3-chlorophenyl, naphthyl, C 3-7 cycloalkyl, C 3-7 cycloalkenyl, heteroaryl, C 3-7 heterocycloalkyl or C 3-7 heterocycloalkenyl wherein the 2-chlorophenyl, 3-chlorophenyl, naphthyl, C 3-7 cycloalkyl, C 3-7 cycloalkenyl, heteroaryl, C 3-7 heterocycloalkyl and C 3-7 heterocycloalkenyl are optionally substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, aryl, substituted aryl, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, heteroaryl, substituted heteroaryl, hydroxyl, nitro and thiol; and
[0023] R 4 is selected from the group consisting of H, C 1-6 alkyl, C 3-6 -cycloalkyl and C 1-6 haloalkyl wherein each are optionally substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, hydroxyl, nitro and thiol.
[0024] In some embodiments, R 4 is selected from the group consisting of H, ethyl, n-propyl, C 4-6 alkyl and C 1-6 haloalkyl wherein each are optionally substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, hydroxyl, nitro and thiol.
[0025] In some embodiments, R 4 is C 3-6 -cycloalkyl optionally substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, hydroxyl, nitro and thiol.
[0026] One aspect of the present invention encompasses pharmaceutical compositions comprising at least one compound according to Formula (I), as described herein, in combination with a pharmaceutically acceptable carrier.
[0027] In some embodiments, the pharmaceutical composition further comprises one or more agents selected from the group consisting of α-glucosidase inhibitor, aldose reductase inhibitor, biguanide, HMG-CoA reductase inhibitor, squalene synthesis inhibitor, fibrate, LDL catabolism enhancer, angiotensin converting enzyme inhibitor, insulin secretion enhancer and thiazolidinedione.
[0028] One aspect of the present invention pertains to methods of treatment of a metabolic-related disorder comprising administering to an individual in need of such treatment a therapeutically-effective amount of a compound according to Formula (I), as described herein or a pharmaceutical composition thereof.
[0029] One aspect of the present invention pertains to methods of modulating a RUP25 receptor comprising contacting the receptor with a compound according to Formula (I), as described herein or a pharmaceutical composition thereof.
[0030] One aspect of the present invention pertains to methods of modulating a RUP25 receptor for the treatment of a metabolic-related disorder in an individual in need of such modulation comprising contacting the receptor with a therapeutically-effective amount of a compound according to Formula (I), as described herein or a pharmaceutical composition thereof.
[0031] One aspect of the present invention pertains to methods of raising HDL in an individual comprising administering to the individual a therapeutically-effective amount of a compound according to Formula (I), as described herein or a pharmaceutical composition thereof.
[0032] One aspect of the present invention pertains to a compound of Formula (I), as described herein, for use in a method of treatment of the human or animal body by therapy.
[0033] One aspect of the present invention pertains to a compound of Formula (I), as described herein, for use in a method of treatment of a metabolic-related disorder of the human or animal body by therapy.
[0034] One aspect of the present invention pertains to the use of compounds of Formula (I), as described herein, in a method of raising HDL of the human or animal body by therapy.
[0035] One aspect of the present invention pertains to the use of compounds of Formula (I), as described herein, for the manufacture of a medicament for use in the treatment of a metabolic-related disorder.
[0036] One aspect of the present invention pertains to the use of compounds of Formula (I), as described herein, for the manufacture of a medicament for use in raising HDL in an individual.
[0037] In some embodiments of the present invention, the metabolic-related disorder is of the group consisting of dyslipidemia, atherosclerosis, coronary heart disease, insulin resistance, obesity, impaired glucose tolerance, atheromatous disease, hypertension, stroke, Syndrome X, heart disease and type 2 diabetes. In some embodiments the metabolic-related disorder is dyslipidemia, atherosclerosis, coronary heart disease, insulin resistance and type 2 diabetes. In some embodiments the metabolic-related disorder is dyslipidemia. In some embodiments the metabolic-related disorder is atherosclerosis. In some embodiments the metabolic-related disorder is coronary heart disease. In some embodiments the metabolic-related disorder is insulin resistance. In some embodiments the metabolic-related disorder is type 2 diabetes.
[0038] One aspect of the present invention encompasses a method of producing a pharmaceutical composition comprising admixing at least one compound according to Formula (I), as described herein and a pharmaceutically acceptable carrier or excipient.
[0039] These and other aspects of the invention disclosed herein will be set forth in greater detail as the patent disclosure proceeds.
DETAILED DESCRIPTION OF THE INVENTION
[0040] The scientific literature has adopted a number of terms, for consistency and clarity, the following definitions will be used throughout this patent document.
[0041] The term “ADMINISTERING” as used herein refers to a step for introducing a compound of the present invention into an individual. The term “administering” shall further encompass the prevention, inhibition or amelioration of the various conditions described herein with a compound of the invention or with a compound which may not be specifically disclosed, but which converts to a specified compound of the invention in vivo after administration to the individual. Various routes can be used for administering a compound, these include, but not limited to oral, parenteral, dermal, injection, aerosol, and the like; additional routes of administration are described herein.
[0042] AGONISTS shall mean moieties that interact and activate the receptor, such as the RUP25 receptor and initiates a physiological or pharmacological response characteristic of that receptor. For example, when moieties activate the intracellular response upon binding to the receptor or enhance GTP binding to membranes.
TABLE 1 AMINO ACID ABBREVIATIONS used herein are set out in TABLE 1: ALANINE ALA A ARGININE ARG R ASPARAGINE ASN N ASPARTIC ACID ASP D CYSTEINE CYS C GLUTAMIC ACID GLU E GLUTAMINE GLN Q GLYCINE GLY G HISTIDINE HIS H ISOLEUCINE ILE I LEUCINE LEU L LYSINE LYS K METHIONINE MET M PHENYLALANINE PHE F PROLINE PRO P SERINE SER S THREONINE THR T TRYPTOPHAN TRP W TYROSINE TYR Y VALINE VAL V
[0043] The term ANTAGONISTS is intended to mean moieties that competitively bind to the receptor at the same site as agonists (for example, the endogenous ligand), but which do not activate the intracellular response initiated by the active form of the receptor and can thereby inhibit the intracellular responses by agonists or partial agonists. Antagonists do not diminish the baseline intracellular response in the absence of an agonist or partial agonist.
[0044] ATHEROSCLEROSIS is intended herein to encompass disorders of large and medium-sized arteries that result in the progressive accumulation within the intima of smooth muscle cells and lipids.
[0045] Chemical Group, Moiety or Radical:
The term “C 1-6 acyl” denotes a C 1-6 alkyl radical attached to a carbonyl wherein the definition of alkyl has the same definition as described herein; some examples include but not limited to, acetyl, propionyl, n-butanoyl, iso-butanoyl, sec-butanoyl, t-butanoyl (i.e., pivaloyl), pentanoyl, and the like. The term “C 1-6 acyloxy” denotes an acyl radical attached to an oxygen atom wherein acyl has the same definition has described herein; some examples include but not limited to acetyloxy, propionyloxy, butanoyloxy, iso-butanoyloxy, sec-butanoyloxy, t-butanoyloxy, and the like. The term “C 2-6 alkenyl” denotes a radical containing 2 to 6 carbons wherein at least one carbon-carbon double bond is present, some embodiments are 2 to 3 carbons and some embodiments have 2 carbons. Both E and Z isomers are embraced by the term “alkenyl.” Furthermore, the term “alkenyl” includes dienes. Accordingly, if more than one double bond is present, then the bonds may be all E or Z or a mixtures of E and Z. Examples of an alkenyl include vinyl, propenyl, alkyl, isopropenyl, 2-methyl-propenyl1-methyl-propenyl, but-1-enyl, but-2-enyl, but-3-enyl, buta-1,3-dienyl, and the like. The term “C 1-6 alkoxy” denotes an alkyl radical, as defined herein, attached directly to an oxygen atom. Examples include methoxy, ethoxy, n-propoxy, iso-propoxy, n-butoxy, t-butoxy, iso-butoxy, sec-butoxy, and the like. The term “C 1-6 alkyl” denotes a straight or branched carbon radical containing the number of carbons as indicated, for examples, in some embodiments, alkyl is a “C 1-4 alkyl” and the group contains 1 to 4 carbons, in still other embodiments, alkyl is a “C 2-6 alkyl” and the group contains 2 to 6 carbons. In some embodiments alkyl contains 1 to 3 carbons, some embodiments contain 1 to 2 carbons and some embodiments contain 1 carbon. Examples of an alkyl include, but not limited to, methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl, t-butyl, sec-butyl, and the like. The term “C 1-6 alkylsulfinyl” denotes a C 1-6 alkyl radical attached to a sulfoxide radical of the formula: —S(O)— wherein the alkyl radical has the same definition as described herein. Examples include, but not limited to, methylsulfinyl, ethylsulfinyl, n-propylsulfinyl, iso-propylsulfinyl, n-butylsulfinyl, sec-butylsulfinyl, iso-butylsulfinyl, t-butyl, and the like. The term “C 1-6 alkylsulfonyl” denotes a C 1-6 alkyl radical attached to a sulfone radical of the formula: —S(O) 2 — wherein the alkyl radical has the same definition as described herein. Examples include, but not limited to, methylsulfonyl, ethylsulfonyl, n-propylsulfonyl, iso-propylsulfonyl, n-butylsulfonyl, sec-butylsulfonyl, iso-butylsulfonyl, t-butylsulfonyl, and the like. The term “C 1-6 alkylthio” denotes a C 1-6 alkyl radical attached to a sulfide group of the formula: —S— wherein the alkyl radical has the same definition as described herein. Examples include, but not limited to, methylsulfanyl (i.e., CH 3 S—), ethylsulfanyl, n-propylsulfanyl, iso-propylsulfanyl, n-butylsulfanyl, sec-butylsulfanyl, iso-butylsulfanyl, t-butyl, and the like. The term “C 2-6 alkynyl” denotes a radical containing 2 to 6 carbons and at least one carbon-carbon triple bond, some embodiments are 2 to 4 carbons and some embodiments have 2 carbons. Examples of an alkynyl include, but not limited to, ethynyl, prop-1-ynyl, 3-prop-2-ynyl, but-1-ynyl, 1-methyl-prop-2-ynyl, buta-1,3-diynyl, and the like. The term “alkynyl” includes dynes. The term “amino” denotes the group —NH 2 . The term “C 1-6 alkylamino” denotes one alkyl radical attached to an amino radical wherein the alkyl radical has the same meaning as described herein. Some examples include, but not limited to, methylamino, ethylamino, n-propylamino, iso-propylamino, n-butylamino, sec-butylamino, iso-butylamino, t-butylamino, and the like. Some embodiments are “C 1-2 alkylamino.” The term “aryl” denotes an aromatic ring radical containing 6 to 10 ring carbons. Examples include phenyl and naphthyl. The term “carbo-C 1-6 -alkoxy” denotes a C 1-6 alkyl ester of a carboxylic acid, wherein the alkyl group is as defined herein. Examples include, but not limited to, carbomethoxy, carboethoxy, carbopropoxy, carboisopropoxy, carbobutoxy, carbo-sec-butoxy, carbo-iso-butoxy, carbo-t-butoxy, and the like. The term “carboxamide” refers to the group —CONH 2 . The term “carboxy” or “carboxyl” denotes the group —CO 2 H; also referred to as a carboxylic acid group. The term “cyano” denotes the group —CN. The term “C 3-7 cycloalkyl” denotes a saturated ring radical containing 3 to 7 carbons; some embodiments, contain 3 to 6 carbons, some embodiments contain 3 to 5 carbons; some embodiments contain 3 to 4 carbons. Examples include, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl. The term “C 3-7 cycloalkenyl” denotes a C 3-7 cycloalkyl, as defined herein, wherein there is at least one endocyclic double bond present, some embodiments, contain 3 to 6 carbons, some embodiments contain 3 to 5 carbons; some embodiments contain 3 to 4 carbons. Examples include, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl. The term “C 2-6 dialkylamino” denotes an amino substituted with two of the same or different alkyl radicals wherein alkyl radical has the same definition as described herein. A C 2-6 dialkylamino may be represented by the following groups:
Examples of C 2-6 dialkylamino include, but not limited to, dimethylamino, methylethylamino, diethylamino, methylpropylamino, methylisopropylamino, and the like. The term “C 1-6 haloalkoxy” denotes a haloalkyl, as defined herein, which is directly attached to an oxygen atom. Examples include, but not limited to, difluoromethoxy, trifluoromethoxy, 2,2,2-trifluoroethoxy, pentafluoroethoxy, and the like. The term “C 1-6 haloalkyl” denotes an alkyl group wherein the alkyl is substituted with halogen ranging from one to fully substituted, wherein a fully substituted haloalkyl can be represented by the formula C h L 2h+1 wherein L is a halogen and “h” represents the number of carbon atoms; when more than one halogen is present then the halogens may be the same or different and selected from the group consisting of F, Cl, Br and I; it is understood that the terms “alkyl” and “halogen” have the same definition as found herein. In some embodiments, haloalkyl is a “C 1-4 haloalkyl” and the group contains 1 to 4 carbons, some embodiments contain 1 to 3 carbons, some embodiments contain 1 to 2 carbons, some embodiments contain 1 carbon. When the haloalkyl is fully substituted with halogen atoms, this group is referred herein as a perhaloalkyl, one example, is an alkyl fully substituted with fluorine atoms and is referred to herein as a “perfluoroalkyl.” In some embodiments, examples of a haloalkyl include, but not limited to, difluoromethyl, fluoromethyl, 2,2,2-trifluoro-ethyl, 2,2-difluoro-ethyl, 2-fluoro-ethyl, 1,2,2-trifluoro-ethyl, 1,2-difluoro-ethyl, 1,1-difluoro-ethyl, 1,1,2-trifluoro-ethyl, 3,3,3-trifluoro-propyl, 2,2-difluoro-propyl, 3,3-difluoro-propyl, 3-fluoro-propyl, 2,3,3-trifluoro-propyl, 2,3-Difluoro-propyl, 2,2,3,3,3-pentafluoro-propyl, 2,2,3,3-tetrafluoro-propyl, 2,2,3-trifluoro-propyl, 1,2,3,3-tetrafluoro-propyl, 1,2,3-trifluoro-propyl, 3,3-difluoro-propyl, 1,2,2,3-tetrafluoro-propyl, 4,4-difluoro-butyl, 3,3-difluoro-butyl, 4,4,4-trifluoro-butyl, 3,3-difluoro-butyl, and the like. In some embodiments, examples of a perfluoroalkyl include, but not limited to, trifluoromethyl, pentafluoroethyl, heptafluoropropyl, 1,2,2,2-tetrafluoro-1-trifluoromethyl-ethyl, and the like. The term “C 1-6 haloalkylsulfinyl” denotes a haloalkyl radical attached to a sulfoxide group of the formula: —S(O)— wherein the haloalkyl radical has the same definition as described herein. The term “C 1-6 haloalkylsulfonyl” denotes a haloalkyl radical attached to a sulfone group of the formula: —S(O) 2 — wherein haloalkyl has the same definition as described herein. The term “C 1-6 haloalkylthio” denotes a haloalkyl radical directly attached to a sulfur atom wherein the haloalkyl has the same meaning as described herein. The term “halogen” or “halo” denotes to a fluoro, chloro, bromo or iodo group. The term “C 3-7 heterocycloalkyl” denotes a cycloalkyl, as defined herein, wherein one, two or three ring carbons are replaced with a heteroatom, such as, O, S, N, wherein the N is substituted with H, C 1-4 acyl or C 1-4 alkyl and ring carbon atoms optionally substituted with oxo or a thiooxo thus forming a carbonyl or thiocarbonyl group. The heterocyclic group is a 3-, 4-, 5-, 6- or 7-membered containing ring. Examples of a heterocyclic group include but not limited to aziridin-1-yl, aziridin-2-yl, azetidin-1-yl, azetidin-2-yl, azetidin-3-yl, piperidin-1-yl, piperidin-4-yl, morpholin-4-yl, piperzin-1-yl, piperzin-4-yl, pyrrolidin-1-yl, pyrrolidin-3-yl, and the like. The term “C 3-7 heterocycloalkenyl” denotes a cycloalkenyl, as defined herein, wherein one, two or three ring carbons are replaced with a heteroatom, such as, O, S, N, wherein the N is substituted with H, C 1-4 acyl or C 1-4 alkyl and ring carbon atoms optionally substituted with oxo or a thiooxo thus forming a carbonyl or thiocarbonyl group. The heterocyclic group is a 3-, 4-, 5-, 6- or 7-membered containing ring. Examples of a heterocyclic group include but not limited to aziridin-1-yl, aziridin-2-yl, azetidin-1-yl, azetidin-2-yl, azetidin-3-yl, piperidin-1-yl, piperidin-4-yl, morpholin-4-yl, piperzin-1-yl, piperzin-4-yl, pyrrolidin-1-yl, pyrrolidin-3-yl, and the like. The term “heteroaryl” denotes an aromatic ring system that may be a single ring or two fused rings containing 2 to 9 carbons and at least one ring heteroatom selected from O, S and N. Examples of heteroaryl groups include, but not limited to, 5-membered heteroaryl including isoxazolyl, isothiazolyl, pyrazolyl, pyrrolyl, furanyl, thienyl, oxazolyl, thiazolyl, imidazolyl, oxadiazolyl, thiadiazolyl, triazolyl, oxadiazolyl, thiadiazolyl, and the like; 6-membered heteroaryl including, pyridyl, pyrazinyl, pyridazinyl, pyrimidinyl, triazinyl, and the like; and two fused ring heteroaryl including benzofuranyl, quinolinyl, isoquinolinyl, benzoxazolyl, benzothiazolyl, benzimidazolyl, quinazolinyl, quinoxalinyl, and the like. The term “hydroxyl” denotes the group —OH. The term “nitro” denotes the group —NO 2 . The term “thiol” denotes the group —SH.
[0078] The term CODON shall mean a grouping of three nucleotides (or equivalents to nucleotides) which generally comprise a nucleoside (adenosine (A), guanosine (G), cytidine (C), uridine (U) and thymidine (T)) coupled to a phosphate group and which, when translated, encodes an amino acid.
[0079] The term COMPOSITION shall mean a material comprising at least two compounds or two components; for example and without limitation, a Pharmaceutical Composition is a Composition comprising a compound of the present invention and a pharmaceutically acceptable carrier.
[0080] The term COMPOUND EFFICACY shall mean a measurement of the ability of a compound to inhibit or stimulate receptor functionality, as opposed to receptor binding affinity.
[0081] The term CONSTITUTIVELY ACTIVATED RECEPTOR shall mean a receptor subject to constitutive receptor activation.
[0082] The term CONSTITUTIVE RECEPTOR ACTIVATION shall mean stabilization of a receptor in the active state by means other than binding of the receptor with its endogenous ligand or a chemical equivalent thereof.
[0083] The terms CONTACT or CONTACTING shall mean bringing the indicated moieties together, whether in an in vitro system or an in vivo system. Thus, “contacting” a RUP25 receptor with a compound of the invention includes the administration of a compound of the present invention to an individual, for example a human, having a RUP25 receptor, as well as, for example, introducing a compound of the invention into a sample containing a cellular or more purified preparation containing a RUP25 receptor.
[0084] CORONARY HEART DISEASE is intended herein to encompass disorders comprising a narrowing of the small blood vessels that supply blood and oxygen to the heart. Coronary heart disease usually results from the build up of fatty material and plaque. As the coronary arteries narrow, the flow of blood to the heart can slow or stop. Coronary heart disease can cause chest pain (stable angina), shortness of breath, heart attack or other symptoms.
[0085] DECREASE is used to refer to a reduction in a measurable quantity and is used synonymously with the terms “reduce”, “diminish”, “lower” and “lessen”.
[0086] DIABETES as used herein is intended to encompass the usual diagnosis of DIABETES made from any of the methods including, but not limited to, the following list: symptoms of diabetes (e.g. polyuria, polydipsia, polyphagia) plus casual plasma glucose levels of greater than or equal to 200 mg/dl, wherein casual plasma glucose is defined any time of the day regardless of the timing of meal or drink consumption; 8 hour fasting plasma glucose levels of less than or equal to 126 mg/dl; and plasma glucose levels of greater than or equal to 200 mg/dl 2 hours following oral administration of 75 g anhydrous glucose dissolved in water.
[0087] The phrase DISORDERS OF LIPID METABOLISM is intended herein to include, but not be limited to, dyslipidemia.
[0088] The term DYSLIPIDEMIA is intended herein to encompass disorders comprising any one of elevated level of plasma free fatty acids, elevated level of plasma cholesterol, elevated level of LDL-cholesterol, reduced level of HDL-cholesterol and elevated level of plasma triglycerides.
[0089] The phrase IN NEED OF TREATMENT, as used herein, refers to a judgment made by a caregiver (e.g. physician, nurse, nurse practitioner, etc. in the case of humans; veterinarian in the case of animals, including non-human mammals) that an individual or animal requires or will benefit from treatment. This judgment is made based on a variety of factors that are in the realm of a caregiver's expertise, that includes the knowledge that the individual is ill or will be ill, as the result of a disease, condition or disorder that is treatable by the compounds of the invention. Further, the phrase “in need of treatment” also refers to the “prophylaxis” of an individual which is the judgment made by the caregiver that the individual will become ill. In this context, the compounds of the invention are used in a protective or preventive manner. Accordingly, “in need of treatment” refers to the judgment of the caregiver that the individual is already ill or will become ill and the compounds of the present invention can be used to alleviate, inhibit, ameliorate or prevent the disease, condition or disorder.
[0090] The term INDIVIDUAL as used herein refers to any animal, including mammals, for example, mice, rats, other rodents, rabbits, dogs, cats, swine, cattle, sheep, horses or primates and in one embodiment, humans.
[0091] The terms INHIBIT or INHIBITING, in relationship to the term “response” shall mean that a response is decreased or prevented in the presence of a compound as opposed to in the absence of the compound.
[0092] INSULIN RESISTANCE as used herein is intended to encompass the usual diagnosis of insulin resistance made by any of a number of methods, including but not restricted to: the intravenous glucose tolerance test or measurement of the fasting insulin level. It is well known that there is an excellent correlation between the height of the fasting insulin level and the degree of insulin resistance. Therefore, one could use elevated fasting insulin levels as a surrogate marker for insulin resistance for the purpose of identifying which normal glucose tolerance (NGT) individuals have insulin resistance. A diagnosis of insulin resistance can also be made using the euglycemic glucose clamp test.
[0093] The term INVERSE AGONISTS shall mean moieties that bind the endogenous form of the receptor or to the constitutively activated form of the receptor and which inhibit the baseline intracellular response initiated by the active form of the receptor below the normal base level of activity which is observed in the absence of agonists or partial agonists or decrease GTP binding to membranes. In some embodiments, the baseline intracellular response is inhibited in the presence of the inverse agonist by at least 30%, in other embodiments, by at least 50% and in still other embodiments, by at least 75%, as compared with the baseline response in the absence of the inverse agonist.
[0094] The term LIGAND shall mean an endogenous, naturally occurring molecule specific for an endogenous, naturally occurring receptor.
[0095] The phrase METABOLIC-RELATED DISORDERS is intended herein to include, but not be limited to, dyslipidemia, atherosclerosis, coronary heart disease, insulin resistance, obesity, impaired glucose tolerance, atheromatous disease, hypertension, stroke, Syndrome X, heart disease and type 2 diabetes.
[0096] As used herein, the terms MODULATE or MODULATING shall mean to refer to an increase or decrease in the amount, quality, response or effect of a particular activity, function or molecule.
[0097] The term PHARMACEUTICAL COMPOSITION shall mean a composition for preventing, treating or controlling a disease state or condition comprising at least one active compound, for example, a compound of the present invention including pharmaceutically acceptable salts, pharmaceutically acceptable solvates and/or hydrates thereof and at least one pharmaceutically acceptable carrier.
[0098] The term PHARMACEUTICALLY ACCEPTABLE CARRIER or EXCIPIENT shall mean any substantially inert substance used as a diluent or vehicle for a compound of the present invention.
[0099] The phrase THERAPEUTICALLY-EFFECTIVE AMOUNT as used herein refers to the amount of active compound or pharmaceutical agent that elicits the biological or medicinal response in a tissue, system, animal, individual or human that is being sought by a researcher, veterinarian, medical doctor or other clinician, which includes one or more of the following:
[0100] (1) Preventing the disease; for example, preventing a disease, condition or disorder in an individual that may be predisposed to the disease, condition or disorder but does not yet experience or display the pathology or symptomatology of the disease,
[0101] (2) Inhibiting the disease; for example, inhibiting a disease, condition or disorder in an individual that is experiencing or displaying the pathology or symptomatology of the disease, condition or disorder (i.e., arresting further development of the pathology and/or symptomatology) and
[0102] (3) Ameliorating the disease; for example, ameliorating a disease, condition or disorder in an individual that is experiencing or displaying the pathology or symptomatology of the disease, condition or disorder (i.e., reversing the pathology and/or symptomatology).
COMPOUNDS OF THE INVENTION
[0103] One aspect of the present invention encompasses 4-oxo-4,5-dihydro-furan-2-carboxylic acid and ester derivatives as shown in Formula (I):
[0104] wherein:
[0105] R 1 is H or C 1-6 alkyl;
[0106] R 2 is H, halogen, C 1-4 alkyl or C 1-4 haloalkyl;
[0107] R 3 is aryl, C 3-7 cycloalkyl, C 3-7 cycloalkenyl, heteroaryl, C 3-7 heterocycloalkyl or C 3-7 heterocycloalkenyl wherein each are optionally substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, aryl, substituted aryl, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, heteroaryl, substituted heteroaryl, hydroxyl, nitro and thiol; and
[0108] R 4 is selected from the group consisting of H, C 1-6 alkyl, C 3-6 -cycloalkyl and C 1-6 haloalkyl wherein each are optionally substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, hydroxyl, nitro and thiol; or a pharmaceutically acceptable salt, hydrate or solvate thereof.
[0109] In some embodiments, when R 1 and R 2 are both H and R 4 is methyl, then R 3 is not phenyl or 4-chlorophenyl.
[0110] In some embodiments, when R 1 and R 2 are both H and R 4 is isopropyl, then R 3 is not phenyl.
[0111] In some embodiments, when R 1 and R 4 are both methyl and R 2 is H, then R 3 is not phenyl.
[0112] One aspect of the present invention encompasses 4-oxo-4,5-dihydro-furan-2-carboxylic acid and ester derivatives as shown in Formula (I):
or a pharmaceutically acceptable salt, hydrate or solvate thereof, wherein:
[0113] R 1 is H or C 1-6 alkyl;
[0114] R 2 is H, halogen, C 1-4 alkyl or C 1-6 haloalkyl; and
[0115] A) R 3 is aryl, C 3-7 cycloalkyl, C 3-7 cycloalkenyl, heteroaryl, C 3-7 heterocycloalkyl or C 3-7 heterocycloalkenyl wherein each are optionally substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, aryl, substituted aryl, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, heteroaryl, substituted heteroaryl, hydroxyl, nitro and thiol; and
[0116] R 4 is selected from the group consisting of H, ethyl, n-propyl, C 4-6 alkyl, C 3-6 -cycloalkyl and C 1-6 haloalkyl wherein each are optionally substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, hydroxyl, nitro and thiol; or
[0117] B) R 3 is a substituted phenyl, 2-chlorophenyl, 3-chlorophenyl, naphthyl, C 3-7 cycloalkyl, C 3-7 cycloalkenyl, heteroaryl, C 3-7 heterocycloalkyl or C 3-7 heterocycloalkenyl wherein the 2-chlorophenyl, 3-chlorophenyl, naphthyl, C 3-7 cycloalkyl, C 3-7 cycloalkenyl, heteroaryl, C 3-7 heterocycloalkyl and C 3-7 heterocycloalkenyl are optionally substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, aryl, substituted aryl, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, heteroaryl, substituted heteroaryl, hydroxyl, nitro and thiol; and
[0118] R 4 is selected from the group consisting of H, C 1-6 alkyl, C 3-6 -cycloalkyl and C 1-6 haloalkyl wherein each are optionally substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, hydroxyl, nitro and thiol.
[0119] The present invention also encompasses all tautomers that can exist for the compounds disclosed herein. For example, but not limited to, when R 4 is H, enol and keto tautomers can exist. These and other tautomers are within the scope of the invention.
[0120] The present invention also encompasses diastereomers as well as optical isomers, e.g. mixtures of enantiomers including racemic mixtures, as well as individual enantiomers and diastereomers, which arise as a consequence of structural asymmetry in certain compounds of the present invention. In some embodiments, compounds of the present invention are enriched with the R enantiomer, defined as compounds having a percent enantiomeric excess (i.e., % ee) of about 1% or greater. In some embodiments, compounds of the present invention are R. In some embodiments, compounds of the present invention are enriched with the S enantiomers. In some embodiments, compounds of the present invention are S. In some embodiments, compounds of the present invention are racemic mixtures.
[0121] It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate 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 subcombinatioin.
[0122] The phrase “pharmaceutically acceptable” is employed herein to refer to those compounds, materials, compositions and/or dosage forms which are, within the scope of sound medical judgement, suitable for use in contact with the tissues of human beings and animals without excessive toxicity, irritation, allergic response or other problem or complication, commensurate with a reasonable benefit/risk ratio.
[0123] The present invention also includes pharmaceutically acceptable salts of the compounds described herein. As used herein, “pharmaceutically acceptable salts” refers to derivatives of the disclosed compounds wherein the parent compound is modified by converting an existing acid or base moiety to its salt form. Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acid salts of basic residues such as amines; alkali or organic salts of acidic residues such as carboxylic acids, and the like. The pharmaceutically acceptable salts of the present invention include the conventional non-toxic salts or the quaternary ammonium salts of the parent compound formed, for example, from non-toxic inorganic or organic acids. The pharmaceutically acceptable salts of the present invention can be synthesized from the parent compound which contains a basic or acidic moiety by conventional chemical methods. Generally, such salts can be prepared by reacting the free acid or base forms of these compounds with a stoichiometric amount of the appropriate base or acid in water or in an organic solvent or in a mixture of the two; generally, nonaqueous media like ether, ethyl acetate, ethanol, isopropanol or acetonitrile are preferred. Lists of suitable salts are found in Remington's Pharmaceutical Sciences, 17th ed., Mack Publishing Company, Easton, Pa., 1985, p. 1418 and the most recent edition thereof; and Journal of Pharmaceutical Science, 66, 2 (1977), each of which is incorporated herein by reference in its entirety.
[0124] As used herein, “substituted” indicates that at least one hydrogen atom of the chemical group is replaced by a non-hydrogen substituent or group. When a chemical group herein is “substituted” it may have up to the full valance of substitution; for example, a methyl group can be substituted by 1, 2 or 3 substituents, a methylene group can be substituted by 1 or 2 substituents, a phenyl group can be substituted by 1, 2, 3, 4 or 5 substituents, a naphthyl group can be substituted by 1, 2, 3, 4, 5, 6 or 7 substituents, and the like.
[0125] In some embodiments, “substituted aryl” indicates an aryl group substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, hydroxyl, nitro and thiol.
[0126] In some embodiments, the term “substituted phenyl” indicates a phenyl group substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, aryl, substituted aryl, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, F, Br, I, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, heteroaryl, substituted heteroaryl, hydroxyl, nitro and thiol.
[0127] In some embodiments, the term “substituted heteroaryl” indicates a heteroaryl group substituted with 1 to 4 groups selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, hydroxyl, nitro and thiol.
[0128] In some embodiments, R 1 is C 1-6 alkyl. In some embodiments, R 1 is methyl or ethyl. In some embodiments, R 1 is methyl. In some embodiments, R 1 is ethyl.
[0129] In some embodiments, R 1 is C 2-6 alkyl.
[0130] In some embodiments, R 1 is H and can be represented by Formula (Ia) as shown below:
wherein each variable in Formula (Ia) has the same meaning as described herein, supra and infra.
[0131] In some embodiments, R 2 is H and can be represented by Formula (Ic) as shown below:
wherein each variable in Formula (Ic) has the same meaning as described herein, supra and infra. In some embodiments, compounds are of Formula (Ic) wherein R 1 is H.
[0132] In some embodiments, R 2 is halogen. In some embodiments, R 2 is F. In some embodiments, R 2 is Cl. In some embodiments, R 2 is Br.
[0133] In some embodiments, R 2 is C 1-4 alkyl. In one embodiment R 2 is methyl (i.e., —CH 3 ) and can be represented by Formula (Ie) as shown below:
wherein each variable in Formula (Ie) has the same meaning as described herein, supra and infra.
[0134] In some embodiments, R 2 is C 1-4 haloalkyl. In some embodiments, R 2 is trifluoromethyl (i.e., —CF 3 ).
[0135] In some embodiments, R 4 is selected from the group consisting of H, C 1-6 alkyl, C 3-6 -cycloalkyl and C 1-6 haloalkyl wherein each are optionally substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, hydroxyl, nitro and thiol.
[0136] In some embodiments, R 4 is selected from the group consisting of H, ethyl, n-propyl, C 4-6 alkyl, C 3-6 cycloalkyl and C 1-6 haloalkyl wherein each are optionally substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylamino, hydroxyl, nitro and thiol.
[0137] In some embodiments, R 4 is C 1-6 alkyl. In some embodiments, R 4 is methyl. In some embodiments, R 4 is ethyl.
[0138] In some embodiments, R 4 is C 1-6 haloalkyl. In some embodiments, R 4 is trifluoromethyl (i.e., —CF 3 ), difluoromethyl (i.e., —CHF 2 ) or fluoromethyl (i.e., —CH 2 F). In some embodiments, R 4 is trifluoromethyl. In some embodiments, R 4 is pentafluoroethyl (i.e., —CF 2 CF 3 ), 2,2,2-trifluoroethyl (i.e., —CH 2 CF 3 ) or 1,1-difluoroethyl (i.e., —CF 2 CH 3 ).
[0139] In some embodiments, R 3 is aryl, C 3-7 cycloalkyl, C 3-7 cycloalkenyl, heteroaryl, C 3-7 heterocycloalkyl or C 3-7 heterocycloalkenyl wherein each are optionally substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, aryl, substituted aryl, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, heteroaryl, substituted heteroaryl, hydroxyl, nitro and thiol.
[0140] In some embodiments, R 3 is a substituted phenyl, 2-chlorophenyl, 3-chlorophenyl, naphthyl, C 3-7 cycloalkyl, C 3-7 cycloalkenyl, heteroaryl, C 3-7 heterocycloalkyl or C 3-7 heterocycloalkenyl wherein the 2-chlorophenyl, 3-chlorophenyl, naphthyl, C 3-7 cycloalkyl, C 3-7 cycloalkenyl, heteroaryl, C 3-7 heterocycloalkyl and C 3-7 heterocycloalkenyl are optionally substituted with 1 to 5 substituents selected from the group consisting of C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, aryl, substituted aryl, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, heteroaryl, substituted heteroaryl, hydroxyl, nitro and thiol.
[0141] In some embodiments, R 3 is substituted phenyl, 3-chlorophenyl, C 3-7 cycloalkyl, C 3-7 cycloalkenyl or heteroaryl, wherein said 3-chlorophenyl, C 3-7 cycloalkyl, C 3-7 cycloalkenyl and heteroaryl are optionally substituted with 1 to 5 substituents selected from the group consisting of C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, aryl, cyano, halogen, C 1-6 haloalkyl and heteroaryl.
[0142] In some embodiments, R 3 is aryl optionally substituted with 1 to 5 substituents. In some embodiments, compounds can be represented by Formula (Ig) as shown below:
wherein R 1 , R 2 and R 4 are as defined herein supra and infra and R 5 to R 9 are each independently selected from the group consisting of H, C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, aryl, substituted aryl, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, heteroaryl, substituted heteroaryl, hydroxyl, nitro and thiol.
[0143] In some embodiments, compounds of the present invention are of Formula (Ig) wherein R 1 , R 2 and R 4 are as defined herein supra and infra, R 5 , R 6 , R 8 and R 9 are each independently selected from the group consisting of H, C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, aryl, substituted aryl, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, heteroaryl, substituted heteroaryl, hydroxyl, nitro and thiol; and R 7 is selected from the group consisting of H, C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, aryl, substituted aryl, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, F, Br, I, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, heteroaryl, substituted heteroaryl, hydroxyl, nitro and thiol.
[0144] In some embodiments, R 3 is selected from the group consisting of biphenyl-3-yl, 3-thiophen-2-yl-phenyl, 3-bromo-phenyl, 3-iodo-phenyl, 3-chloro-phenyl, 3-fluoro-phenyl, 3,5-difluoro-phenyl, m-tolyl, 3-ethyl-phenyl, 3-trifluoromethyl-phenyl, 4-fluoro-phenyl, 2-fluoro-phenyl, 3,4-difluoro-phenyl, 2,4-difluoro-phenyl, 2,6-difluoro-phenyl, 2,5-dichloro-phenyl, 3-methoxy-phenyl, 3,5-dichloro-phenyl, 3-cyano-phenyl, 3-propenyl-phenyl, 3-hex-1-enyl-phenyl and 3-vinyl-phenyl.
[0145] In some embodiments, when R 5 , R 6 , R 8 and R 9 are all H, then R 7 is not Cl.
[0146] In some embodiments, at least one R 5 , R 6 , R 7 , R 8 and R 9 is a group other than H.
[0147] In some embodiments, R 3 is phenyl optionally substituted with C 1-6 alkyl, aryl, substituted aryl, halogen, C 1-6 haloalkyl, heteroaryl or substituted heteroaryl.
[0148] In some embodiments, R 3 is phenyl optionally substituted with C 1-6 alkyl, aryl, halogen, C 1-6 haloalkyl or heteroaryl. In some embodiments, R 3 is phenyl optionally substituted with methyl, ethyl, phenyl, F, Cl, Br, I, trifluoromethyl or thiophene.
[0149] In some embodiments, R 3 is a substituted phenyl. In some embodiments, R 3 is a phenyl substituted with 1 to 5 substituents selected from the group consisting of C 1-6 alkyl, aryl, substituted aryl, F, Br, I, C 1-6 haloalkyl, heteroaryl and substituted heteroaryl. In some embodiments, the phenyl is substituted with 1 to 5 substituents selected from the group consisting of methyl, ethyl, phenyl, F, Br, I, trifluoromethyl and thiophene.
[0150] In some embodiments, R 3 is 2-chlorophenyl or 3-chlorophenyl wherein each is optionally substituted with 1 to 4 substituents selected from the group consisting of C 1-6 alkyl, aryl, substituted aryl, halogen, C 1-6 haloalkyl, heteroaryl and substituted heteroaryl. In some embodiments, R 3 is 2-chlorophenyl or 3-chlorophenyl wherein each is optionally substituted with 1 to 5 substituents selected from the group consisting of methyl, ethyl, phenyl, F, Cl, Br, trifluoromethyl and thiophene.
[0151] In some embodiments, R 3 is C 3-7 cycloalkenyl optionally substituted with 1 to 5 substituents. In some embodiments, R 3 is cyclopentyl optionally substituted with 1 to 5 substituents. In some embodiments, R 3 is cyclohexenyl optionally substituted with 1 to 5 substituents.
[0152] In some embodiments, R 3 is heteroaryl optionally substituted with 1 to 4 substituents. In some embodiments, R 3 is heteroaryl optionally substituted with 1 to 4 substituents each independently selected from the group consisting of C 1-6 alkyl, halogen and C 1-6 haloalkyl. In some embodiments, R 3 is heteroaryl optionally substituted with 1 to 4 substituents each independently selected from the group consisting of methyl, ethyl, F, Cl, Br, I and trifluoromethyl.
[0153] In some embodiments, R 3 is a 5-membered heteroaryl optionally substituted with 1 to 4 substituents. In some embodiments, R 3 is a thienyl and can be represented by Formula (Ii) as shown below:
wherein R 1 , R 2 and R 4 in Formula (Ii) are as defined herein supra and infra and R 5 to R 7 are each independently selected from the group consisting of H, C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, aryl, substituted aryl, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, heteroaryl, substituted heteroaryl, hydroxyl, nitro and thiol. In some embodiments, R 3 is thienyl optionally substituted with C 1-6 alkyl, halogen or C 1-6 haloalkyl. In some embodiments, R 3 is thienyl optionally substituted with methyl, ethyl, F, Cl, Br, I or trifluoromethyl.
[0154] In some embodiments, R 3 is selected from the group consisting of thiophen-3-yl, thiophen-2-yl, 4-bromo-thiophen-2-yl, 5-methyl-thiophen-2-yl, 5-chloro-thiophen-2-yl, 5-bromo-thiophen-3-yl, 5-chloro-thiophen-3-yl, 4-bromo-5-methyl-thiophen-2-yl, pyridin-3-yl, furan-2-yl, 4-methyl-thiophen-2-yl and 5-methyl-thiophen-3-yl.
[0155] In some embodiments, R 3 is thien-2-yl optionally substituted with 1 to 3 substituents and can be represented by Formula (Ik) as shown below:
wherein R 1 , R 2 and R 4 in Formula (Ik) are as defined herein supra and infra and R 5 to R 7 are each independently selected from the group consisting of H, C 1-6 acyloxy, C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, C 1-6 alkylcarboxamide, C 2-6 alkynyl, C 1-6 alkylsulfonamide, C 1-6 alkylsulfinyl, C 1-6 alkylsulfonyl, C 1-6 alkylthio, C 1-6 alkylureyl, C 1-6 alkylamino, amino, aryl, substituted aryl, carbo-C 1-6 -alkoxy, carboxamide, cyano, C 3-7 cycloalkyl, C 2-6 dialkylamino, C 2-6 dialkylcarboxamide, C 2-6 dialkylsulfonamide, halogen, C 1-6 haloalkoxy, C 1-6 haloalkyl, C 1-6 haloalkylsulfinyl, C 1-6 haloalkylsulfonyl, C 1-6 haloalkylthio, heteroaryl, substituted heteroaryl, hydroxyl, nitro and thiol. In some embodiments, R 5 to R 7 are each independently selected from the group consisting of H, C 1-6 alkyl, halogen and C 1-6 haloalkyl. In some embodiments, R 5 to R 7 are each independently selected from the group consisting of H, methyl, ethyl, F, Cl, Br, I or trifluoromethyl.
[0156] In some embodiments, R 3 is selected from the group consisting of cyclohex-1-enyl, cyclopent-1-enyl and cyclopentyl.
[0157] In some embodiments,
[0158] R 1 is H;
[0159] R 2 is H;
[0160] R 4 is C 1-6 alkyl or C 1-6 haloalkyl; and
[0161] R 3 is substituted phenyl, 3-chlorophenyl, C 3-7 cycloalkyl, C 3-7 cycloalkenyl or heteroaryl, wherein said 3-chlorophenyl, C 3-7 cycloalkyl, C 3-7 cycloalkenyl and heteroaryl are optionally substituted with 1 to 5 substituents selected from the group consisting of C 2-6 alkenyl, C 1-6 alkoxy, C 1-6 alkyl, aryl, cyano, halogen, C 1-6 haloalkyl and heteroaryl.
[0162] In some embodiments,
[0163] R 1 is H;
[0164] R 2 is H;
[0165] R 4 is methyl, ethyl or trifluoromethyl; and
[0166] R 3 is selected from the group consisting of biphenyl-3-yl, 3-thiophen-2-yl-phenyl, 3-bromo-phenyl, 3-iodo-phenyl, 3-chloro-phenyl, 3-fluoro-phenyl, 3,5-difluoro-phenyl, m-tolyl, 3-ethyl-phenyl, 3-trifluoromethyl-phenyl, 3,4-difluoro-phenyl, 2,4-difluoro-phenyl, 2,6-difluoro-phenyl, 2,5-dichloro-phenyl, 3-methoxy-phenyl, 3,5-dichloro-phenyl, 3-cyano-phenyl, 3-propenyl-phenyl, 3-hex-1-enyl-phenyl and 3-vinyl-phenyl.
[0167] In some embodiments,
[0168] R 1 is H;
[0169] R 2 is H;
[0170] R 4 is methyl, ethyl or trifluoromethyl; and
[0171] R 3 is thienyl optionally substituted with C 1-6 alkyl or halogen.
[0172] In some embodiments,
[0173] R 1 is H;
[0174] R 2 is H;
[0175] R 4 is methyl, ethyl or trifluoromethyl; and
[0176] R 3 is selected from the group consisting of thiophen-3-yl, thiophen-2-yl, 4-bromo-thiophen-2-yl, 5-methyl-thiophen-2-yl, 5-chloro-thiophen-2-yl, 5-bromo-thiophen-3-yl, 5-chloro-thiophen-3-yl, 4-bromo-5-methyl-thiophen-2-yl, pyridin-3-yl, furan-2-yl, 4-methyl-thiophen-2-yl and 5-methyl-thiophen-3-yl.
[0177] In some aspects of each embodiment of the present invention, compounds have in vitro EC 50 values at the RUP25 receptor of less than 1/2, 1/3, 1/4 or 1/5 of the in vitro EC 50 value at the RUP25 receptor for acifran.
Methods for Making the Compounds of the Invention
[0000] Synthesis of Compounds of Formula (I)
[0178] The compounds of the invention can be made using conventional organic syntheses and/or by the following illustrative methods.
[0179] In one embodiment of the present invention is a novel synthetic process for the preparation of compounds of Formula (I). The compounds of the present invention can be prepared according to this novel process utilizing a variety of starting materials that are either commercially available or readily prepared by synthetic regimes that would be familiar to ones skilled in the art. In the illustrated syntheses outlined below, the labeled substituents have the same identifications as set out in the definitions of the compound described above for Formula (I) and throughout this disclosure.
[0180] One method that can be used to prepare compounds of the present invention, wherein R 2 is H, C 1-4 is alkyl or C 1-4 haloalkyl, utilizes intermediates derived from Compound (B) as illustrated in Reaction Scheme (1) below:
Compounds of the invention can be prepared via the intermediates as shown in the above reaction scheme. By selecting the desired Compound (B) a variety of R 3 and R 4 groups can be introduced into the compounds of the invention. Compound (B) can either be obtained via commercial sources or prepared by methods known to organic chemists. Compound (B) can be reacted with the anion of Dithiane (A) to provide Hydroxydithiane (C). Bases of appropriate strength to form the anion are known in the art, for example, but not limited to, “C 1-10 alkyl lithium bases” such as methyl lithium, ethyl lithium, propyl lithium, n-butyl lithium, sec-butyl lithium, t-butyl lithium, and the like; “C 1-10 alkylamide bases” such as lithium diisopropylamide (i.e., LDA), and the like; “metal C 1-10 alkyldisilazane bases” such as lithium hexamethyldisilazane, sodium hexamethyldisilazane, potassium hexamethyldisilazane and like bases. Hydroxydithiane (C) is deprotected to provide Hydroxyketone (D). Suitable deprotecting reagents, include but not limited to, mercury-(II)-inorganic salts such as, Hg(ClO 4 ) 2 , HgO, HgCl 2 , and the like; deprotecting reagents can be used either separately or in combination with other deprotecting reagent. Hydroxyketone (D) is reacted with Orthoester (E) in the presence of a base which can be treated directly with an acid to give Compounds of Formula (I). Suitable bases include alkali metal alkoxides, for example, sodium methoxide, sodium ethoxide, potassium ethoxide, potassium t-butoxide, and the like; metal hydride bases, for example, NaH, KH, LiH, and the like; and the bases as described above. Compounds of Formula (I), where R 1 is C 1-6 alkyl, can be converted to Acid (Ia) via methods known in the art, for example but not limited to, hydrolysis, under basic conditions such as KOH, NaOH, LiOH, K 2 CO 3 , and the like; or under acidic conditions such as HCl, HBr, HI, H 2 SO 4 , H 3 PO 4 , and the like.
[0181] Alternately, compounds of the present invention can be prepared utilizing the Reaction Scheme (2) as illustrated below:
In a similar manner as described herein, supra, by selecting the desired Compound (B) a variety of R 3 and R 4 groups can be introduced into the compounds of the invention. Compound (B) can be converted to Olefin (H) via an olefination reaction known in the art, for example, Wittig Reaction, as shown in the Reaction Scheme (2), Peterson Olefination, a modified Horner-Wadsworth-Emmons Reaction, and the like. Suitable bases include the bases of appropriate strength to form the anion as known in the art for a particular olefination reaction, for example, but not limited to, “C 1-10 alkyl lithium bases” such as methyl lithium, ethyl lithium, propyl lithium, n-butyl lithium, sec-butyl lithium, t-butyl lithium, and the like; “C 1-10 alkylamide bases” such as lithium diisopropylamide (i.e., LDA), and the like; “metal C 1-10 alkyldisilazane bases” such as lithium hexamethyldisilazane, sodium hexamethyldisilazane, potassium hexamethyldisilazane; metal C 1-10 alkoxide, such as potassium t-butoxide; and like bases. Olefin (H) can be oxidized to provide Diol (J). Suitable oxidizing reagents include but not limited to, OsO 4 , and the like. Diol (J) is subsequently oxidized to give Ketone (D). Suitable oxidation reagents/reactions include, Dess-Martin, Swern Oxidation, Corey Oxidation using DMS/NCS and suitable procedures described in Hudlicky, M., Oxidation in Organic Chemistry , ACS Monograph 186 (1990), incorporated herein by reference in its entirety. Ketone (D) is converted to compounds of the invention in a similar manner as described above in Reaction Scheme (1).
[0182] One method that can be used to prepare compounds of the present invention, wherein R 2 is halogen, utilizes compounds of Formula (Ic), wherein R 1 is C 1-6 alkyl, as illustrated in Reaction Scheme (3) below:
Compounds (Ic) can be halogenated to give Compounds of Formula (I), where R 2 is halogen, using a variety of halogenating agents. Suitable halogenating agents include, but not limited to, F 2 , Cl 2 , Br 2 , I 2 , various known fluorinating agents (such as, Selectfluor™, and the like), NCS, NBS, NIS, I 2 and an Ag salt (such as, AgF), and the like. Compounds of Formula (I), where R 2 is halogen, can be converted to the corresponding carboxylic acids (i.e., compounds of Formula (Ia) where R 2 is halogen) in an analoguous manner as described above.
[0183] Compounds of the present invention can be resolved into pure or substantially pure enantiomers using methods known in the art. One particular method is illustrated in Reaction Scheme (4) as shown below:
Acid (Ia) can be coupled to a chiral amine to form the corresponding diasteomeric amide mixture. This mixture can be separated using methods known in the art, such as, chromatography, recrystallization, and the like. Each diasteromeric acid is independently hydrolyzed to provide the separate enantiomer. One particularly useful chiral amine is (+)-α-methylbenzylamine as shown in Example 10, infra.
[0184] The various organic group transformations and protecting groups utilized herein can be performed by a number of procedures other than those described above. References for other synthetic procedures that can be utilized for the preparation of intermediates or compounds disclosed herein can be found in, for example, Smith, M. B.; and March, J., Advanced Organic Chemistry, 5 th Edition, Wiley-Interscience (2001); Larock, R. C., Comprehensive Organic Transformations, A Guide to Functional Group Preparations, 2 nd Edition, VCH Publishers, Inc. (1999) or Wuts, P. G. M.; Greene, T. W.; Protective Groups in Organic Synthesis, 3 rd Edition, John Wiley and Sons, (1999), all three citations incorporated herein by reference in their entirety.
[0185] Compounds of the invention may have one or more chiral centers and therefore exist as enantiomers or diastereomers. The invention is understood to extend to all such enantiomers, diastereomers and mixtures thereof, including racemates. Formula (I) and the formulae described herein, supra, are intended to represent all individual isomers and mixtures thereof, unless stated or shown otherwise.
[0186] Racemic mixtures can be resolved into the optical pure enantiomers by known methods, for example, by separation of diastereomeric salts thereof with an optically active acid and liberating the optically active amine compound by treatment with a base. Similarly, racemic mixtures can be resolved by separation of diastereomeric salts thereof with an optically active base and liberating the optically active acid compound by treatment with an acid. Another method for resolving racemates into the optical pure enantiomers is based upon chromatography on an optically active matrix or chiral support. Certain racemic compounds of the present invention can thus be resolved into their optical antipodes, e.g., by fractional crystallization of d- or 1-(tartrates, mandelates or camphorsulphonate) salts for example. The compounds of the present invention may also be resolved by the formation of diastereomeric amides or esters by reaction of the compounds of the present invention with an optically active amine or alcohol such as that derived from (+) or (−) α-methylbenzylamine or the like, separated via fractional recrystallization, chiral chromatography or similar method and subsequently hydrolyzed.
[0187] Additional methods for the resolution of optical isomers known to those skilled in the art can be used and will be apparent to the average worker skilled in the art. Such methods include those discussed by J. Jaques, A. Collet and S. Wilen in “Enantiomers, Racemates and Resolutions”, John Wiley and Sons, New York (1981).
[0188] It is understood that the chemistry described herein is representative and is not intended to be limiting in any manner.
[0189] Representative compounds of the invention are shown below in TABLE A.
[0190] The compounds disclosed in TABLE A, TABLE B and certain intermediates within the Examples, infra, were named according to AutoNom Version 2.2 found in Chem Draw Ultra Version 7.0 or AutoNom 2000 found in Isis Draw.
TABLE A Cmpd # Structure Chemical Name 1 5-Cyclohex-1-enyl-5-methyl-4- oxo-4,5-dihydro-furan-2- carboxylic acid 2 5-Methyl-4-oxo-5-thiophen-3-yl- 4,5-dihydro-furan-2-carboxylic acid methyl ester 3 5-Methyl-4-oxo-5-thiophen-2-yl- 4,5-dihydro-furan-2-carboxylic acid methyl ester 4 5-(4-Bromo-thiophen-2-yl)-5- methyl-4-oxo-4,5-dihydro-furan- 2-carboxylic acid methyl ester 5 5-(4-Bromo-thiophen-2-yl)-5- methyl-4-oxo-4,5-dihydro-furan- 2-carboxylic acid 6 5-Methyl-5-(5-rnethyl-thiophen-2- yl)-4-oxo-4,5-dihydro-furan-2- carboxylic acid methyl ester 7 5-Methyl-5-(5-methyl-thiophen-2- yl)-4-oxo-4,5-dihydro-furan-2- carboxylic acid 8 5-(5-Chloro-thiophen-2-yl)-5- methyl-4-oxo-4,5-dihydro-furan- 2-carboxylic acid methyl ester 9 5-Cyclopent-1-enyl-5-methyl-4- oxo-4,5-dihydro-furan-2- carboxylic acid 10 5-Biphenyl-3-yl-5-methyl-4-oxo- 4,5-dihydro-furan-2-carboxylic acid methyl ester 11 5-Methyl-4-oxo-5-(3-thiophen-2- yl-phenyl)-4,5-dihydra-furan-2- carboxylic acid methyl ester 12 5-(3-Bromo-phenyl)-5-methyl-4- oxo-4,5-dihydro-furan-2- carboxylic acid methyl ester 13 5-(3-Bromo-phenyl)-5-methyl-4- oxo-4,5-dihydro-furan-2- carboxylic acid 14 5-(3-Iodo-phenyl)-5-methyl-4- oxo-4,5-dihydro-furan-2- carboxylic acid 15 5-(3-Chloro-phenyl)-5-methyl-4- oxo-4,5-dihydro-furan-2- carboxylic acid 16 5-(3-Fluoro-phenyl)-5-methyl-4- oxo-4,5-dihydro-furan-2- carboxylic acid 17 5-(3,5-Difluoro-phenyl)-5-methyl- 4-oxo-4,5-dihydro-furan-2- carboxylic acid 18 5-Methyl-4-oxo-5-m-tolyl-4,5- dihydro-furan-2-carboxylic acid 19 5-(3-Ethyl-phenyl)-5-methyl-4- oxo-4,5-dihydro-furan-2- carboxylic acid 20 5-Methyl-4-oxo-5-(3- trifluoromethyl-phenyl)-4,5- dihydro-furan-2-carboxylic acid 21 5-(5-Chloro-thiophen-2-yl)-5- methyl-4-oxo-4,5-dihydro-furan- 2-carboxylic acid 22 5-Methyl-4-oxo-5-thiophen-2-yl- 4,5-dihydro-furan-2-carboxylic acid 23 5-(5-Bromo-thiophen-3-yl)-5- methyl-4-oxo-4,5-dihydro-furan- 2-carboxylic acid methyl ester 24 5-(5-Bromo-thiophen-3-yl)-5- methyl-4-oxo-4,5-dihydro-furan- 2-carboxylic acid 25 5-(5-Chloro-thiophen-3-yl)-5- methyl-4-oxo-4,5-dihydro-furan- 2-carboxylic acid methyl ester 26 5-(5-Chloro-thiophen-3-yl)-5- methyl-4-oxo-4,5-dihydro-furan- 2-carboxylic acid 27 5-(4-Bromo-5-methyl-thiophen-2- yl)-5-methyl-4-oxo-4,5-dihydro- furan-2-carboxylic acid 28 5-Methyl-4-oxo-5-thiophen-3-yl- 4,5-dihydro-furan-2-carboxylic acid
[0191] Representative compounds of the invention are shown below in TABLE B.
TABLE B Cmpd # Chemical Structure Chemical Name 29 5-(4-Fluoro-phenyl)-5-methyl-4- oxo-4,5-dihydro-furan-2- carboxylic acid 30 5-Methyl-4-oxo-5-pyridin-3-yl- 4,5-dihydro-furan-2-carboxylic acid 31 5-Ethyl-4-oxo-5-phenyl-4,5- dihydro-furan-2-carboxylic acid 32 5-(2-Fluoro-phenyl)-5-methyl-4- oxo-4,5-dihydro-furan-2- carboxylic acid 33 2-Methyl-3-oxo-2,3-dihydro- [2,2′]bifuranyl-5-carboxylic acid 34 5-(3,4-Difluoro-phenyl)-5-methyl- 4-oxo-4,5-dihydro-furan-2- carboxylic acid 35 5-(2,4-Difluoro-phenyl)-5-methyl- 4-oxo-4,5-dihydro-furan-2- carboxylic acid 36 5-(2,6-Difluoro-phenyl)-5-methyl- 4-oxo-4,5-dihydro-furan-2- carboxylic acid 37 5-(2,5-Dichloro-phenyl)-5- methyl-4-oxo-4,5-dihydro-furan- 2-carboxylic acid 38 5-(3-Methoxy-phenyl)-5-methyl- 4-oxo-4,5-dihydro-furan-2- carboxylic acid 39 5-Methyl-4-oxo-5-m-tolyl-4,5- dihydro-furan-2-carboxylic acid methyl ester 40 5-(3-Ethyl-phenyl)-5-methyl-4- oxo-4,5-dihydro-furan-2- carboxylic acid methyl ester 41 5-Cyclohex-1-enyl-5-methyl-4- oxo-4,5-dihydro-furan-2- carboxylic acid methyl ester 42 5-(3,5-Dichloro-phenyl)-5- methyl-4-oxo-4,5-dihydro-furan- 2-carboxylic acid methyl ester 43 5-(3,5-Dichloro-phenyl)-5- methyl-4-oxo-4,5-dihydro-furan- 2-carboxylic acid 44 5-(3-Iodo-phenyl)-5-methyl-4- oxo-4,5-dihydro-furan-2- carboxylic acid methyl ester 45 5-Cyclopentyl-5-methyl-4-oxo- 4,5-dihydro-furan-2-carboxylic acid methyl ester 46 5-Cyclopentyl-5-methyl-4-oxo- 4,5-dihydro-furan-2-carboxylic acid 47 5-(3-Cyano-phenyl)-5-methyl-4- oxo-4,5-dihydro-furan-2- carboxylic acid methyl ester 48 5-(3-Cyano-phenyl)-5-methyl-4- oxo-4,5-dihydro-furan-2- carboxylic acid 49 5-Methyl-4-oxo-5-{((E)-3- propenyl)-phenyl]-4,5-dihydro- furan-2-carboxylic acid 50 5-(4-Bromo-5-methyl-thiophen-2- yl)-5-methyl-4-oxo-4,5-dihydro- furan-2-carboxylic acid methyl ester 51 5-Biphenyl-3-yl-5-methyl-4-oxo- 4,5-dihydro-furan-2-carboxylic acid 52 5-[((E)-3-Hex-1-enyl)-phenyl]-5- methyl-4-oxo-4,5-dihydro-furan- 2-carboxylic acid 53 5-Methyl-5-(4-methyl-thiophen-2- yl)-4-oxo-4,5-dihydro-furan-2- carboxylic acid methyl ester 54 5-Methyl-4-oxo-5-(3-vinyl- phenyl)-4,5-dihydro-furan-2- carboxylic acid 55 5-Methyl-5-(4-methyl-thiophen-2- yl)-4-oxo-4,5-dihydro-furan-2- carboxylic acid 56 5-Methyl-5-(5-methyl-thiophen-3- yl)-4-oxo-4,5-dihydro-furan-2- carboxylic acid 57 4-Oxo-5-phenyl-5- trifluoromethyl-4,5-dihydro- furan-2-carboxylic acid
Methods and Uses
[0192] Compounds of the present invention can modulate the activity of the RUP25 receptor. The term “modulate” is meant to refer to the ability to increase or decrease activity of the receptor. In some embodiments, compounds of the invention can be used in methods of modulating a RUP25 receptor by contacting the receptor with any one or more of the compound as described herein. In still other embodiments, compounds of the invention can be used in methods of modulating a RUP25 receptor for the treatment of a metabolic-related disorder in an individual in need of such modulation comprising contacting the receptor with a therapeutically-effective amount of a compound of Formula (I). In some embodiments, compounds of the invention increase activity of the RUP25 receptor. In further embodiments, compounds of the invention are agonists of the RUP25 receptor. The term “agonist”, as used herein, refers to agents that can stimulate activity of the receptor (i.e., activate), like the RUP25 receptor. In some embodiments, compounds of the invention are partial agonists of the RUP25 receptor.
[0193] Another aspect of the present invention pertains to methods of treatment of a metabolic-related disorder comprising administering to an individual in need of such treatment a therapeutically-effective amount of a compound of Formula (I).
[0194] Another aspect of the present invention pertains to methods of raising HDL in an individual comprising administering to the individual a therapeutically-effective amount of a compound of Formula (I).
[0195] Another aspect of the present invention pertains to compounds of Formula (I), as described herein, for use in a method of treatment of the human or animal body by therapy.
[0196] Another aspect of the present invention pertains to compounds of Formula (I), as described herein, for use in a method of treatment of a metabolic-related disorder of the human or animal body by therapy.
[0197] Another aspect of the present invention pertains to compounds of Formula (I), as described herein, for use in a method of treatment of a metabolic-related disorder of the human or animal body by therapy wherein the metabolic-related disorder is selected from the group consisting of dyslipidemia, atherosclerosis, coronary heart disease, insulin resistance, obesity, impaired glucose tolerance, atheromatous disease, hypertension, stroke, Syndrome X, heart disease and type 2 diabetes.
[0198] Another aspect of the present invention pertains to compounds of Formula (I), as described herein, for use in a method of treatment of a metabolic-related disorder of the human or animal body by therapy wherein the metabolic-related disorder is selected from the group consisting of dyslipidemia, atherosclerosis, coronary heart disease, insulin resistance and type 2 diabetes.
[0199] Another aspect of the present invention pertains to compounds of Formula (I), as described herein, for use in a method of treatment of atherosclerosis of the human or animal body by therapy.
[0200] Another aspect of the present invention pertains to compounds of Formula (I), as described herein, for use in a method of raising HDL of the human or animal body by therapy.
[0201] Another aspect of the present invention pertains to uses of the compounds of Formula (I), as described herein, for the manufacture of a medicament for use in the treatment of a metabolic-related disorder.
[0202] Another aspect of the present invention pertains to uses of the compounds of Formula (I), as described herein, for the manufacture of a medicament for use in the treatment of a metabolic-related disorder selected from the group consisting of dyslipidemia, atherosclerosis, coronary heart disease, insulin resistance, obesity, impaired glucose tolerance, atheromatous disease, hypertension, stroke, Syndrome X, heart disease and type 2 diabetes.
[0203] Another aspect of the present invention pertains to uses of the compounds of Formula (I), as described herein, for the manufacture of a medicament for use in the treatment of atherosclerosis.
[0204] Another aspect of the present invention pertains to uses of the compounds of Formula (I), as described herein, for the manufacture of a medicament for use in raising HDL in an individual.
[0205] Some embodiments of the present invention relate to methods of treatment of metabolic-related disorders. In some embodiments the metabolic-related disorder is of the group consisting of dyslipidemia, atherosclerosis, coronary heart disease, insulin resistance, obesity, impaired glucose tolerance, atheromatous disease, hypertension, stroke, Syndrome X, heart disease and type 2 diabetes. In some embodiments the metabolic-related disorder is dyslipidemia, atherosclerosis, coronary heart disease, insulin resistance and type 2 diabetes. In some embodiments the metabolic-related disorder is dyslipidemia. In some embodiments the metabolic-related disorder is atherosclerosis. In some embodiments the metabolic-related disorder is coronary heart disease. In some embodiments the metabolic-related disorder is insulin resistance. In some embodiments the metabolic-related disorder is type 2 diabetes.
[0206] In some embodiments related to methods of the present invention, the individual is a mammal. In further embodiments, the mammal is a human.
[0207] Another aspect of the present invention pertains to methods of producing a pharmaceutical composition comprising admixing or combining a compound of Formula (I), as described herein and a pharmaceutically acceptable carrier.
[0000] Compositions of the Present Invention
[0208] Some embodiments of the present invention include pharmaceutical compositions comprising a compound according to Formula (I) in combination with a pharmaceutically acceptable carrier.
[0209] Some embodiments of the present invention include a method of producing a pharmaceutical composition comprising admixing at least one compound according to any of the compound embodiments disclosed herein and a pharmaceutically acceptable carrier.
[0210] Formulations can be prepared by any suitable method, typically by uniformly mixing the active compound(s) with liquids or finely divided solid carriers or both, in the required proportions and then, if necessary, forming the resulting mixture into a desired shape.
[0211] Conventional excipients, such as binding agents, fillers, acceptable wetting agents, tabletting lubricants and disintegrants can be used in tablets and capsules for oral administration. Liquid preparations for oral administration can be in the form of solutions, emulsions, aqueous or oily suspensions and syrups. Alternatively, the oral preparations can be in the form of dry powder that can be reconstituted with water or another suitable liquid vehicle before use. Additional additives such as suspending or emulsifying agents, non-aqueous vehicles (including edible oils), preservatives and flavorings and colorants can be added to the liquid preparations. Parenteral dosage forms can be prepared by dissolving the compound of the invention in a suitable liquid vehicle and filter sterilizing the solution before filling and sealing an appropriate vial or ampoule. These are just a few examples of the many appropriate methods well known in the art for preparing dosage forms.
[0212] A compound of the present invention can be formulated into pharmaceutical compositions using techniques well known to those in the art. Suitable pharmaceutically-acceptable carriers, outside those mentioned herein, are known in the art; for example, see Remington, The Science and Practice of Pharmacy, 20 th Edition, 2000, Lippincott Williams & Wilkins, (Editors: Gennaro, A. R., et al.).
[0213] While it is possible that a compound for use in the treatment of the present invention may, in an alternative use, be administered as a raw or pure chemical, it is preferable however to present the compound or “active ingredient” as a pharmaceutical formulation or composition further comprising a pharmaceutically acceptable carrier. Therefore, one aspect of the present invention encompasses pharmaceutical compositions comprising a pharmaceutically acceptable carrier in combination with at least one compound according to Formula (I).
[0214] The invention provides pharmaceutical formulations comprising a compound of the invention or a pharmaceutically acceptable salt, hydrate or solvate thereof together with one or more pharmaceutically acceptable carriers therefor. The carrier(s) must be “acceptable” in the sense of being compatible with the other ingredients of the formulation and not overly deleterious to the recipient thereof.
[0215] Pharmaceutical formulations include those suitable for oral, rectal, nasal, topical (including buccal and sub-lingual), vaginal or parenteral (including intramuscular, sub-cutaneous and intravenous) administration or in a form suitable for administration by inhalation, insufflation or by a transdermal patch. Transdermal patches dispense a drug at a controlled rate by presenting the drug for absorption in an efficient manner with a minimum of degradation of the drug. Typically, transdermal patches comprise an impermeable backing layer, a single pressure sensitive adhesive and a removable protective layer with a release liner. One of ordinary skill in the art will understand and appreciate the techniques appropriate for manufacturing a desired efficacious transdermal patch based upon the needs of the artisan.
[0216] The compounds of the invention, together with a conventional adjuvant, carrier or diluent, may thus be placed into the form of pharmaceutical formulations and unit dosages thereof and in such form can be employed as solids, such as tablets or filled capsules or liquids such as solutions, suspensions, emulsions, elixirs, gels or capsules filled with the same, all for oral use, in the form of suppositories for rectal administration; or in the form of sterile injectable solutions for parenteral (including subcutaneous) use. Such pharmaceutical compositions and unit dosage forms thereof may comprise conventional ingredients in conventional proportions, with or without additional active compounds or principles and such unit dosage forms may contain any suitable effective amount of the active ingredient commensurate with the intended daily dosage range to be employed.
[0217] For oral administration, the pharmaceutical composition can be in the form of, for example, a tablet, capsule, suspension or liquid. The pharmaceutical composition is preferably made in the form of a dosage unit containing a particular amount of the active ingredient. Examples of such dosage units are capsules, tablets, powders, granules or a suspension, with conventional additives such as lactose, mannitol, corn starch or potato starch; with binders such as crystalline cellulose, cellulose derivatives, acacia, corn starch or gelatins; with disintegrators such as corn starch, potato starch or sodium carboxymethyl-cellulose; and with lubricants such as talc or magnesium stearate. The active ingredient may also be administered by injection as a composition wherein, for example, saline, dextrose or water can be used as a suitable pharmaceutically acceptable carrier.
[0218] Compounds of the present invention or a solvate or physiologically functional derivative thereof can be used as active ingredients in pharmaceutical compositions, specifically as RUP25 receptor agonists. By the term “active ingredient” is defined in the context of a “pharmaceutical composition” and shall mean a component of a pharmaceutical composition that provides the primary pharmacological effect, as opposed to an “inactive ingredient” which would generally be recognized as providing no pharmaceutical benefit.
[0219] The dose when using the compounds of the present invention can vary within wide limits and as is customary and is known to the physician, it is to be tailored to the individual conditions in each individual case. It depends, for example, on the nature and severity of the illness to be treated, on the condition of the patient, on the compound employed or on whether an acute or chronic disease state is treated is conducted or on whether further active compounds are administered in addition to the compounds of the present invention. Representative doses of the present invention include, but not limited to, about 0.001 mg to about 5000 mg, about 0.001 to about 2500 mg, about 0.001 to about 1000 mg, 0.001 to about 500 mg, 0.001 mg to about 250 mg, about 0.001 mg to 100 mg, about 0.001 mg to about 50 mg and about 0.001 mg to about 25 mg. Multiple doses can be administered during the day, especially when relatively large amounts are deemed to be needed, for example 2, 3 or 4, doses. Depending on the individual and as deemed appropriate from the patient's physician or care-giver it may be necessary to deviate upward or downward from the doses described herein.
[0220] The amount of active ingredient or an active salt or derivative thereof, required for use in treatment will vary not only with the particular salt selected but also with the route of administration, the nature of the condition being treated and the age and condition of the patient and will ultimately be at the discretion of the attendant physician or clinician. In general, one skilled in the art understands how to extrapolate in vivo data obtained in a model system to another, for example, an animal model to a human. Typically, animal models include, but are not limited to, the rodents diabetes models as described in Example 1, infra; the mouse artherosclerosis model as described in Example 2, infra; or the in vivo animal arthosclerosis model as described in Example 5, infra. In some circumstances, these extrapolations may merely be based on the weight of the animal model in comparison to another, such as a mammal, preferably a human, however, more often, these extrapolations are not simply based on weight differences, but rather incorporate a variety of factors. Representative factors include the type, age, weight, sex, diet and medical condition of the patient, the severity of the disease, the route of administration, pharmacological considerations such as the activity, efficacy, pharmacokinetic and toxicology profiles of the particular compound employed, whether a drug delivery system is utilized, on whether an acute or chronic disease state is being treated is conducted or on whether further active compounds are administered in addition to the compounds of the Formula (I) and as part of a drug combination. The dosage regimen for treating a disease condition with the compounds and/or compositions of this invention is selected in accordance with a variety factors, such as, those cited above. Thus, the actual dosage regimen employed may vary widely and therefore may deviate from a preferred dosage regimen and one skilled in the art will recognize that dosage and dosage regimen outside these typical ranges can be tested and, where appropriate, can be used in the methods of this invention.
[0221] The desired dose may conveniently be presented in a single dose or as divided doses administered at appropriate intervals, for example, as two, three, four or more sub-doses per day. The sub-dose itself can be further divided, e.g., into a number of discrete loosely spaced administrations. The daily dose can be divided, especially when relatively large amounts are administered as deemed appropriate, into several, for example 2, 3 or 4, part administrations. If appropriate, depending on individual behavior, it can be necessary to deviate upward or downward from the daily dose indicated.
[0222] The compounds of the present invention can be administrated in a wide variety of oral and parenteral dosage forms. It will be obvious to those skilled in the art that the following dosage forms may comprise, as the active component, either a compound of the invention or a pharmaceutically acceptable salt of a compound of the invention.
[0223] For preparing pharmaceutical compositions from the compounds of the present invention, pharmaceutically acceptable carriers can be either solid or liquid. Solid form preparations include powders, tablets, pills, capsules, cachets, suppositories and dispersible granules. A solid carrier can be one or more substances which may also act as diluents, flavouring agents, solubilizers, lubricants, suspending agents, binders, preservatives, tablet disintegrating agents or an encapsulating material.
[0224] In powders, the carrier is a finely divided solid which is in a mixture with the finely divided active component.
[0225] In tablets, the active component is mixed with the carrier having the necessary binding capacity in suitable proportions and compacted to the desire shape and size.
[0226] The powders and tablets may contain varying percentage amounts of the active compound. A representative amount in a powder or tablet may contain from 0.5 to about 90 percent of the active compound; however, an artisan would know when amounts outside of this range are necessary. Suitable carriers for powders and tablets are magnesium carbonate, magnesium stearate, talc, sugar, lactose, pectin, dextrin, starch, gelatin, tragacanth, methylcellulose, sodium carboxymethylcellulose, a low melting wax, cocoa butter, and the like. The term “preparation” is intended to include the formulation of the active compound with encapsulating material as carrier providing a capsule in which the active component, with or without carriers, is surrounded by a carrier, which is thus in association with it. Similarly, cachets and lozenges are included. Tablets, powders, capsules, pills, cachets and lozenges can be used as solid forms suitable for oral administration.
[0227] For preparing suppositories, a low melting wax, such as an admixture of fatty acid glycerides or cocoa butter, is first melted and the active component is dispersed homogeneously therein, as by stirring. The molten homogenous mixture is then poured into convenient sized molds, allowed to cool and thereby to solidify.
[0228] Formulations suitable for vaginal administration can be presented as pessaries, tampons, creams, gels, pastes, foams or sprays containing in addition to the active ingredient such carriers as are known in the art to be appropriate.
[0229] Liquid form preparations include solutions, suspensions and emulsions, for example, water or water-propylene glycol solutions. For example, parenteral injection liquid preparations can be formulated as solutions in aqueous polyethylene glycol solution. Injectable preparations, for example, sterile injectable aqueous or oleaginous suspensions can be formulated according to the known art using suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution or suspension in a nontoxic parenterally acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that can be employed are water, Ringer's solution and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil can be employed including synthetic mono- or diglycerides. In addition, fatty acids such as oleic acid find use in the preparation of injectables.
[0230] The compounds according to the present invention may thus be formulated for parenteral administration (e.g. by injection, for example bolus injection or continuous infusion) and can be presented in unit dose form in ampoules, pre-filled syringes, small volume infusion or in multi-dose containers with an added preservative. The compositions may take such forms as suspensions, solutions or emulsions in oily or aqueous vehicles and may contain formulatory agents such as suspending, stabilizing and/or dispersing agents. Alternatively, the active ingredient can be in powder form, obtained by aseptic isolation of sterile solid or by lyophilization from solution, for constitution with a suitable vehicle, e.g. sterile, pyrogen-free water, before use.
[0231] Aqueous solutions suitable for oral use can be prepared by dissolving the active component in water and adding suitable colorants, flavours, stabilizing and thickening agents, as desired.
[0232] Aqueous suspensions suitable for oral use can be made by dispersing the finely divided active component in water with viscous material, such as natural or synthetic gums, resins, methylcellulose, sodium carboxymethylcellulose or other well known suspending agents.
[0233] Also included are solid form preparations which are intended to be converted, shortly before use, to liquid form preparations for oral administration. Such liquid forms include solutions, suspensions and emulsions. These preparations may contain, in addition to the active component, colorants, flavors, stabilizers, buffers, artificial and natural sweeteners, dispersants, thickeners, solubilizing agents, and the like.
[0234] For topical administration to the epidermis the compounds according to the invention can be formulated as ointments, creams or lotions or as a transdermal patch.
[0235] Ointments and creams may, for example, be formulated with an aqueous or oily base with the addition of suitable thickening and/or gelling agents. Lotions can be formulated with an aqueous or oily base and will in general also contain one or more emulsifying agents, stabilizing agents, dispersing agents, suspending agents, thickening agents or coloring agents.
[0236] Formulations suitable for topical administration in the mouth include lozenges comprising active agent in a flavored base, usually sucrose and acacia or tragacanth; pastilles comprising the active ingredient in an inert base such as gelatin and glycerin or sucrose and acacia; and mouthwashes comprising the active ingredient in a suitable liquid carrier.
[0237] Solutions or suspensions are applied directly to the nasal cavity by conventional means, for example with a dropper, pipette or spray. The formulations can be provided in single or multi-dose form. In the latter case of a dropper or pipette, this can be achieved by the patient administering an appropriate, predetermined volume of the solution or suspension. In the case of a spray, this can be achieved for example by means of a metering atomizing spray pump.
[0238] Administration to the respiratory tract may also be achieved by means of an aerosol formulation in which the active ingredient is provided in a pressurized pack with a suitable propellant. If the compounds of the Formula (I) or pharmaceutical compositions comprising them are administered as aerosols, for example as nasal aerosols or by inhalation, this can be carried out, for example, using a spray, a nebulizer, a pump nebulizer, an inhalation apparatus, a metered inhaler or a dry powder inhaler. Pharmaceutical forms for administration of the compounds of the Formula (I) as an aerosol can be prepared by processes well-known to the person skilled in the art. For their preparation, for example, solutions or dispersions of the compounds of the Formula (I) in water, water/alcohol mixtures or suitable saline solutions can be employed using customary additives, for example benzyl alcohol or other suitable preservatives, absorption enhancers for increasing the bioavailability, solubilizers, dispersants and others and, if appropriate, customary propellants, for example include carbon dioxide, CFC's, such as, dichlorodifluoromethane, trichlorofluoromethane or dichlorotetrafluoroethane, and the like. The aerosol may conveniently also contain a surfactant such as lecithin. The dose of drug can be controlled by provision of a metered valve.
[0239] In formulations intended for administration to the respiratory tract, including intranasal formulations, the compound will generally have a small particle size for example of the order of 10 microns or less. Such a particle size can be obtained by means known in the art, for example by micronization. When desired, formulations adapted to give sustained release of the active ingredient can be employed.
[0240] Alternatively the active ingredients can be provided in the form of a dry powder, for example, a powder mix of the compound in a suitable powder base such as lactose, starch, starch derivatives such as hydroxypropylmethyl cellulose and polyvinylpyrrolidone (PVP). Conveniently the powder carrier will form a gel in the nasal cavity. The powder composition can be presented in unit dose form for example in capsules or cartridges of, e.g., gelatin or blister packs from which the powder can be administered by means of an inhaler.
[0241] The pharmaceutical preparations are preferably in unit dosage forms. In such form, the preparation is subdivided into unit doses containing appropriate quantities of the active component. The unit dosage form can be a packaged preparation, the package containing discrete quantities of preparation, such as packeted tablets, capsules and powders in vials or ampoules. Also, the unit dosage form can be a capsule, tablet, cachet or lozenge itself or it can be the appropriate number of any of these in packaged form.
[0242] Tablets or capsules for oral administration and liquids for intravenous administration are preferred compositions.
[0243] Compounds of the present invention can be converted to “pro-drugs.” The term “pro-drugs” refers to compounds that have been modified with specific chemical groups known in the art and when administered into an individual these groups undergo biotransformation to give the parent compound. Pro-drugs can thus be viewed as compounds of the invention containing one or more specialized non-toxic protective groups used in a transient manner to alter or to eliminate a property of the compound. In general, the “pro-drug” approach is utilized to facilitate oral absorption. A thorough discussion is provided in T. Higuchi and V. Stella, “Pro-drugs as Novel Delivery Systems,” Vol. 14 of the A.C.S. Symposium Series and in Bioreversible Carriers in Drug Design, ed. Edward B. Roche, American Pharmaceutical Association and Pergamon Press, 1987, both of which are hereby incorporated by reference in their entirety.
[0000] Combination Therapy:
[0244] While the compounds of the present invention can be administered as the sole active pharmaceutical agent (i.e., mono-therapy), they can also be used in combination with other pharmaceutical agents (i.e., combination-therapy) for the treatment of the diseases/conditions/disorders described herein. Therefore, another aspect of the present invention includes methods of treatment of metabolic related diseases comprising administering to an individual in need of such treatment a therapeutically-effective amount of a compound of the present invention in combination with one or more additional pharmaceutical agent as described herein.
[0245] Suitable pharmaceutical agents that can be used in combination with the compounds of the present invention include anti-obesity agents such as apolipoprotein-B secretion/microsomal triglyceride transfer protein (apo-B/MTP) inhibitors, MCR-4 agonists, cholescystokinin-A (CCK-A) agonists, serotonin and norepinephrine reuptake inhibitors (for example, sibutramine), sympathomimetic agents, β 3 adrenergic receptor agonists, dopamine agonists (for example, bromocriptine), melanocyte-stimulating hormone receptor analogs, cannabinoid 1 receptor antagonists [for example, SR141716: N-(piperidin-1-yl)-5-(4-chlorophenyl)-1-(2,4-dichlorophenyl)-4-methyl-1H-pyrazole-3-carboxamide], melanin concentrating hormone antagonists, leptons (the OB protein), leptin analogues, leptin receptor agonists, galanin antagonists, lipase inhibitors (such as tetrahydrolipstatin, i.e. orlistat), anorectic agents (such as a bombesin agonist), Neuropeptide-Y antagonists, thyromimetic agents, dehydroepiandrosterone or an analogue thereof, glucocorticoid receptor agonists or antagonists orexin receptor antagonists, urocortin binding protein antagonists, glucagon-like peptide-1 receptor agonists, ciliary neutrotrophic factors (such as Axokine™ available from Regeneron Pharmaceuticals, Inc., Tarrytown, N.Y. and Procter & Gamble Company, Cincinnati, Ohio), human agouti-related proteins (AGRP), ghrelin receptor antagonists, histamine 3 receptor antagonists or reverse agonists, neuromedin U receptor agonists, noradrenergic anorectic agents (for example, phentermine, mazindol, and the like) and appetite suppressants (for example, bupropion).
[0246] Other anti-obesity agents, including the agents set forth infra, are well known or will be readily apparent in light of the instant disclosure, to one of ordinary skill in the art.
[0247] In some embodiments, the anti-obesity agents are selected from the group consisting of orlistat, sibutramine, bromocriptine, ephedrine, leptin and pseudoephedrine. In a further embodiment, compounds of the present invention and combination therapies are administered in conjunction with exercise and/or a sensible diet.
[0248] It is understood that the scope of combination-therapy of the compounds of the present invention with other anti-obesity agents, anorectic agents, appetite suppressant and related agents is not limited to those listed above, but includes in principle any combination with any pharmaceutical agent or pharmaceutical composition useful for the treatment of overweight and obese individuals.
[0249] Other suitable pharmaceutical agents, in addition to anti-obesity agents, that can be used in combination with the compounds of the present invention include agents useful in the treatment of concomitant disorders. Treatment of such disorders include the use of one or more pharmaceutical agents known in the art that belong to the classes of drugs referred to, but not limited to, the following: sulfonylureas, meglitinides, biguanides, α-glucosidase inhibitors, peroxisome proliferators-activated receptor-γ (i.e., PPAR-γ) agonists, insulin, insulin analogues, HMG-CoA reductase inhibitors, cholesterol-lowering drugs (for example, fibrates that include: fenofibrate, bezafibrate, gemfibrozil, clofibrate, and the like; bile acid sequestrants which include: cholestyramine, colestipol, and the like; and niacin), antiplatelet agents (for example, aspirin and adenosine diphosphate receptor antagonists that include: clopidogrel, ticlopidine, and the like), angiotensin-converting enzyme inhibitors, angiotensin II receptor antagonists and adiponectin. In accordance to one aspect of the present invention, a compound of the present can be used in combination with a pharmaceutical agent or agents belonging to one or more of the classes of drugs cited herein.
[0250] It is understood that the scope of combination-therapy of the compounds of the present invention with other pharmaceutical agents is not limited to those listed herein, supra or infra, but includes in principle any combination with any pharmaceutical agent or pharmaceutical composition useful for the treatment of diseases, conditions or disorders that are linked to metabolic-related disorders.
[0251] Some embodiments of the present invention include methods of treatment of a disease, disorder or condition as described herein comprising administering to an individual in need of such treatment a therapeutically effect amount or dose of a compound of the present invention in combination with at least one pharmaceutical agent selected from the group consisting of: sulfonylureas, meglitinides, biguanides, α-glucosidase inhibitors, peroxisome proliferators-activated receptors (i.e., PPAR-γ) agonists, insulin, insulin analogues, HMG-CoA reductase inhibitors, cholesterol-lowering drugs (for example, fibrates that include: fenofibrate, bezafibrate, gemfibrozil, clofibrate, and the like; bile acid sequestrants which include: cholestyramine, colestipol, and the like; and niacin), antiplatelet agents (for example, aspirin and adenosine diphosphate receptor antagonists that include: clopidogrel, ticlopidine, and the like), angiotensin-converting enzyme inhibitors, angiotensin II receptor antagonists and adiponectin. In some embodiments, the pharmaceutical composition further comprises one or more agents selected from the group consisting of α-glucosidase inhibitor, aldose reductase inhibitor, biguanide, HMG-CoA reductase inhibitor, squalene synthesis inhibitor, fibrate, LDL catabolism enhancer, angiotensin converting enzyme inhibitor, insulin secretion enhancer and thiazolidinedione.
[0252] One aspect of the present invention encompasses pharmaceutical compositions comprising at least one compound according to Formula (I), as described herein. In some embodiments, the pharmaceutical composition further comprises one or more agents selected from the group consisting of, for example, α-glucosidase inhibitor, aldose reductase inhibitor, biguanide, HMG-CoA reductase inhibitor, squalene synthesis inhibitor, fibrate, LDL catabolism enhancer, angiotensin converting enzyme inhibitor, insulin secretion enhancer and thiazolidinedione.
[0253] Suitable pharmaceutical agents that can be used in conjunction with compounds of the present invention include α-glucosidase inhibitors. α-Glucosidase inhibitors belong to the class of drugs which competitively inhibit digestive enzymes such as α-amylase, maltase, α-dextrinase, sucrase, etc. in the pancreas and or small intestine. The reversible inhibition by α-glucosidase inhibitors retard, diminish or otherwise reduce blood glucose levels by delaying the digestion of starch and sugars. Some representative examples of α-glucosidase inhibitors include acarbose, N-(1,3-dihydroxy-2-propyl)valiolanine (generic name; voglibose), miglitol and α-glucosidase inhibitors known in the art.
[0254] Suitable pharmaceutical agents that can be used in conjunction with compounds of the present invention include sulfonylureas. The sulfonylureas (SU) are drugs which promote secretion of insulin from pancreatic β cells by transmitting signals of insulin secretion via SU receptors in the cell membranes. Examples of the sulfonylureas include glyburide, glipizide, glimepiride and other sulfonylureas known in the art.
[0255] Suitable pharmaceutical agents that can be used in conjunction with compounds of the present invention include the meglitinides. The meglitinides are benzoic acid derivatives represent a novel class of insulin secretagogues. These agents target postprandial hyperglycemia and show comparable efficacy to sulfonylureas in reducing HbA 1c . Examples of meglitinides include repaglinide, nateglinide and other meglitinides known in the art.
[0256] Suitable pharmaceutical agents that can be used in conjunction with compounds of the present invention include the biguanides. The biguanides represent a class of drugs that stimulate anaerobic glycolysis, increase the sensitivity to insulin in the peripheral tissues, inhibit glucose absorption from the intestine, suppress of hepatic gluconeogenesis and inhibit fatty acid oxidation. Examples of biguanides include phenformin, metformin, buformin and biguanides known in the art.
[0257] Suitable pharmaceutical agents that can be used in conjunction with compounds of the present invention include the α-glucosidase inhibitors. The α-glucosidase inhibitors competitively inhibit digestive enzymes such as α-amylase, maltase, α-dextrinase, sucrase, etc. in the pancreas and or small intestine. The reversible inhibition by α-glucosidase inhibitors retard, diminish or otherwise reduce blood glucose levels by delaying the digestion of starch and sugars. Examples of α-glucosidase inhibitors include acarbose, N-(1,3-dihydroxy-2-propyl)valiolamine (generic name; voglibose), miglitol and α-glucosidase inhibitors known in the art.
[0258] Suitable pharmaceutical agents that can be used in conjunction with compounds of the present invention include the peroxisome proliferators-activated receptor-γ (i.e., PPAR-γ) agonists. The peroxisome proliferators-activated receptor-γ agonists represent a class of compounds that activates the nuclear receptor PPAR-γ and therefore regulate the transcription of insulin-responsive genes involved in the control of glucose production, transport and utilization. Agents in the class also facilitate the regulation of fatty acid metabolism. Examples of PPAR-γ agonists include rosiglitazone, pioglitazone, tesaglitazar, netoglitazone, GW-409544, GW-501516 and PPAR-γ agonists known in the art.
[0259] Suitable pharmaceutical agents that can be used in conjunction with compounds of the present invention include the HMG-CoA reductase inhibitors. The HMG-CoA reductase inhibitors are agents also referred to as Statin compounds that belong to a class of drugs that lower blood cholesterol levels by inhibiting hydroxymethylglutalkyl CoA (HMG-CoA) reductase. HMG-CoA reductase is the rate-limiting enzyme in cholesterol biosynthesis. The statins lower serum LDL concentrations by upregulating the activity of LDL receptors and are responsible for clearing LDL from the blood. Some representative examples the statin compounds include rosuvastatin, pravastatin and its sodium salt, simvastatin, lovastatin, atorvastatin, fluvastatin, cerivastatin, rosuvastatin, pitavastatin, BMS's “superstatin” and HMG-CoA reductase inhibitors known in the art.
[0260] Suitable pharmaceutical agents that can be used in conjunction with compounds of the present invention include the angiotensin converting enzyme (ACE) inhibitors. The angiotensin converting enzyme inhibitors belong to the class of drugs that partially lower blood glucose levels as well as lowering blood pressure by inhibiting angiotensin converting enzymes. Examples of the angiotensin converting enzyme inhibitors include captopril, enalapril, alacepril, delapril; ramipril, lisinopril, imidapril, benazepril, ceronapril, cilazapril, enalaprilat, fosinopril, moveltopril, perindopril, quinapril, spirapril, temocapril, trandolapril and angiotensin converting enzyme inhibitors known in the art.
[0261] Suitable pharmaceutical agents that can be used in conjunction with compounds of the present invention include the angiotensin II receptor antagonists. Angiotensin II receptor antagonists target the angiotensin II receptor subtype 1 (i.e., AT1) and demonstrate a beneficial effect on hypertension. Examples of angiotensin II receptor antagonists include losartan (and the potassium salt form) and angiotensin II receptor antagonists known in the art.
[0262] Other treatments for one or more of the diseases cited herein include the use of one or more pharmaceutical agents known in the art that belong to the classes of drugs referred to, but not limited to, the following: amylin agonists (for example, pramlintide), insulin secretagogues (for example, GLP-1 agonists; exendin-4; insulinotropin (NN2211); dipeptyl-peptidase inhibitors (for example, NVP-DPP-728), acyl CoA cholesterol acetyltransferase inhibitors (for example, Ezetimibe, eflucimibe and like compounds), cholesterol absorption inhibitors (for example, ezetimibe, pamaqueside and like compounds), cholesterol ester transfer protein inhibitors (for example, CP-529414, JTT-705, CETi-1 and like compounds), microsomal triglyceride transfer protein inhibitors (for example, implitapide and like compounds), cholesterol modulators (for example, NO-1886 and like compounds), bile acid modulators (for example, GT103-279 and like compounds) and squalene synthase inhibitors.
[0263] Squalene synthesis inhibitors belong to a class of drugs that lower blood cholesterol levels by inhibiting synthesis of squalene. Examples of the squalene synthesis inhibitors include (S)-α-[Bis[2,2-dimethyl-1-oxopropoxy)methoxy]phosplinyl]-3-phenoxybenzenebutanesulfonic acid, mono potassium salt (BMS-188494) and squalene synthesis inhibitors known in the art.
[0264] In accordance with the present invention, the combination of a compound of the present invention and pharmaceutical agent can be prepared by mixing the respective active components either all together or independently with a pharmaceutically acceptable carrier, excipient, binder, diluent, etc. as described herein, and administering the mixture or mixtures either orally or non-orally as a pharmaceutical composition. When a compound or a mixture of compounds of Formula (I) are administered as a combination therapy with another active compound the therapeutic agents can be formulated as a separate pharmaceutical compositions given at the same time or at different times or the therapeutic agents can be given as a single composition.
[0000] Labeled Compounds and Assay Methods
[0265] Another object of the present invention relates to radio-labeled compounds of Formula (I) that are useful not only in radio-imaging but also in assays, both in vitro and in vivo, for localizing and quantitating RUP25 in tissue samples, including human and for identifying RUP25 ligands by inhibition binding of a radio-labeled compound. It is a further object of this invention to include novel RUP25 assays of which comprise such radio-labeled compounds.
[0266] The present invention embraces isotopically-labeled compounds of Formula (I) and any subgenera herein, such as but not limited to, Formulae (Ia) to (Ik). An “isotopically” or “radio-labeled” compounds are those which are identical to compounds disclosed herein, but for the fact that one or more atoms are replaced or substituted by an atom having an atomic mass or mass number different from the atomic mass or mass number typically found in nature (i.e., naturally occurring). Suitable radionuclides that can be incorporated in compounds of the present invention include but are not limited to 2 H (also written as D for deuterium), 3 H (also written as T for tritium), 11 C, 13 C, 14 C, 13 N, 15 N, 15 O, 17 O, 18 O, 18 F, 35 S, 36 Cl, 82 Br, 75 Br, 76 Br, 77 Br, 123 I, 124 I, 125 I and 131 I. The radionuclide that is incorporated in the instant radio-labeled compounds will depend on the specific application of that radio-labeled compound. For example, for in vitro RUP25 labeling and competition assays, compounds that incorporate 3 H, 14 C, 82 Br, 125 I, 131 I, 35 S or will generally be most useful. For radio-imaging applications 11 C, 18 F, 125 I, 123 I, 124 I, 131 I, 75 Br, 76 Br or 77 Br will generally be most useful.
[0267] It is understood that a “radio-labeled” or “labeled compound” is a compound of Formula (I) that has incorporated at least one radionuclide; in some embodiments the radionuclide is selected from the group consisting of 3 H, 14 C, 125 I, 35 S and 82 Br.
[0268] Certain isotopically-labeled compounds of the present invention are useful in compound and/or substrate tissue distribution assays. In some embodiments the radionuclide 3 H and/or 14 C isotopes are useful in these studies. Further, substitution with heavier isotopes such as deuterium (i.e., 2 H) may afford certain therapeutic advantages resulting from greater metabolic stability (e.g., increased in vivo half-life or reduced dosage requirements) and hence can be preferred in some circumstances. Isotopically labeled compounds of the present invention can generally be prepared by following procedures analogous to those disclosed in the Schemes supra and Examples infra, by substituting an isotopically labeled reagent for a non-isotopically labeled reagent. Other synthetic methods that are useful are discussed infra. Moreover, it should be understood that all of the atoms represented in the compounds of the invention can be either the most commonly occurring isotope of such atoms or the more scarce radio-isotope or nonradio-active isotope.
[0269] Synthetic methods for incorporating radio-isotopes into organic compounds are applicable to compounds of the invention and are well known in the art. These synthetic methods, for example, incorporating activity levels of tritium into target molecules and are as follows:
[0270] A. Catalytic Reduction with Tritium Gas—This procedure normally yields high specific activity products and requires halogenated or unsaturated precursors.
[0271] B. Tritium Gas Exposure Labeling—This procedure involves exposing precursors containing exchangeable protons to tritium gas in the presence of a suitable catalyst.
[0272] C. N-Methylation using Methyl Iodide [ 3 H]—This procedure is usually employed to prepare O-methyl or N-methyl ( 3 H) products by treating appropriate precursors with high specific activity methyl iodide ( 3 H). This method in general allows for higher specific activity, such as for example, about 70-90 Ci/mmol.
[0273] Synthetic methods for incorporating activity levels of 125 I into target molecules include:
[0274] A. Sandmeyer and like reactions—This procedure transforms an aryl or heteroaryl amine into a diazonium salt, such as a tetrafluoroborate salt and subsequently to 125 I labeled compound using Na 125 I. A represented procedure was reported by Zhu, D.-G. and co-workers in J. Org. Chem. 2002, 67, 943-948.
[0275] B. Ortho 125 Iodination of phenols—This procedure allows for the incorporation of 125 I at the ortho position of a phenol as reported by Collier, T. L. and co-workers in J. Labeled Compd. Radiopharm. 1999, 42, S264-S266.
[0276] C. Aryl and heteroaryl bromide exchange with 125 I—This method is generally a two step process. The first step is the conversion of the aryl or heteroaryl bromide to the corresponding tri-alkyltin intermediate using for example, a Pd catalyzed reaction [i.e. Pd(Ph 3 P) 4 ] or through an aryl or heteroaryl lithium, in the presence of a tri-alkyltinhalide or hexaalkylditin [e.g., (CH 3 ) 3 SnSn(CH 3 ) 3 ]. A represented procedure was reported by Bas, M.-D. and co-workers in J. Labeled Compd Radiopharm. 2001, 44, S280-S282.
[0277] A radio-labeled RUP25 compound of Formula (I) can be used in a screening assay to identify/evaluate compounds. In general terms, a newly synthesized or identified compound (i.e., test compound) can be evaluated for its ability to reduce binding of the “radio-labeled compound of Formula (I)” to the RUP25 receptor. Accordingly, the ability of a test compound to compete with the “radio-labeled compound of Formula (I)” for the binding to the RUP25 receptor directly correlates to its binding affinity.
[0278] The labeled compounds of the present invention bind to the RUP25 receptor. In one embodiment the labeled compound has an EC 50 less than about 500 μM, in another embodiment the labeled compound has an EC 50 less than about 100 μM, in yet another embodiment the labeled compound has an EC 50 less than about 10 μM, in yet another embodiment the labeled compound has an EC 50 less than about 1 μM and in still yet another embodiment the labeled inhibitor has an EC 50 less than about 0.1 μM.
[0279] Other uses of the disclosed receptors and methods will become apparent to those in the art based upon, inter alia, a review of this disclosure.
[0280] As will be recognized, the steps of the methods of the present invention need not be performed any particular number of times or in any particular sequence. Additional objects, advantages and novel features of this invention will become apparent to those skilled in the art upon examination of the following examples thereof, which are intended to be illustrative and not intended to be limiting.
EXAMPLES
[0281] The following Examples are provided for illustrative purposes and not as a means of limitation. One of ordinary skill in the art would be able to design equivalent assays and methods based on the disclosure herein, all of which form part of the present invention.
Example 1
Rodent Diabetes Models
[0282] Rodent models of type 2 diabetes associated with obesity and insulin resistance have been developed. Genetic models such as db/db and ob/ob [see Diabetes (1982) 31:1-6] in mice and fa/fa in zucker rats have been developed for understanding the pathophysiology of disease and for testing candidate therapeutic compounds [Diabetes (1983) 32:830-838; Annu Rep Sankyo Res Lab (1994) 46:1-57]. The homozygous animals, C57 BL/KsJ-db/db mice developed by Jackson Laboratory are obese, hyperglycemic, hyperinsulinemic and insulin resistant [J Clin Invest (1990) 85:962-967], whereas heterozygotes are lean and normoglycemic. In the db/db model, mice progressively develop insulinopenia with age, a feature commonly observed in late stages of human type 2 diabetes when sugar levels are insufficiently controlled. Since this model resembles that of human type 2 diabetes, the compounds of the present invention are tested for activities including, but not limited to, lowering of plasma glucose and triglycerides. Zucker (fa/fa) rats are severely obese, hyperinsulinemic and insulin resistant {Coleman, Diabetes (1982) 31:1; E Shafrir in Diabetes Mellitus, H Rifkin and D Porte, Jr, Eds [Elsevier Science Publishing Co, New York, ed. 4, (1990), pp. 299-340]} and the fa/fa mutation may be the rat equivalent of the murine db mutation [Friedman et al, Cell (1992) 69:217-220; Truett et al, Proc Natl Acad Sci USA (1991)88:7806]. Tubby (tub/tub) mice are characterized by obesity, moderate insulin resistance and hyperinsulinemia without significant hyperglycemia [Coleman et al, Heredity (1990) 81:424].
[0283] The present invention encompasses the use of compounds of the invention for reducing the insulin resistance and hyperglycemia in any or all of the above rodent diabetes models, in humans with type 2 diabetes or other preferred metabolic-related disorders or disorders of lipid metabolism described previously or in models based on other mammals. Plasma glucose and insulin levels will be tested, as well as other factors including, but not limited to, plasma free fatty acids and triglycerides.
[0000] In Vivo Assay for Anti-Hyperglycemic Activity of Compounds of the Invention
[0284] Genetically altered obese diabetic mice (db/db) (male, 7-9 weeks old) are housed (7-9 mice/cage) under standard laboratory conditions at 22° C. and 50% relative humidity and maintained on a diet of Purina rodent chow and water ad libitum. Prior to treatment, blood is collected from the tail vein of each animal and blood glucose concentrations are determined using One Touch Basic Glucose Monitor System (Lifescan). Mice that have plasma glucose levels between 250 to 500 mg/dl are used. Each treatment group consists of seven mice that are distributed so that the mean glucose levels are equivalent in each group at the start of the study. db/db mice are dosed by micro-osmotic pumps, inserted using isoflurane anesthesia, to provide compounds of the invention, saline or an irrelevant compound to the mice subcutaneously (s.c.). Blood is sampled from the tail vein at intervals thereafter and analyzed for blood glucose concentrations. Significant differences between groups (comparing compounds of the invention to saline-treated) are evaluated using Student t-test.
Example 2
Mouse Atherosclerosis Model
[0285] Adiponectin-deficient mice generated through knocking out the adiponectin gene have been shown to be predisposed to atherosclerosis and to be insulin resistant. The mice are also a suitable model for ischemic heart disease [Matsuda, M et al. J Biol Chem (2002) July and references cited therein, the disclosures of which are incorporated herein by reference in their entirety].
[0286] Adiponectin knockout mice are housed (7-9 mice/cage) under standard laboratory conditions at 22° C. and 50% relative humidity. The mice are dosed by micro-osmotic pumps, inserted using isoflurane anesthesia, to provide compounds of the invention, saline or an irrelevant compound to the mice subcutaneously (s.c.). Neointimal thickening and ischemic heart disease are determined for different groups of mice sacrificed at different time intervals. Significant differences between groups (comparing compounds of the invention to saline-treated) are evaluated using Student t-test.
Example 3
In Vitro Biological Activity
[0287] A modified Flash Plate™ Adenylyl Cyclase kit (New England Nuclear; Cat. No. SMP004A) was utilized for direct identification of candidate compounds as agonists to hRUP25 (Seq. Id. Nos. 1 & 2) in accordance with the following protocol:
[0288] CHO cells stably transfected with an expression vector encoding hRUP25 and cultured under condition permissive for cell surface expression of the encoded hRUP25 receptor were harvested from flasks via non-enzymatic means. The cells were washed in PBS and resuspended in the manufacturer's Assay Buffer. Live cells were counted using a hemacytometer and Trypan blue exclusion and the cell concentration was adjusted to 2×10 6 cells/ml. cAMP standards and Detection Buffer (comprising 2 μCi of tracer [ 125 I]-cAMP (100 μl) to 11 ml Detection Buffer) were prepared and maintained in accordance with the manufacturer's instructions. Candidate compounds identified as per above (if frozen, thawed at room temperature) were added to their respective wells (preferably wells of a 96-well plate) at increasing concentrations (3 μl/well; 12 μM final assay concentration). To these wells, 100,000 cells in 50 μl of Assay Buffer were added and the mixture was then incubated for 30 minutes at room temperature, with gentle shaking. Following the incubation, 100 μl of Detection Buffer was added to each well, followed by incubation for 2-24 hours. Plates were counted in a Wallac MicroBeta™ plate reader using “Prot. #31” (as per manufacturer instructions).
Example 4
Representative Biological Activity
[0289] The biological in vitro activity was determined using the cAMP Whole Cell method. Certain compounds of the invention have an EC 50 in the range of about 30 nM to about 20 μM.
Example 5
In Vivo Animal Model
[0290] One utility of the compound of the present invention as a medical agent in the prophylaxis and treatment of a high total cholesterol/HDL-cholesterol ratio and conditions relating thereto is demonstrated by the activity of the compound in lowering the ratio of total cholesterol to HDL-cholesterol, in elevating HDL-cholesterol or in protection from atherosclerosis in an in vivo pig model. Pigs are used as an animal model because they reflect human physiology, especially lipid metabolism, more closely than most other animal models. An illustrative in vivo pig model not intended to be limiting is presented here.
[0291] Yorkshire albino pigs (body weight 25.5±4 kg) are fed a saturated fatty acid rich and cholesterol rich (SFA-CHO) diet during 50 days (1 kg chow 35 kg −1 pig weight), composed of standard chow supplemented with 2% cholesterol and 20% beef tallow [Royo T et al., European Journal of Clinical Investigation (2000) 30:843-52; which disclosure is hereby incorporated by reference in its entirety]. Saturated to unsaturated fatty acid ratio is modified from 0.6 in normal pig chow to 1.12 in the SFA-CHO diet. Animals are divided into two groups, one group (n=8) fed with the SFA-CHO diet and treated with placebo and one group (n=8) fed with the SFA-CHO diet and treated with the compound (3.0 mg kg −1 ). Control animals are fed a standard chow for a period of 50 days. Blood samples are collected at baseline (2 days after the reception of the animals) and 50 days after the initiation of the diet. Blood lipids are analyzed. The animals are sacrificed and necropsied.
[0292] Alternatively, the foregoing analysis comprises a plurality of groups each treated with a different dose of the compound. Preferred doses are selected from the group consisting of: 0.1 mg kg −1 , 0.3 mg kg −1 , 1.0 mg kg −1 , 3.0 mg kg −1 , 10 mg kg −1 , 30 mg kg −1 and 100 mg kg −1 . Alternatively, the foregoing analysis is carried out at a plurality of timepoints. Preferred timepoints are selected from the group consisting of 10 weeks, 20 weeks, 30 weeks, 40 weeks and 50 weeks.
[0000] HDL-Cholesterol
[0293] Blood is collected in trisodium citrate (3.8%, 1:10). Plasma is obtained after centrifugation (1200 g 15 min) and immediately processed. Total cholesterol, HDL-cholesterol and LDL-cholesterol are measured using the automatic analyzer Kodak Ektachem DT System (Eastman Kodak Company, Rochester, N.Y., USA). Samples with value parameters above the range are diluted with the solution supplied by the manufacturer and then re-analyzed. The total cholesterol/HDL-cholesterol ratio is determined. Comparison is made of the level of HDL-cholesterol between groups. Comparison is made of the total cholesterol/HDL-cholesterol ratio between groups.
[0294] Elevation of HDL-cholesterol or reduction of the total cholesterol/HDL-cholesterol ratio on administration of the compound is taken as indicative of the compound having the aforesaid utility.
[0000] Atherosclerosis
[0295] The thoracic and abdominal aortas are removed intact, opened longitudinally along the ventral surface and fixed in neutral-buffered formalin after excision of samples from standard sites in the thoracic and abdominal aorta for histological examination and lipid composition and synthesis studies. After fixation, the whole aortas are stained with Sudan IV and pinned out flat and digital images are obtained with a TV camera connected to a computerized image analysis system (Image Pro Plus; Media Cybernetics, Silver Spring, Md.) to determine the percentage of aortic surface involved with atherosclerotic lesions [Gerrity R G et al, Diabetes (2001) 50:1654-65; Cornhill J F et al, Arteriosclerosis, Thrombosis and Vascular Biology (1985) 5:415-26; which disclosures are hereby incorporated by reference in their entirety]. Comparison is made between groups of the percentage of aortic surface involved with atherosclerotic lesions.
[0296] Reduction of the percentage of aortic surface involved with atherosclerotic lesions on administration of the compound is taken as indicative of the compound having the aforesaid utility.
Example 6
Receptor Binding Assay
[0297] In addition to the methods described herein, another means for evaluating a test compound is by determining binding affinities to the RUP25 receptor. This type of assay generally requires a radiolabelled ligand to the RUP25 receptor. Absent the use of known ligands for the RUP25 receptor and radiolabels thereof, compounds of Formula (I) can be labelled with a radioisotope and used in an assay for evaluating the affinity of a test compound to the RUP25 receptor.
[0298] A radiolabelled RUP25 compound of Formula (I) can be used in a screening assay to identify/evaluate compounds. In general terms, a newly synthesized or identified compound (i.e., test compound) can be evaluated for its ability to reduce binding of the “radiolabelled compound of Formula (I)” to the RUP25 receptor. Accordingly, the ability to compete with the “radio-labelled compound of Formula (I)” or Radiolabelled RUP25 Ligand for the binding to the RUP25 receptor directly correlates to its binding affinity of the test compound to the RUP25 receptor.
[0000] Assay Protocol for Determining Receptor Binding for RUP25
[0299] A. RUP25 Receptor Preparation
[0300] 293 cells (human kidney, ATCC), transiently transfected with 10 ug human RUP25 receptor and 60 ul Lipofectamine (per 15-cm dish), are grown in the dish for 24 hours (75% confluency) with a media change and removed with 10 ml/dish of Hepes-EDTA buffer (20 mM Hepes+10 mM EDTA, pH 7.4). The cells are centrifuged in a Beckman Coulter centrifuge for 20 minutes, 17,000 rpm (JA-25.50 rotor). Subsequently, the pellet is resuspended in 20 mM Hepes+1 mM EDTA, pH 7.4 and homogenized with a 50-ml Dounce homogenizer and again centrifuged. After removing the supernatant, the pellets are stored at −80° C., until used in binding assay. When used in the assay, membranes are thawed on ice for 20 minutes and then 10 mL of incubation buffer (20 mM Hepes, 1 mM MgCl 2 , 100 mM NaCl, pH 7.4) added. The membranes are vortexed to resuspend the crude membrane pellet and homogenized with a Brinkmann PT-3100 Polytron homogenizer for 15 seconds at setting 6. The concentration of membrane protein is determined using the BRL Bradford protein assay.
[0301] B. Binding Assay
[0302] For total binding, a total volume of 50 ul of appropriately diluted membranes (diluted in assay buffer containing 50 mM Tris HCl (pH 7.4), 10 mM MgCl 2 and 1 mM EDTA; 5-50 ug protein) is added to 96-well polyproylene microtiter plates followed by addition of 100 ul of assay buffer and 50 ul of Radiolabelled RUP25 Ligand. For nonspecific binding, 50 ul of assay buffer is added instead of 100 ul and an additional 50 ul of 10 uM cold RUP25 is added before 50 ul of Radiolabelled RUP25 Ligand is added. Plates are then incubated at room temperature for 60-120 minutes. The binding reaction is terminated by filtering assay plates through a Microplate Devices GF/C Unifilter filtration plate with a Brandell 96-well plate harvestor followed by washing with cold 50 mM Tris HCl, pH 7.4 containing 0.9% NaCl. Then, the bottom of the filtration plate are sealed, 50 ul of Optiphase Supermix is added to each well, the top of the plates are sealed and plates are counted in a Trilux MicroBeta scintillation counter. For compound competition studies, instead of adding 100 ul of assay buffer, 100 ul of appropriately diluted test compound is added to appropriate wells followed by addition of 50 ul of Radiolabelled RUP25 Ligand.
[0303] C. Calculations
[0304] The test compounds are initially assayed at 1 and 0.1 μM and then at a range of concentrations chosen such that the middle dose would cause about 50% inhibition of a Radio-RUP25 Ligand binding (i.e., IC 50 ). Specific binding in the absence of test compound (B O ) is the difference of total binding (B T ) minus non-specific binding (NSB) and similarly specific binding (in the presence of test compound) (B) is the difference of displacement binding (B D ) minus non-specific binding (NSB). IC 50 is determined from an inhibition response curve, logit-log plot of % B/B O vs concentration of test compound.
[0305] K i is calculated by the Cheng and Prustoff transformation:
K i =IC 50 /(1 +[L]/K D )
[0306] where [L] is the concentration of a Radio-RUP25 Ligand used in the assay and K D is the dissociation constant of a Radio-RUP25 Ligand determined independently under the same binding conditions.
Example 7
Flushing via Laser Doppler
[0307] Procedure—Male C57B16 mice (˜25 g) are anesthetized using 10 mg/ml/kg Nembutal sodium. When antagonists are to be administered the are co-injected with the Nembutal anesthesia. After ten minutes the animal is placed under the laser and the ear is folded back to expose the ventral side. The laser is positioned in the center of the ear and focused to an intensity of 8.4-9.0 V (with is generally ˜4.5 cm above the ear). Data acquisition is initiated with a 15 by 15 image format, auto interval, 60 images and a 20 sec time delay with a medium resolution. Test compounds are administered following the 10th image via injection into the peritoneal space. Images 1-10 are considered the animal's baseline and data is normalized to an average of the baseline mean intensities.
[0000] Materials and Methods—Laser Doppler Pirimed PimII; Niacin (Sigma); Nembutal (Abbott labs).
Example 8
Inhibition of Free Fatty-Acid Production, In Vivo, in Catheterized Male Sprague-Daly Rats
[0308] FIG. 2A depicts nicotinic acid inhibiting plasma free fatty acid concentrations in food deprived animals at various concentrations.
[0309] FIG. 2B depicts Compound 1 is able to inhibit free fatty acid production to the same extent, at similar doses and within the same time-frame as compared to nicotinic acid dose-response.
[0310] Non-esterified free-fatty acid (NEFA) assays were done on serum derived from live, freely moving rats. Jugular vein catheters were surgically implanted into the jugular veins and the animals were allowed to recover at least 48 hr post surgery. Food was removed from the animals approximately 16 hours prior to the assay. A draw of ˜200 μl blood was pulled from the catheter and represents the baseline NEFA serum sample. Drug was administered intra-peritoneally (IP) at various concentrations to individual rats and then ˜200 μl blood draws were pulled from the catheter at the indicated time points for further NEFA analysis. NEFA assays were performed according to the manufacturer's specifications (Wako Chemicals, USA; NEFA C) and free fatty acid concentrations were determined via regression analysis of a known standard curve (range of known free fatty acids). Data was analyzed using Excel and PrismGraph.
Example 9
Compounds of the Invention—Syntheses
Example 9.1
5 -Cyclohex-1-enyl-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid (Compound 1)—General Synthesis
[0311]
[0312] To a solution of 5-cyclohex-1-enyl-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid methyl ester (47 mg, 0.2 mmol) in THF/MeOH (1/1, 2 mL) was added LiOH.H 2 O (8.4 mg, 0.2 mmol). The reaction mixture was stirred at room temperature for 5 hours. After concentration, the residue was dissolved in H 2 O (4 mL), washed with ethyl ether (2×5 mL). The separated aqueous layer was acidified to pH 2. This acidified solution was extracted with ethyl ether (3×5 mL). The extracts were dried (Na 2 SO 4 ), filtered and concentrated. The crude product was purified with a silica gel column using EtOAc/AcOH (20/1) providing 35 mg (79%) of racemic 5-cyclohex-1-enyl-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid: LC-MS m/z 221 (M−1); 1 H NMR (400 MHz, CDCl 3 ) δ 6.30 (s, 1H), 5.90 (m, 1H), 2.16-2.06 (m, 3H), 1.79-1.70 (m, 1H), 1.67-1.51 (m, 4H), 1.58 (s, 3H).
[0313] In intermediate 5-Cyclohex-1-enyl-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid methyl ester was prepared in the following manner:
[0314] A. 1-Cyclohex-1-enyl-1-(2-methyl-[1,3]dithian-2-yl)-ethanol.
[0315] To an oven-dried round-bottom flask with stirring bar was added 2-methyl-[1,3]dithiane (4.31 mL, 36.0 mmol) and THF (150 mL). The flask was flushed with argon, cooled to −78° C. and n-butyl lithium (22.5 mL of 1.6 M solution in hexanes, 36.0 mmol) was added over 10 min. by syringe. The flask was warmed to −10° C., stirred for 2 h, cooled to −78° C. and 1-cyclohex-1-enyl-ethanone (3.73 g, 30.0 mmol) was added dropwise. After stirring overnight, the reaction was quenched with NH 4 Cl (100 mL) and extracted with EtOAc (3×100 mL). The combined organic extracts were dried (Na 2 SO 4 ), filtered and concentrated. The crude product was purified with a Biotage 60+M silica gel column using isocratic 9:1 Hexanes/EtOAc providing 5.17 g (67%) of 1-cyclohex-1-enyl-1-(2-methyl-[1,3]dithian-2-yl)-ethanol: 1 H NMR (400 MHz, CDCl 3 ) δ (m, 1H), 2.97-2.80 (m, 4H), 2.70 (bs, 1OH), 2.32-2.18 (m, 2H), 2.17-2.09 (m, 2H), 2.06-1.95 (m, 1H), 1.93-1.82 (m, 1H), 1.79 (s, 3H), 1.62-1.51 (m, 4H), 1.56 (s, 3H).
[0316] B. 3-Cyclohex-1-enyl-3-hydroxy-butan-2-one.
[0317] To a solution of 1-cyclohex-1-enyl-1-(2-methyl-[1,3]dithian-2-yl)-ethanol (5.17 g, 20.0 mmol) in MeOH (100 mL) was added Hg(ClO 4 ) 2 (16.0 g, 40.0 mmol). The suspension was stirred for 2 h at room temperature. The suspension was filtered through Celite and the filtrate was concentrated. The resulting residue was dissolved in H 2 O (150 mL) and extracted with EtOAc (3×100 mL). The combined organic extracts were washed with H 2 O (70 mL), dried (Na 2 SO 4 ), filtered and concentrated. The crude product was purified on the SiO 2 column using a gradient of 2% to 41% EtOAc in hexanes providing 2.3 g (68%) of 3-cyclohex-1-enyl-3-hydroxy-butan-2-one: 1 H NMR (400 MHz, CDCl 3 ) (m, 1H), 4.07 (s, 1OH), 2.14 (s, 3H), 2.14-2.09 (m, 2H), 1.68-1.48 (m, 6H), 1.46 (s, 3H).
[0318] C. 5-Cyclohex-1-enyl-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid methyl ester.
[0319] To an oven-dried 10 mL vial was added 3-cyclohex-1-enyl-3-hydroxy-butan-2-one (0.80 g, 4.80 mmol), THF (4 mL) and trimethoxy-acetic acid methyl ester (0.94 g, 5.76 mmol). The vial was capped with a septum and flushed with Ar. In a dried round-bottom flask with stirring bar was added sodium hydride (60% dispersion in mineral oil, 0.57 g, 14.4 mmol) and THF (20 mL). The flask was capped with a septum and flushed with Ar. The contents of the vial were added dropwise via syringe to the round-bottom flask. The round-bottom flask was equipped with a condenser and septum and heated to 65° C. under Ar for 12 h. The reaction was quenched with sat'd NH 4 Cl (20 mL) and the layers were separated. The organic extract was concentrated and dissolved in 1,4-dioxane (4 mL). The solution was mixed with conc. HCl (0.5 mL) and stirred overnight at rt. Saturated NaHCO 3 solution (20 mL) was added and the reaction was extracted with EtOAc (3×50 mL). The extracts were dried (Na 2 SO 4 ), filtered and concentrated. The crude product was purified with a Biotage 25+M silica gel column using a gradient of 0-10% EtOAc in hexanes providing 0.37 g (32%) of racemic 5-cyclohex-1-enyl-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid methyl ester: LC-MS) m/z 235 (M−1); 1 H NMR (400 MHz, CDCl 3 ) 6.20 (s, 1H), 5.90-5.88 (m, 1H), 3.96 (s, 3H), 2.14-2.04 (m, 3H), 1.87-1.78 (m, 1H), 1.63-1.52 (m, 4H), 1.54 (s, 3H).
Example 9.2
5-Methyl-4-oxo-5-thiophen-3-yl-4,5-dihydro-furan-2-carboxylic acid methyl ester (Compound 2)
[0320] 5-Methyl-4-oxo-5-thiophen-3-yl-4,5-dihydro-furan-2-carboxylic acid methyl ester was prepared in a similar manner as described in Example 9.1. LC-MS m/z 239 (M+1); 1 H NMR (400 MHz, DMSO-d 6 ) δ 7.64-7.61 (m, 2H), 7.13 (dd, J=4.9, 1.5 Hz, 1H), 6.46 (s, 1H), 3.94 (s, 3H), 1.76 (s, 3H).
Example 9.3
5-Methyl-4-oxo-5-thiophen-2-yl-4,5-dihydro-furan-2-carboxylic acid methyl ester (Compound 3)
[0321] 5-Methyl-4-oxo-5-thiophen-2-yl-4,5-dihydro-furan-2-carboxylic acid methyl ester was prepared in a similar manner as described in Example 9.1. LC-MS m/z 239 (M+1); 1 H NMR (400 MHz, CDCl 3 ) 7.30 (dd, J=5.1, 1.2 Hz, 1H), 7.10 (J=13.6, 1.1 Hz, 1H), 6.99 (dd, J=5.0, 3.6 Hz, 1H), 6.28 (s, 1H), 3.98 (s, 3H), 1.86 (s, 3H).
Example 9.4
5-(4-Bromo-thiophen-2-yl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid methyl ester (Compound 4)
[0322] 5-(4-Bromo-thiophen-2-yl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid methyl ester was prepared in a similar manner as described in Example 9.1. LC-MS m/z 315 (M−1); 1 H NMR (400 MHz, CDCl 3 ) 7.20 (d, J=1.4 Hz, 1H), 7.04 (d, J=1.4 Hz, 1H), 6.27 (s, 1H), 3.99 (s, 3H), 1.82 (s, 3H).
Example 9.5
5-(4-Bromo-thiophen-2-yl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid (Compound 5)
[0323] 5-(4-Bromo-thiophen-2-yl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid was prepared in a similar manner as described in Example 9.1. LC-MS m/z 301 (M−1); 1 H NMR (400 MHz, CDCl 3 ) 7.21 (d, J=1.4 Hz, 1H), 7.05 (d, J=1.4 Hz, 1H), 6.38 (s, 1H), 1.85 (s, 3H).
Example 9.6
5-Methyl-5-(5-methyl-thiophen-2-yl)-4-oxo-4,5-dihydro-furan-2-carboxylic acid methyl ester (Compound 6)
[0324] 5-Methyl-5-(5-methyl-thiophen-2-yl)-4-oxo-4,5-dihydro-furan-2-carboxylic acid methyl ester was prepared in a similar manner as described in Example 9.1. LC-MS m/z 251 (M−1); 1 H NMR (400 MHz, CDCl 3 ) 6.87 (d, J=3.6 Hz, 1H), 6.62 (dt, J=3.5, 1.0 Hz, 1H), 6.26 (s, 1H), 3.97 (s, 3H), 2.44 (s, 3H), 1.82 (s, 3H).
Example 9.7
5-Methyl-5-(5-methyl-thiophen-2-yl)-4-oxo-4,5-dihydro-furan-2-carboxylic acid (Compound 7)
[0325] 5-Methyl-5-(5-methyl-thiophen-2-yl)-4-oxo-4,5-dihydro-furan-2-carboxylic acid was prepared in a similar manner as described in Example 9.1. LC-MS m/z 237 (M−1); 1 H NMR (400 MHz, CDCl 3 ) δ 6.82 (d, J=2.8 Hz, 1H), 6.58 (bs, 1H), 6.26 (s, 1H), 2.41 (s, 3H), 1.80 (s, 3H).
Example 9.8
5-(5-Chloro-thiophen-2-3,1)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid methyl ester (Compound 8)
[0326] 5-(5-Chloro-thiophen-2-yl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid methyl ester was prepared in a similar manner as described in Example 9.1. LC-MS m/z 271 (M−1); 1 H NMR (400 MHz, CDCl 3 ) 6.88 (d, J=3.9 Hz, 1H), 6.80 (d, J=3.9 Hz, 1H), 6.27 (s, 1H), 3.98 (s, 3H), 1.81 (s, 3H).
Example 9.9
5-Cyclopent-1-enyl-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid (Compound 9)
[0327] 5-Cyclopent-1-enyl-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid was prepared in a similar manner as described in Example 9.1. LC-MS m/z 207 (M−1); 1 H NMR (400 MHz, DMSO-d 6 ) 6.19 (s, 1H), 5.79 (m, 1H), 2.35-2.26 (m, 3H), 2.14-2.05 (m, 1H), 1.86-1.78 (m, 2H), 1.49 (s, 3H).
Example 9.10
5-Biphenyl-3-yl-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid methyl ester (Compound 10)
[0328] 5-Biphenyl-3-yl-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid methyl ester was prepared in a similar manner as described in Example 9.1. 1 H NMR (400 MHz, CDCl 3 ) 7.71 (t, J=1.8 Hz, 1H), 7.59-7.34 (m, 8H), 6.26 (s, 1H), 3.99 (s, 3H), 1.86 (s, 3H).
Example 9.11
5-Methyl-4-oxo-5-(3-thiophen-2-yl-phenyl)-4,5-dihydro-furan-2-carboxylic acid methyl ester (Compound 11)
[0329] 5-Methyl-4-oxo-5-(3-thiophen-2-yl-phenyl)-4,5-dihydro-furan-2-carboxylic acid methyl ester was prepared in a similar manner as described in Example 9.1. 1 H NMR (400 MHz; CDCl 3 ) 7.74(s, 1H), 7.56 (d, J=7.5 Hz, 1H), 7.44 (d, J=7.9 Hz, 1H), 7.37 (t, J=7.7 Hz, 1H), 7.33 (d, J=3.6 Hz, 1H), 7.30 (d, J=5.1 Hz, 1H), 7.08 (t, J=4.0 Hz, 1H), 6.26 (s, 1H), 4.01 (s, 3H), 1.84 (s, 3H).
Example 9.12
5-(3-Bromo-phenyl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid methyl ester (Compound 12)
[0330] 5-(3-Bromo-phenyl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid methyl ester was prepared in a similar manner as described in Example 9.1. 1 H NMR (400 MHz, CDCl 3 ) 7.65 (t, J=1.8 Hz, 1H), 7.46 (d, J=7.9 Hz, 1H), 7.45 (d, J=7.9 Hz, 1H), 7.24 (t, J=8.2 Hz, 1H), 6.24 (s, 1H), 4.00 (s, 3H), 1.78 (s, 3H).
Example 9.13
5-(3-Bromo-phenyl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid (Compound 13)
[0331] 5-(3-Bromo-phenyl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid was prepared in a similar manner as described in Example 9.1. LC-MS m/z 295 (M−1); 1 H NMR (400 MHz, CDCl 3 ) 7.66 (t, J=1.8 Hz, 1H), 7.49-7.45 (m, 2H), 7.25 (t, J=8.0 Hz, 1H), 6.36 (s, 1H), 1.81 (s, 3H).
Example 9.14
5-(3-Iodo-phenyl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid (Compound 14)
[0332] 5-(3-Iodo-phenyl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid was prepared in a similar manner as described in Example 9.1. LC-MS m/z 343 (M−1); 1 H NMR (400 MHz, CDCl 3 ) 7.84 (t, J=1.7 Hz, 1H), 7.68 (ddd, J=7.9, 1.6, 1.0 Hz, 1H), 7.51 (ddd, J=7.9, 1.7, 1.0 Hz, 1H), 7.11 (t, J=7.9 Hz, 1H), 6.36 (s, 1H), 1.80 (s, 3H).
Example 9.15
5-(3-Chloro-phenyl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid (Compound 15)
[0333] 5-(3-Chloro-phenyl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid was prepared in a similar manner as described in Example 9.1. LC-MS m/z 251 (M−1); 1 H NMR (400 MHz, CDCl 3 ) δ 7.42 (bs, 1H), 7.33 (bs, 1H), 7.25 (bs, 2H), 6.20 (s, 1H), 1.73 (s, 3H).
Example 9.16
5-(3-Fluoro-phenyl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid (Compound 16)
[0334] 5-(3-Fluoro-phenyl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid was prepared in a similar manner as described in Example 9.1. 1 H NMR (400 MHz, CD 3 OD) 7.41 (td, J=8.0, 6.0 Hz, 1H), 7.33 (ddd, J=7.9, 1.5, 1.0 Hz, 1H), 7.24 (ddd, J=10.3, 2.4, 1.8 Hz, 1H), 7.08 (ddd, J=8.5, 2.5, 1.0 Hz, 1H), 6.22 (s, 1H), 1.77 (s, 3H).
Example 9.17
5-(3,5-Difluoro-phenyl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid (Compound 17)
[0335] 5-(3,5-Difluoro-phenyl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid was prepared in a similar maimer as described in Example 9.1. LC-MS m/z 253 (M−1); 1 H NMR (400 MHz, DMSO-d 6 ) δ 7.27 (tt, J=9.3, 2.3 Hz, 1H), 7.16-7.09 (m, 2H), 6.11 (s, 1H), 1.72 (s, 3H).
Example 9.18
5-Methyl-4-oxo-5-m-tolyl-4,5-dihydro-furan-2-carboxylic acid (Compound 18)
[0336] 5-Methyl-4-oxo-5-m-tolyl-4,5-dihydro-furan-2-carboxylic acid was prepared in a similar manner as described in Example 9.1. 1 H NMR (400 MHz, CDCl 3 ) 7.30 (d, J=7.3 Hz, 1H), 7.30 (s, 1H), 7.26 (t, J=7.3 Hz, 1H), 7.15 (d, J=7.3 Hz, 1H), 6.34 (s, 1H), 2.36 (s, 3H), 1.82 (s, 3H).
Example 9.19
5-(3-Ethyl-phenyl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid (Compound 19)
[0337] 5-(3-Ethyl-phenyl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid was prepared in a similar manner as described in Example 9.1. LC-MS m/z 245 (M−1); 1 H NMR (400 MHz, CDCl 3 ) 7.34-7.27 (m, 3H), 7.18 (d, J=7.1 Hz, 1H), 6.37 (s, 1H), 2.66 (q, J=8.0 Hz, 2H), 1.83 (s, 3H), 1.23 (t, J=8.0 Hz, 3H).
Example 9.20
5-Methyl-4-oxo-5-(3-trifluoromethyl-phenyl)-4,5-dihydro-furan-2-carboxylic acid (Compound 20)
[0338] 5-Methyl-4-oxo-5-(3-trifluoromethyl-phenyl)-4,5-dihydro-furan-2-carboxylic acid was prepared in a similar manner as described in Example 9.1. 1 H NMR (400 MHz, CDCl 3 ) 7.78 (s, 1H), 7.74 (d, J=8.0 Hz, 1H), 7.60 (d, J=7.7 Hz, 1H), 7.51 (t, J=7.8 Hz, 1H), 6.34 (s, 1H), 1.83 (s, 3H).
Example 9.21
5-(5-Chloro-thiophen-2-yl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid (Compound 21)
[0339] 5-(5-Chloro-thiophen-2-yl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid was prepared in a similar manner as described in Example 9.1. LC-MS m/z 257 (M−1); 1 H NMR (400 MHz, CDCl 3 ) δ 6.88 (d, J=3.9 Hz, 1H), 6.80 (d, J=3.9 Hz, 1H), 6.38 (s, 1H), 1.84 (s, 3H).
Example 9.22
5-Methyl-4-oxo-5-thiophen-2-yl-4,5-dihydro-furan-2-carboxylic acid (Compound 22)
[0340] 5-Methyl-4-oxo-5-thiophen-2-yl-4,5-dihydro-furan-2-carboxylic acid was prepared in a similar manner as described in Example 9.1. LC-MS m/z 223 (M−1); 1 H NMR (400 MHz, CDCl 3 ) δ 7.31 (dd, J=5.1, 0.9 Hz, 1H), 7.11 (J=13.6, 0.9 Hz, 1H), 7.00 (dd, J=5.0, 3.7 Hz, 1H), 6.40 (s, 1H), 1.89 (s, 3H).
Example 9.23
5-(5-Bromo-thiophen-3-yl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid methyl ester (Compound 23)
[0341] 5-(5-Bromo-thiophen-3-yl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid methyl ester was prepared in a similar manner as described in Example 9.1 except the intermediate 3-(5-bromo-thiophen-3-yl)-3-hydroxy-butan-2-one was prepared in a manner as described below. Compound 23 was characterized NMR and MS; LC-MS m/z 317 (M+1); 1 H NMR (400 MHz, CDCl 3 ) δ 7.25 (d, J=1.7 Hz, 1H), 7.12 (d, J=1.7 Hz, 1H), 6.25 (s, 1H), 3.99 (s, 3H), 1.75 (s, 3H).
[0342] The intermediate 3-(5-bromo-thiophen-3-yl)-3-hydroxy-butan-2-one was prepared using the following procedure.
A) 2-Bromo-4-(1-methyl-propenyl)-thiophene.
[0343] To a solution of ethyl-triphenyl-phosphonium bromide (27.0 mmol, 10.02 g) in anhydrous THF (90 mL) was added at 0° C. a solution of KO t Bu (27.0 mmol, 27 mL, 1 M in THF). The solution was stirred for 1 h at room temperature, cooled down to −78° C. and treated with a solution of 1-(5-bromo-thiophen-3-yl)-ethanone (19.1 mmol, 3.92 g) in anhydrous THF (30 mL) at the temperature. The reaction mixture was slowly warmed to room temperature overnight with stirring. After dilution of the reaction mixture with EtOAc (200 mL), it was washed with water (70 mL×2) and brine (70 mL), dried (MgSO 4 ) and concentrated in vacuo. Chromatography on SiO 2 (Hexanes/EtOAc, 20/1) gave 4.15 g (100%) of 2-bromo-4-(1-methyl-propenyl)-thiophene as a liquid of isomeric mixture (Z/E isomer, 9/1). Z isomer; 1 H NMR (400 MHz, CDCl 3 ) δ 7.04 (d, J=1.7 Hz, 1H), 6.98 (d, J=1.7 Hz, 1H), 5.55 (m, 1H), 1.97 (quint, J=1.5 Hz, 3H), 1.72 (dq, J=7.0, 1.5 Hz, 3H). E isomer; 1 H NMR (400 MHz, CDCl 3 ) δ 7.17 (d, J=1.7 Hz, 1H), 6.94 (d, J=1.7 Hz, 1H), 5.90 (m, 1H), 1.94 (quint, J=1.1 Hz, 3H), 1.77 (d, J=6.9, 1.0 Hz, 3H).
B) 2-(5-Bromo-thiophen-3-yl)-butane-2,3-diol.
[0344] To a solution of 2-bromo-4-(1-methyl-propenyl)-thiophene (19.1 mmol, 4.15 g) in a cosolvent of acetone and water (15 mL/30 mL) was added at room temperature N-methyl morpholine oxide (NMO) (21.0 mmol, 4.92 g, 50% in H 2 O) and OsO 4 (0.2 mmol, 1.27 g, 4% in H 2 O). The reaction mixture was stirred for 24 h at the temperature. After evaporation of acetone in vacuo, it was extracted with EtOAc (70 mL×4). The combined solution was washed with brine (70 mL), dried (MgSO 4 ) and concentrated in vacuo. Chromatography on SiO 2 (EtOAc/Hexanes, 2/3) gave 4.3 g (90%) of 2-(5-bromo-thiophen-3-yl)-butane-2,3-diol as an oil of isomeric mixture (major/minor, 8/1). Major isomer; 1 H NMR (400 MHz, CDCl 3 ) δ 7.10 (d, J=1.7 Hz, 1H), 7.02 (d, J=1.7 Hz, 1H), 3.81 (m, 1H), 2.54 (s, 1OH), 1.99 (d, J=5.7 Hz, 1OH), 1.53 (s, 3H), 1.04 (d, J=6.4 Hz, 3H). Minor isomer; 1 H NMR (400 MHz, CDCl 3 ) δ 7.14 (d, J=1.7 Hz, 1H), 7.04 (d, J=1.7 Hz, 1H), 3.90 (m, 1H), 2.58 (s, 1OH), 2.07 (d, J=4.0 Hz, 1OH), 1.46 (s, 3H), 1.13 (d, J=6.4 Hz, 3H).
C) 3-(5-Bromo-thiophen-3-yl)-3-hydroxy-butan-2-one.
[0345] A solution of oxalyl chloride (19.12 mmol, 2.43 g) in anhydrous CH 2 C 1 2 (100 mL) was cooled to −50° C. to −60° C. DMSO (39.83 mmol, 2.83 mL) is added dropwise at a rapid rate, with stirring. After 5 min, a solution of 2-(5-bromo-thiophen-3-yl)-butane-2,3-diol (15.93 mmol, 4.0 g) in anhydrous CH 2 Cl 2 (25 mL) was added dropwise over 10 min, keeping the temperature at −50° C. to −60° C. After 15 min stirring, triethylamine (80 mmol, 11.15 mL) was added dropwise, keeping the temperature below −50° C. Stirring was then continued for 5 min. The reaction mixture was allowed to warm to room temperature and water (100 mL) was added. The separated aqueous layer was extracted with CH 2 Cl 2 (70 mL×2). The combined organic layer was washed with brine (100 mL), dried (MgSO 4 ), concentrated in vacuo. Chromatography on SiO 2 (EtOAc/Hexanes, 1/2) gave 3.2 g (81%) of 3-(5-bromo-thiophen-3-yl)-3-hydroxy-butan-2-one as an oil; 1 H NMR (400 MHz, CDCl 3 ) δ 7.22 (d, J=1.7 Hz, 1H), 6.98 (d, J=1.7 Hz, 1H), 4.48)s, 1OH), 2.16 (s, 3H), 1.72 (s, 3H).
Example 9.24
5-(5-Bromo-thiophen-3-yl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid (Compound 24)
[0346] 5-(5-Bromo-thiophen-3-yl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid was prepared in a similar manner as described in Example 9.1. LC-MS m/z 301 (M−1); 1 H NMR (400 MHz, DMSO-d 6 ) δ 7.56 (d, J=1.7 Hz, 1H), 7.23 (d, J=1.7 Hz, 1H), 6.30 (s, 1H), 1.69 (s, 3H).
Example 9.25
5-(5-Chloro-thiophen-3-yl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid methyl ester (Compound 25)
[0347] 5-(5-Chloro-thiophen-3-yl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid methyl ester was prepared in a similar manner as described in Example 9.1. LC-MS m/z 273 M+1); 1 H NMR (400 MHz, DMSO-d 6 ) δ 7.47 (d, J=1.7 Hz, 1H), 7.18 (d, J=1.7 Hz, 1H), 6.42 (s, 1H), 3.89 (s, 3), 1.70 (s, 3H).
Example 9.26
5-(5-Chloro-thiophen-3-yl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid (Compound 26)
[0348] 5-(5-Chloro-thiophen-3-yl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid was prepared in similar maimer as described in Example 9.1. LC-MS m/z 259 (M+1); 1 H NMR (400 MHz, DMSO-d 6 ) δ 7.45 (d, J=1.8 Hz, 1H), 7.15 (d, J=1.8 Hz, 1H), 6.30 (s, 1H), 1.68 (s, 3H).
Example 9.27
5-(4-Bromo-5-methyl-thiophen-2-yl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid (Compound 27)
[0349] 5-(4-Bromo-5-methyl-thiophen-2-yl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid was prepared in a similar manner as described in Example 9.1. LC-MS m/z 315 (M−1); 1 H NMR (400 MHz, CDCl 3 ) δ 6.92 (s, 1H), 6.38 (s, 1H), 2.36 (s, 3H), 1.82 (s, 3H).
Example 9.28
5-Methyl-4-oxo-5-thiophen-3-yl-4,5-dihydro-furan-2-carboxylic acid (Compound 28)
[0350] 5-Methyl-4-oxo-5-thiophen-3-yl-4,5-dihydro-furan-2-carboxylic acid was prepared in a similar manner as described in Example 9.1. LC-MS m/z 223 (M−1); 1 H NMR (400 MHz, CDCl 3 ) δ 7.37 (dd, J=2.9, 1.3 Hz, 1H), 7.34 (dd, J=5.0, 3.0 Hz, 1H), 7.17 (dd, J=5.0, 1.3 Hz, 1H), 6.39 (s, 1H), 1.82 (s, 3H).
Example 9.29
Preparation of Compounds of the Invention (Compounds 29 to 57)
[0351] Compounds 29 to 57 of the present invention were prepared in a similar manner as described herein. The MS data for each of these compounds are shown in the following table:
Cmpd# Chemical Name m/z 29 5-(4-Fluoro-phenyl)-5-methyl-4-oxo-4,5-dihydro- 235.0 furan-2-carboxylic acid (M − 1) 30 5-Methyl-4-oxo-5-pyridin-3-yl-4,5-dihydro-furan- 220.0 2-carboxylic acid (M + 1) 31 5-Ethyl-4-oxo-5-phenyl-4,5-dihydro-furan-2- 231.0 carboxylic acid (M − 1) 32 5-(2-Fluoro-phenyl)-5-methyl-4-oxo-4,5-dihydro- 235.0 furan-2-carboxylic acid (M − 1) 33 2-Methyl-3-oxo-2,3-dihydro-[2,2′]bifuranyl-5- 207.0 carboxylic acid (M − 1) 34 5-(3,4-Difluoro-phenyl)-5-methyl-4-oxo-4,5-dihydro- 253.2 furan-2-carboxylic acid (M − 1) 35 5-(2,4-Difluoro-phenyl)-5-methyl-4-oxo-4,5-dihydro- 253.2 furan-2-carboxylic acid (M − 1) 36 5-(2,6-Difluoro-phenyl)-5-methyl-4-oxo-4,5-dihydro- 253.2 furan-2-carboxylic acid (M − 1) 37 5-(2,5-Dichloro-phenyl)-5-methyl-4-oxo-4,5-dihydro- 285.2 furan-2-carboxylic acid (M − 1) 38 5-(3-Methoxy-phenyl)-5-methyl-4-oxo-4,5-dihydro- 247.0 furan-2-carboxylic acid (M − 1) 39 5-Methyl-4-oxo-5-m-tolyl-4,5-dihydro-furan-2- 247.0 carboxylic acid methyl ester (M + 1) 40 5-(3-Ethyl-phenyl)-5-methyl-4-oxo-4,5-dihydro- 259.0 furan-2-carboxylic acid methyl ester (M − 1) 41 5-Cyclohex-l-enyl-5-methyl-4-oxo-4,5-dihydro-furan- 235.0 2-carboxylic acid methyl ester (M − 1) 42 5-(3,5-Dichloro-phenyl)-5-methyl-4-oxo-4,5- 301.0 dihydro-furan-2-carboxylic acid methyl ester (M + 1) 43 5-(3,5-Dichloro-phenyl)-5-methyl-4-oxo-4,5- 285.2 dihydro-furan-2-carboxylic acid (M − 1) 44 5-(3-Iodo-phenyl)-5-methyl-4-oxo-4,5-dihydro- 359.0 furan-2-carboxylic acid methyl ester (M + 1) 45 5-Cyclopentyl-5-methyl-4-oxo-4,5-dihydro-furan- 225.0 2-carboxylic acid methyl ester (M + 1) 46 5-Cyclopentyl-5-methyl-4-oxo-4,5-dihydro-furan- 209.0 2-carboxylic acid (M − 1) 47 5-(3-Cyano-phenyl)-5-methyl-4-oxo-4,5-dihydro- 258.2 furan-2-carboxylic acid methyl ester (M + 1) 48 5-(3-Cyano-phenyl)-5-methyl-4-oxo-4,5-dihydro- 242.0 furan-2-carboxylic acid (M − 1) 49 5-Methyl-4-oxo-5-[((E)-3-propenyl)-phenyl]-4,5- 257.4 dihydro-furan-2-carboxylic acid (M − 1) 50 5-(4-Bromo-5-methyl-thiophen-2-yl)-5-methyl-4-oxo- 331.0 4,5-dihydro-furan-2-carboxylic acid methyl ester (M + 1) 51 5-Biphenyl-3-yl-5-methyl-4-oxo-4,5-dihydro-furan- 293.0 2-carboxylic acid (M − 1) 52 5-[((E)-3-Hex-1-enyl)-phenyl]-5-methyl-4-oxo- 299.2 4,5-dihydro-furan-2-carboxylic acid (M − 1) 53 5-Methyl-5-(4-methyl-thiophen-2-yl)-4-oxo-4,5- 251.2 dihydro-furan-2-carboxylic acid methyl ester (M − 1) 54 5-Methyl-4-oxo-5-(3-vinyl-phenyl)-4,5-dihydro- 243.0 furan-2-carboxylic acid (M − 1) 55 5-Methyl-5-(4-methyl-thiophen-2-yl)-4-oxo-4,5- 237.0 dihydro-furan-2-carboxylic acid (M − 1) 56 5-Methyl-5-(5-methyl-thiophen-3-yl)-4-oxo-4,5- 237.0 dihydro-furan-2-carboxylic acid (M − 1) 57 4-Oxo-5-phenyl-5-trifluoromethyl-4,5-dihydro-furan- 271.2 2-carboxylic acid (M − 1)
Example 10
Resolution of Compounds of the Invention
Example 10.1
Resolution of 5-(3-Bromo-phenyl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid (Compound 13)
[0352] To a solution of racemic 5-(3-Bromo-phenyl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid (4.12 g, 13.87 mmol) in anhydrous CH 2 Cl 2 (110 mL) was added triethylamine (3.11 g, 30 51 mmol). The solution cooled down to 0° C. and mesyl chloride (1.75 g, 15.26 mmol) was added at the temperature. After 2 h stirring at room temperature, the reaction mixture was again cooled to 0° C. and R(+)-α-methylbenzyl-amine (1.68 g, 13.87 mmol) was added. After 4 h stirring at room temperature, the reaction mixture was washed with water (100 mL) and brine (70 mL), dried (MgSO 4 ) and concentrated in vacuo. Chromatography on SiO 2 (Hexanes/EtOAc, 3/1) gave 1.64 g (30%) of Diastereomer Amide 13A (>98 de % by 1 H-NMR) and 1.96 g (35%) of Diastereomer Amide 13B (>98 de % by 1 H-NMR).
[0353] Diastereomer Amide 13A: R f =0.5 (Hexanes/EtOAc, 2/1); LC-MS m/z 400 (M+1); 1 H NMR (400 MHz, CDCl 3 ) δ 7.53 (t, J=1.8 Hz, 1H), 7.46 (ddd, J=8.0, 1.8, 1.0 Hz, 1H), 7.42-7.38 (m, 4H), 7.36-7.31 (m, 2H), 7.23 (t, J=8.0 Hz, 1H), 6.93 (d, J=7.8 Hz, 1H), 6.29 (s, 1H), 5.29 (quint, J=7.1 Hz, 1H), 1.80 (s, 3H), 1.66 (d, J=6.8 Hz, 3H).
[0354] Diastereomer Amide 13B: R f =0.6 (Hexanes/EtOAc, 2/1); LC-MS m/z 400 (M+1); 1 H NMR (400 MHz, CDCl 3 ) δ 7.57 (t, J=1.8 Hz, 1H), 7.49 (ddd, J=8.0, 1.8, 1.0 Hz, 1H), 7.42-7.38 (m, 4H), 7.36-7.31 (m, 2H), 7.26 (t, J=8.0 Hz, 1H), 6.88 (d, J=7.8 Hz, 1H), 6.29 (s, 1H), 5.29 (quint, J=7.1 Hz, 1H), 1.76 (s, 3H), 1.66 (d, J=6.8 Hz, 3H).
(−)-5-(3-Bromo-phenyl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid, [(−)-Compound 13]
[0355] A solution of Diastereomer Amide 13B (1.6 g, 4.0 mmol) in dioxane (10 mL) was heated with conc HCl (10 mL) at 107° C. for 29 h (or microwave irradiation at 140° C. for 20 min). After cooling the reaction mixture, it was extracted with ether (50 mL). The separated organic layer was treated with NaHCO 3 solution for the acid product to disappear in organic layer. The separated aqueous layer was acidified to pH 2 and extracted with EtOAc (50 mL×2). The combined organic layer was washed with water (50 mL×5) and brine (50 mL), dried (MgSO 4 ), concentrated to give 920 mg (77%) of (−)-Compound 13 as a solid:
[0356] [α] D −102.6° (c 1.0, MeOH); LC-MS m/z 297 (M+1); 1 H NMR (400 MHz, CDCl 3 ) δ 8.45 (brs, 1H), — OH ), 7.66 (t, J=1.8 Hz, 1H), 7.49-7.45 (m, 2H), 7.26 (t, J=8.0 Hz, 1H), 6.40 (s, 1H), 1.82 (s, 3H).
(+)-5-(3-Bromo-phenyl)-5-methyl-4-oxo-4,5-dihydro-furan-2-carboxylic acid, [(+)-Compound 13]
[0357] Diastereomer Amide 13A was hydrolyzed in a similar manner as described above to give (+)-Compound 13
[0358] [α] D +141.0° (c 1.0, MeOH); LC-MS m/z 297 (M+1); 1 H NMR (400 MHz, CDCl 3 ) δ 8.69 (brs, 1H, — OH ), 7.66 (t, J=1.8 Hz, 1H), 7.49-7.45 (m, 2H), 7.26 (t, J=8.0 Hz, 1H), 6.40 (s, 1H), 1.82 (s, 3H).
Example 10.2
[0359] Compounds 24, 26 and 56 were separated into their respective (+) and (−) enantiomers using a similar method as described in Example 10.1.
[0360] Throughout this application, various publications, patents and published patent applications are cited. The disclosures of these publications, patents and published patent applications referenced in this application are hereby incorporated by reference in their entirety into the present disclosure. Modifications and extension of the disclosed inventions that are within the purview of the skilled artisan are encompassed within the above disclosure and the claims that follow.
[0361] Although a variety of expression vectors are available to those in the art, for purposes of utilization for both the endogenous and non-endogenous human GPCRs, it is most preferred that the vector utilized be pCMV. This vector was deposited with the American Type Culture Collection (ATCC) on Oct. 13, 1998 (10801 University Blvd., Manassas, Va. 20110-2209 USA) under the provisions of the Budapest Treaty for the International Recognition of the Deposit of Microorganisms for the Purpose of Patent Procedure. The DNA was tested by the ATCC and determined to be viable. The ATCC has assigned the following deposit number to pCMV: ATCC #203351.
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System for selecting a colour shade comprising a very small number of colour display cards with mixed shades of two or more colours. The system comprises means for selecting one shade among mixed shades, means for presenting the selected mixed shade as well as means for specifying the selected mixed shade for making paint in the desired colour tone.
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The present invention relates to a heat exchanger.
More specifically, the present invention relates to a heat exchanger for a gas boiler for producing hot water.
BACKGROUND OF THE INVENTION
A gas boiler for producing hot water normally comprises a gas burner, and at least one heat exchanger through which combustion fumes and water flow. Some types of gas boilers, known as condensation boilers, condense the steam in the combustion fumes and transfer the latent heat in the fumes to the water. Condensation boilers are further divided into a first type, equipped with a first exchanger close to the burner, and a second exchanger for simply condensing the fumes; and a second type, equipped with only one heat exchanger which provides solely for thermal exchange along a first portion, and for both thermal exchange and fume condensation along a second portion. Condensation or dual-function exchangers of the above type normally comprise a casing extending along a first axis and through which combustion fumes flow; and a tube along which water flows, and which extends along a second axis and coils about the first axis to form a succession of turns. The combustion fumes flow over and between the turns to transfer heat to the water flowing along the tube.
EP 0 678 186 discloses a heat exchanger for a gas boiler for producing hot water. The heat exchanger comprises a casing extending along a first axis and through which combustion fumes flow; a tube forming a plurality of tube sections along which water flows; said tube sections being arranged inside said casing so as to forms gaps between adjacent tube sections; guiding means for guiding said fumes trough said gaps; and bosses for spacing adjacent tube sections.
Each tube section is provided with a cross section delimited by two parallel, opposite, flat walls. Bosses protrude from one of said flat walls for abutting a flat wall without bosses of an adjacent tube section and forming the above mentioned gaps between adjacent tube sections.
Even though the above described heat exchanger is provided with integrally made spacers, a rather expensive and time-consuming hydro-forming process is needed to form bosses in tube sections. The hydro-forming process is performed by a press that squeezes the tube sections between dies in order to form the flat walls and, at the same time, forms the bosses by injecting inside the tube sections a fluid under high pressure. It follows that hydro-forming process lacks flexibility because a modification of the distributions pitch or the height of the bosses requires different dies.
In addition to that, the process is not extremely accurate and small gaps cannot be formed by embossed tube sections.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a heat exchanger for a gas boiler for producing hot water, which overcomes the drawbacks of the prior art.
According to the present invention, there is provided a heat exchanger for a gas boiler for producing hot water; characterised in that said spacing means are teeth integrally made with said tube.
Replacing bosses with teeth has the advantage of not requiring hydro-forming process and increasing the accuracy.
The present invention also relates to a method of producing a heat exchanger.
According to the present invention, there is provided a method of producing a heat exchanger, as claimed in the attached Claims.
BRIEF DESCRIPTION OF THE DRAWINGS
A number of non-limiting embodiments of the present invention will be described by way of example with reference to the accompanying drawings, in which:
FIG. 1 shows a schematic front view, with parts in section and parts removed for clarity, of a gas boiler equipped with a heat exchanger in accordance with the present invention;
FIG. 2 shows a larger-scale section of a detail of the FIG. 1 heat exchanger;
FIG. 3 shows a view in perspective of a tube used to produce the FIG. 1 exchanger; and
FIGS. 4 and 5 shows variations of the FIG. 3 tube.
DETAILED DESCRIPTION OF THE INVENTION
Number 1 in FIG. 1 indicates as a whole a gas boiler. Boiler 1 is a wall-mounted condensation boiler, i.e. in which the vapour in the combustion fumes is condensed, and comprises an outer structure 2 in which are housed a burner 3 ; a heat exchanger 4 ; a gas supply conduit 5 ; a pipe 6 for supplying an air-gas mixture to burner 3 ; a combustion gas exhaust pipe 7 ; a fan 8 connected to supply pipe 6 , and which performs the dual function of supplying the air-gas mixture to burner 3 , and expelling the combustion fumes; and a water circuit 9 . Burner 3 is connected to pipe 6 , is cylindrical in shape, and comprises a lateral wall with holes (not shown) for emitting the air-gas mixture and feeding the flame. Burner 3 is housed inside exchanger 4 which, in fact, also acts as a combustion chamber. Heat exchanger 4 is substantially cylindrical in shape, extends along a substantially horizontal axis A 1 , and comprises a casing 10 , through which the combustion products flow; a tube 11 , along which water flows; and a disk 12 for directing the fumes along a given path inside exchanger 4 . Casing 10 comprises a cylindrical lateral wall 13 about axis A 1 ; an annular wall 14 connected to lateral wall 13 , to supply pipe 6 , and to burner 3 ; and an annular wall 15 connected to lateral wall 13 and to exhaust pipe 7 . Burner 3 extends, coaxially with exchanger 4 , inside of exchanger 4 for a given length. Tube 11 coils about axis A 1 to form a helix 16 comprising a succession of adjacent turns 17 , each located close to lateral wall 13 , and has two opposite ends with known fittings (not shown) for connecting tube 11 to water circuit 9 outside exchanger 4 . Disk 12 is shaped so as to fit with the shape of the coiled tube 11 .
Exchanger 4 comprises three spacers 18 for keeping turns 17 a given distance from lateral wall 13 . Each spacer 18 comprises a straight portion 19 parallel to axis A 1 , and from which project fingers 20 for clamping the helix 16 .
With reference to FIG. 2 , tube 11 , disk 12 , and spacers 18 define, inside casing 11 , a region B 1 housing burner 3 ; a region B 2 communicating directly with exhaust pipe 7 ; and three regions B 3 , each extending between two spacers 18 , turns 17 , and lateral wall 13 . Combustion of the air-gas mixture takes place in region B 1 ; and the resulting fumes, being prevented by disk 12 from flowing directly to region B 2 , flow between turns 17 , in a direction D 1 substantially perpendicular to axis A 1 , to regions B 3 , along which they flow in a direction D 2 substantially parallel to axis A 1 . On reaching regions B 3 , the fumes flow between turns 17 in direction D 3 opposite to D 1 to region B 2 and then along exhaust pipe 7 .
Tube 11 is preferably made of aluminium or aluminium-based alloy. With reference to FIG. 3 , tube 11 is an extruded tube, which extends along an axis A 2 , and comprises a wall 21 with an oval cross-section (major axis X and a minor axis Y) and a longitudinal rib 22 shown partially in dotted lines in FIG. 3 . Wall 21 has an outer surface 21 a and an inner surface 21 b and a constant thickness. Rib 22 protrudes from the outer surface 21 a at the intersection of outer surface 21 a and minor axis Y and has two lateral faces 23 substantially parallel to minor axis Y and a distal face 24 substantially parallel to major axis X. In other words, rib 22 protrudes from the area of the cross section having the largest radius.
After extrusion, rib 22 is partially machined in order to separate teeth 25 , which, in the best embodiment, are equally distributed along the length of the tube 11 . Each tooth 25 has a cross-section corresponding to the cross-section of rib 22 .
In an alternative embodiment, not shown, the cross-section of teeth 25 is modified by reducing the height of the teeth 25 by machining.
As an example of the sizes of the teeth 25 and of the tube 11 , tube 11 may have an axis Y 20 mm high and teeth 0.8 mm high per 1.1 mm wide. The ratio between the height of the tube 11 and the eight of the teeth 25 is roughly about 23.
Once the rib 22 is machined, tube 11 is coiled about axis A 1 , so that axis A 2 of tube 14 also assumes a helical shape. Tube 11 is coiled with a constant pitch and radius, so that each turn 17 faces an adjacent turn 17 . This operation actually comprises calendering tube 11 , with the minor axis Y of the section of tube 11 maintained substantially parallel to axis A 1 . The three spacers 18 are then fitted to helix 16 , and arranged 120 degrees apart, so as to compress turns 17 along axis 1 .
Then, teeth 25 of a given turn 17 comes into contact with the outer surface 21 a of the adjacent turn 17 so as to form a gap between the two adjacent turns 17 .
With reference, to FIG. 2 , the fumes flow from region B 1 to regions B 3 in direction D 1 towards wall 13 , then flow in direction D 2 between turns 17 and wall 13 , flow between turns 17 in direction D 3 from regions B 3 to region B 2 , and are finally expelled by exhaust pipe 7 . The successive gaps therefore define compulsory fume paths.
With reference to the FIG. 4 variation, tube 11 is provided with four fins 26 , 27 , 28 , and 29 tangent to wall 21 and parallel to each other and to major axis X. Fins 26 and 27 are located on the same side of tube 11 , whereas fins 28 and 29 are located on the opposite side. Then, fin 26 is coplanar to fin 28 and fin 27 is coplanar to fin 29 . Fins 26 , 27 , 28 and 29 have a surface 26 a , 27 a , 28 a , and 29 a , which is tangent to outer surface 21 a of wall 21 so that surfaces 26 a and 28 a form a single surface from which teeth 25 protrude. Surfaces 27 a and 29 a form a single surface without any protruding teeth 25 . Once tube 11 is coiled in a helix 16 and clamped by spacers 18 , teeth abut against the single surface formed by surfaces 27 a and 29 a.
With reference to the FIG. 5 variation, tube 11 is provided with fins 26 and 27 , fins 28 and 29 being omitted.
Many other variations in shape of tube 11 cross-section and arrangement of the fins are possible without departing from the essence of the present invention.
Exchanger 4 as described above may also be used in condensation boilers comprising a main exchanger, and in which exchanger 4 provides solely for condensing the fumes, as opposed to acting as a combustion chamber as in the example described.
Exchanger 4 as described above has numerous advantages, by combining straightforward construction as a result of teeth 25 formed directly by the tube 11 extrusion process and extremely flexible machining operation.
Even though the embodiment disclosed in the detailed description refers to a tube 11 coiled in a helix 16 to form a plurality of turns, the invention is not limited to this embodiment and turns 17 should be intended more generally as adjacent tube sections.
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A heat exchanger for a gas boiler for producing hot water is provided with a casing extending along a first axis and through which combustion fumes flow; a tube forming a plurality of turns along which water flows arranged inside the casing so as to form gaps between adjacent turns; a disk for guiding said fumes trough the gaps; and teeth integrally made with the tube for spacing adjacent turns apart and forming said gaps.
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BACKGROUND OF THE INVENTION
The present invention relates to a method for measuring the concentration of an adhesive on the surface of a coating layer coated on a support such as coated paper.
Paper is coated on the surface thereof with various types of pigments to improve its smoothness, brightness, ink receptivity, gloss and opacity. To fabricate such coated paper, adhesives are used to bind pigment particles to each other and to keep the particles on the surface of the base stock. The adhesive typically contains coating slurry together with pigment such as clay or calcium carbonate, and is applied to the surface of the base stock.
When coatings are applied to porous materials such as paper, the adhesive might, however, migrate on the surface of the coating layer or toward the base paper, sometimes into the base paper, a phenomenon known as binder migration, especially during, for example, a drying step. When binder migration occurs, the concentration of adhesive on the surface correspondingly increases, adversely affecting the printability of the paper. For example, binder migration may cause improper inking (print mottle). When the concentration of the adhesive is mottled on the surface of the coating layer, an undesirable effect is produced in that the ink is mottled when offset printing is being conducted. This adverse influence probably occurs because the adhesive itself has no affinity to the printing ink.
In view of the problems discussed above, it is very important to know the concentration of the adhesive on the surface of the coating layer and to know the surface concentration distribution to predict the printability of the coated paper. Thus, the present invention is directed to a technique for accurately measuring the surface concentration of the adhesive and for accurately measuring the surface concentration distribution. Known methods for measuring the concentration of the adhesive on the surface of a coating layer include infrared spectroscopic analysis, analysis with an X-ray microanalyzer and the like.
The infrared spectroscopic analysis is simple but is subject to large errors since the sensitivity of the adhesive is much lower than that of the pigment. The X-ray microanalyzer has, on the other hand, high sensitivity and can measure the distribution of the adhesive on the surface of the coating layer, but necessitates prior treatment with a dye, such as osmium or bromine.
The inventor of the present invention has discovered a correlation between the adhesive concentration on the surface of the coating layer of the coated paper and the ultraviolet ray absorbance and has discovered that styrene-butadiene latex (SB latex) exhibits special absorbance in the ultraviolet ray zone and that the absorbance significantly differs from that of the pigment. The inventor of the present invention has applied the ultraviolet ray absorbance of SB latex to the measurement of the concentration of the adhesive.
However, reflection measurement of light scattered on a sample surface must be employed in the measurement of the concentration of adhesive on the surface of the coating layer. Thus, when light is scattered on the surface of the coating layer because of gloss, the measurement is affected by the scattered light and the concentration of the adhesive cannot be accurately measured.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a method for measuring the concentration of adhesive on the surface of a coating layer and its flat surface concentration distribution by measuring with ultraviolet rays, while compensating for the influence of gloss, to obtain the measured result with high reliability.
In accordance with the present invention, it has been found that the influence of light scattered due to the state of the surface of a coating layer, for example, gloss, is removed by measurement using three wavelengths within absorption. The peak absorption of the adhesive in the coating layer is the center of the quantitative surface concentration measurement.
More particularly, in order to achieve the above and other objects, there is provided according to the present invention a method for measuring the concentration of adhesive on the surface of a coating layer comprising the steps of: (1) irradiating the surface of the coating layer with an ultraviolet ray of the highest peak absorption wavelength of the adhesive, an ultraviolet ray of a shorter wavelength and an ultraviolet ray of longer wavelength, and (2) photoelectrically converting the reflected rays and further comparing to calculate them.
These and other objects and features will become more apparent from the following description of the preferred embodiments of the present invention when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the relationship between the gloss of the coating layer and absorbance corrected according to the present invention;
FIG. 2 is a graph showing the relationship between the gloss of the coating layer and the absorbance before correction;
FIG. 3 is a graph showing the relationship between the wavelength of the ultraviolet ray for the gloss and the absorbance;
FIG. 4 is a graph showing the ultraviolet absorbance of SB latex;
FIG. 5 is a graph showing the relationship between the adhesive concentration of the coating layer and the corrected absorbance; and
FIG. 6 is an explanatory view showing an example of the construction of an apparatus for measuring in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments for measuring the concentration of adhesive on the surface of coating layers according to the present invention will now be described in detail with reference to the accompanying drawings.
FIG. 4 is a graph showing the relationship between the wavelength of ultraviolet rays and the absorbance thereof by SB latex. In FIG. 4, the wavelength of ultraviolet rays at which the highest peak of the absorption by the SB latex occurs is about 260 nm. When measuring the concentration of the SB latex, ultraviolet rays of a wavelength near 260 nm are used as the center of the three wavelengths. Similarly, when measuring the concentration of other adhesives, the absorption ultraviolet ray wavelength of the highest peak must be determined to measure the concentration.
In the method of the present invention, ultraviolet rays of shorter and longer wavelengths are used in addition to ultraviolet rays having the highest peak absorption wavelength. As will be described with reference to FIG. 2, correct quantitative measurement cannot be obtained by analysis using only ultraviolet rays having the highest peak absorption wavelength. FIG. 2 shows the relationship between the gloss and the absorbance of ultraviolet rays having a wavelength of 260 nm by coated paper using three types of solution comprising 5, 10 and 15 parts of starch to 100 parts of calcium carbonate pigment and three types of solution comprising 5 parts of starch and 5, 10 and 20 parts of SB latex. The absorbance of light of wavelength equal to 260 nm is affected by the gloss of the surface of coated paper, and is also affected by the presence of the starch which does not absorb the ultraviolet ray. Therefore, the correct quantitative result cannot be obtained by measurement with light of only one wavelength. The reason that the increase in the starch increases the absorbance is not always apparent, but it is possible that the absorbance is increased due to a variation in the scattering state of the light on the surface of the coating layer as a result of the presence of the starch.
An embodiment of an apparatus for measuring the concentration of the adhesive on the surface of a coating layer according to the present invention is shown in FIG. 6. This apparatus comprises a detector 1, a converter amplifier 2, and an external output unit 3 as main components. The detector has deuterium lamp 4, a filter 5, a diaphragm 6, a half mirror 7, a reference light electrophotomultiplier 8, a reflected light electrophotomultiplier 9 and a sample base 10.
To measure the concentration of adhesive on a coating layer, the ultraviolet ray irradiated from the deuterium lamp 4 passes through the filter 5 after which it is monochromatic light of specific wavelength. The monochromic light is focused by the diaphragm 6 into a spot light and is then spectrally analyzed by the half mirror 7. A portion of the light is photometered as a reference light by the reference light electrophotomultiplier 8, and another portion of the light is reflected on the sample being analyzed, which sample is mounted on the sample base 10. Part of the reflected light is photometered by the reflected light electrophotomultiplier 9. The light is converted by the electrophotomultiplier into a current, and the resultant current is then converted into voltages E 1 and E 2 by operation amplifiers 11, 12 of the converter amplifier 2. The voltages E1, E2 are subtracted by a subtractor 13, and are converted by an analog-to-digital converter 14 of the external output unit 3 into a digital signal. The digital signal is transferred to a data processor such as a computer or a recorder.
In accordance with the present invention, the measured result is not affected by the influence of other physical properties such as gloss and can be quantitatively obtained by calculating and comparing the optical densities of the three wavelengths. The removal of the influence of gloss will be described in detail.
FIG. 3 shows measurement of the absorbance of ultraviolet ray (of wavelengths from 200 to 350 nm) prepared with 10% and 34% of gloss. The difference in gloss is obtained by applying different degrees of supercalendering coated paper with solution comprising 5 parts of starch and 5 parts of SB latex in 100 parts of calcium carbonate of coated paper such as that used in formulating the graph shown in FIG. 2. Referring to FIG. 3, the apparent absorbance of light of any wavelength is greater when the gloss of the coated paper is 34% as opposed to 10%.
When the curves of both the absorption spectra of 34% and 10% of gloss are designated by f(x) and g(x), the relationship between both the curves can be substantially represented by the equation f(x)-g(x)=ax+b. Base lines BC and FG were drawn using the measured values at wavelengths of 235 nm and 285 nm as the end points. These are the shorter and longer wavelengths, discussed above, relative to the highest peak absorption wavelength (260 nm) of SB latex. The differences of the points D and H on the base lines in the wavelength of 260 nm and the measured values A and E of the wavelength of 260 nm, respectively, are denoted AD and EH. If the relationship between the curves of both the spectra is represented by the equation f(x)-g(x)=ax+b, AD and EH are equal. Thus, by calculation according to this relationship, the influence of the gloss can be compensated for. Even when the relationship between the curves of the spectra differs slightly from the equation f(x)-g(x)=ax+b, AD is nearly equal to EH, and the influence of the gloss can be substantially compensated for,
The equation for producing the base line will be described.
The absorbance at corrected 260 nm=S 260 -((S 285 -S 235 )/2+S 235 ) where S 260 , S 235 , S 285 represent the apparent absorbance measured at wavelengths of 260, 235 and 285 nm, respectively.
In the present invention, the ultraviolet rays of shorter and longer wavelength, relative to the highest peak absorption wavelength may be somewhat arbitrarily set. In FIG. 3, the reason that 235 and 285 nm are selected is because of the convenience of calculations and the exclusion of the measuring error. More specifically, since the shorter and longer wavelenths each differ from the highest peak absorption wavelength by 25 nm, FG/FH=2, thereby simplifying calculation.
In general, as shown in FIG. 3, FG/FH=(L-S)/(P-S), where L=the wavelength of the ultraviolet ray of longer wavelength, P=the wavelength of the ultraviolet ray of the highest peak absorption, and S=the wavelength of the ultraviolet ray of shorter wavelength.
Thus, the complete equation for the calculation of corrected absorbance is:
S.sub.c =S.sub.p -((S.sub.1 -S.sub.s)/(L-S)/(P-S))+S.sub.s),
wherein:
S c is the corrected abosrbance,
S p is the absorbance of the ulraviolet ray of the highest peak absorption wavelength,
S s is the absorbance of the ultraviolet ray of shorter wavelength, and
S 1 is the absorbance of the ultraviolet ray of longer wavelength.
As discussed above, when L and S differ from P by equal amounts, (L-S)/(P-S)=2, and the equation simplifies to S c =S p -((S 1 -S s )/2+S s ). Since 235 nm is not very far from the highest peak and is situated at a minimum peak, the measuring error can be effectively compensated for.
As described above, when the graph in FIG. 2 is corrected as described above, a graph such as the one shown in FIG. 1 is obtained. FIG. 1 therefore shows the influence of the starch with the influence of the gloss of the sample having been compensated for. The influence of the presence of starch in the absence of gloss is apparent from the fact that the plots for samples containing starch in amounts of 5, 10 and 15 parts fall on approximately the same line in FIG. 1.
FIG. 5 shows a graph of the measurement of the surface of coated paper fabricated with an adhesive solution containing 60 percent by weight of adhesive mixed with 5, 10, 15 or 20 parts of SB latex to 100 parts of clay or calcium carbonate pigment. The amount of adhesive in the sample was 10 g/m2 (dry weight), and only one side was coated with adhesive. The concentration of the SB latex is shown to be proportional to the absorbance after the correction in accordance with the present invention. The slopes of the lines differ depending upon the type of pigment because of the differences in the shapes and sizes of the pigments. These measured values are obtained by superposing the sample, lining a glass plate of ultraviolet ray absorption substance on the sample, and lining a silica gel plate exhibiting no absorption. In all cases, the measured values were the same, because the scattered light on the surface of the coating layer is detected.
The measurement of the distribution of adhesive on the surface of the coating layer will now be described. To effect this measurement, an apparatus capable of moving laterally and longitudinally relatively between the sample and the ultraviolet rays is provided. For example, in the apparatus shown in FIG. 6, the sample base 10 is moved laterally and longitudinally at predetermined intervals using an XY stage having a stepping motor for the sample base 10.
The distributed state of the adhesive may be measured by the following procedure using an apparatus constructed as described above. Samples of coated paper coated with adhesive solution of 60% of solid concentration mixed with 100 parts of clay, 10 parts of SB latex containing 10 g/m2 (dry weight) of adhesive on the surface of base paper, were dried by natural drying at room temperature and by hot blast drying. The samples were irradiated with fine ultraviolet light spots having three wavelengths, namely, 235, 260 and 285 nm longitudinally at 4 mm intervals, 60 mm long and laterally at 1 mm intervals, 63 mm long. The size of each sample was 0.4 mm×0.4 mm.
The average absorbance after correction of the samples formed by natural drying was 0.326, and its standard deviation was 0.004. The average absorbance after correction of the samples formed by hot blast drying was 0.432, and its standard deviation ws 0.006. These measured results indicate that the SB latex moves onto the surface of the coating layer due to the abrupt hot blast drying and its distribution is irregular as compared with that of the natural drying. The result conforms to the empirical fact that the printability of coated paper decreases when abrupt hot blast drying is executed. As described above, according to the method of the present invention, the surface concentration distribution of the adhesive on the coating layer can be measured.
A method of irradiating with an ultraviolet ray of a specific wavelength will be further described. The longitudinal and lateral size of the fine ultraviolet ray spot is suitably from 0.01 to 2 mm. When the adhesive distribution on the surface of the coating layer is measured, the sample base and the spot are continuously moved laterally and longitudinally relative to one another. The size of the spot is determined by considering the area and the measuring interval of the samples. For example, when a 50 cm 2 sample is measured at an interval of 2 mm longitudinally and laterally, satisfactory results can be obtained by using a spot measuring 0.5 mm laterally and longitudinally.
According to the present invention as described above, the adhesive concentration and the distribution can be accurately and rapidly measured despite any influence of scattered light on the irregular surface of the coating layer and without the necessity of pretreatment. In accordance with the present invention, irradiating light of the highest peak absorption wavelength as well as irradiating light having shorter and longer wavelengths are used to make the measurements of the coating layer being analyzed. This measuring method is not limited to any particular type of paper. That is, coated layers can be analyzed irrespective of the nature of the support, for example, coated synthetic resin, metal or glass layers can be analyzed.
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A method for measuring the concentration of adhesive on the surface of a coating layer which has the steps of irradiating the surface of the coating layer with an ultraviolet ray of the highest peak absorption wavelength of the adhesive, ultraviolet ray of shorter wavelength and ultraviolet ray of longer wavelength, photoelectrically converting the reflected rays and further comparing to calculate them. Thus, this method can be used to measure the concentration of adhesive on the surface of a coating layer and the flat surface distribution of the adhesive by fundamentally measuring with ultraviolet rays. The method is of high reliability despite the presence of gloss or the like.
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FIELD OF THE INVENTION
[0001] The present invention relates to an apparatus for separating gas fractions from a gas mixture having multiple gas fractions. In particular, the present invention relates to a rotary valve gas separation system having a plurality of rotating adsorbent beds disposed therein for implementing a pressure swing adsorption process for separating out the gas fractions.
BACKGROUND OF THE INVENTION
[0002] Pressure swing adsorption (PSA) and vacuum pressure swing adsorption (VPSA) separate gas fractions from a gas mixture by coordinating pressure cycling and flow reversals over an adsorbent bed which preferentially adsorbs a more readily adsorbed component relative to a less readily adsorbed component of the mixture. The total pressure of the gas mixture in the adsorbent bed is elevated while the gas mixture is flowing through the adsorbent bed from a first end to a second end thereof, and is reduced while the gas mixture is flowing through the adsorbent from the second end back to the first end. As the PSA or VPSA cycle is repeated, the less readily adsorbed component is concentrated adjacent the second end of the adsorbent bed, while the more readily adsorbed component is concentrated adjacent the first end of the adsorbent bed. As a result, a “light” product (a gas fraction depleted in the more readily adsorbed component and enriched in the less readily adsorbed component) is delivered from the second end of the bed, and a “heavy” product (a gas fraction enriched in the more strongly adsorbed component) is exhausted from the first end of the bed.
[0003] The conventional system for implementing pressure swing adsorption or vacuum pressure swing adsorption uses two or more stationary adsorbent beds in parallel, with directional valving at each end of each adsorbent bed to connect the beds in alternating sequence to pressure sources and sinks. However, this system is often difficult and expensive to implement due to the complexity of the valving required.
[0004] Furthermore, the conventional PSA or VPSA system makes inefficient use of applied energy, because feed gas pressurization is provided by a compressor whose delivery pressure is the highest pressure of the cycle. In PSA, energy expended in compressing the feed gas used for pressurization is then dissipated in throttling over valves over the instantaneous pressure difference between the adsorber and the high pressure supply. Similarly, in VPSA, where the lower pressure of the cycle is established by a vacuum pump exhausting gas at that pressure, energy is dissipated in throttling over valves during countercurrent blowdown of adsorbers whose pressure is being reduced. A further energy dissipation in both systems occurs in throttling of light reflux gas used for purge, equalization, cocurrent blowdown and product pressurization or backfill steps.
[0005] Numerous attempts have been made at overcoming the deficiencies associated with the conventional PSA or VPSA system. For example, Siggelin (U.S. Pat. No. 3,176,446), Mattia (U.S. Pat. No. 4,452,612), Davidson and Lywood (U.S. Pat. No. 4,758,253), Boudet et al (U.S. Pat. No. 5,133,784), Petit et al (U.S. Pat. No. 5,441,559) and Schartz (PCT publication WO 94/04249) disclose PSA devices using rotary distributor valves having rotors fitted with multiple angularly separated adsorbent beds. Ports communicating with the rotor-mounted adsorbent beds sweep past fixed ports for feed admission, product delivery and pressure equalization. However, these prior art rotary distributor valves are impracticable for large PSA/VPSA units, owing to the weight of the rotating assembly. Furthermore, since the valve faces are remote from the ends of the adsorbent beds, these rotary distributor valves have considerable dead volume for flow distribution and collection. As a result, the prior art rotary distributor valves have poor flow distribution, particularly at high cycle frequencies.
[0006] Hay (U.S. Pat. No. 5,246,676) and Engler (U.S. Pat. No. 5,393,326) provide examples of vacuum pressure swing adsorption systems which reduce throttling losses in an attempt to improve the efficiency of the gas separation process system. The systems taught by Hay and Engler use a plurality of vacuum pumps to pump down the pressure of each adsorbent bed sequentially in turn, with the pumps operating at successively lower pressures, so that each vacuum pump reduces the pressure in each bed a predetermined amount. However, with these systems, the vacuum pumps are subjected to large pressure variations, stressing the compression machinery and causing large fluctuations in overall power demand. Because centrifugal or axial compression machinery cannot operate under such unsteady conditions, rotary lobe machines are typically used in such systems. However, such machines have lower efficiency than modem centrifugal compressors/vacuum pumps working under steady conditions.
[0007] Accordingly, there remains a need for a PSA/VPSA system which is suitable for high volume and high frequency production, while reducing the losses associated with the prior art devices.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention provide a rotary module for implementing a high frequency pressure swing adsorption process with high energy efficiency.
[0009] The rotary module, in accordance with the invention, comprises a stator and a rotor rotatably coupled to the stator. The stator includes a first stator valve surface, a second stator valve surface, a plurality of first function compartments opening into the first stator valve surface, and a plurality of second function compartments opening into the second stator valve surface. The rotor includes a first rotor valve surface in communication with the first stator valve surface, a second rotor valve surface in communication with the second stator valve surface, and a plurality of flow paths for receiving adsorbent material therein. Each said flow path includes a pair of opposite ends, and a plurality of apertures provided in the rotor valve surfaces and in communication with the flow path ends and the function ports for cyclically exposing each said flow path to a plurality of discrete pressure levels between the upper and lower pressures for maintaining uniform gas flow through the first and second function compartments.
[0010] During pressurization and blowdown steps, the several adsorbers passing through the step will converge to the nominal pressure level of each step by a throttling pressure equalization from the pressure level of the previous step experienced by the adsorbers. Flow is provided to the adsorbers in a pressurization step or withdrawn in a blowdown step by compression machinery at the nominal pressure level of that step. Hence flow and pressure pulsations seen by the compression machinery at each intermediate pressure level are minimal by averaging from the several adsorbers passing through the step, although each adsorber undergoes large cyclic changes of pressure and flow.
[0011] During the pressurization steps for each adsorber, either (or both) of the apertures of an adsorber already at a pressure is (are) opened respectively to a first or second pressurization compartment at a stepwise higher pressure. Similarly, during the pressurization steps for each adsorber, either (or both) of the apertures of an adsorber already at a pressure is (are) opened respectively to a first or second pressurization compartment at a stepwise lower pressure. Equalization then takes place by flow through the open aperture(s) from the pressurization/blowdown compartment into the adsorber, which by the end of the pressurization/blowdown step has attained approximately the same pressure as the pressurization/blowdown compartment(s). Each pressurization/blowdown compartment is in communication with typically several adsorbers being pressurized (in differing angular and time phase) at any given time, so the pressure in that compartment and the pressurization flow to that compartment are substantially steady.
[0012] The flow path through the adsorbers may be radial or axial. If the adsorbers are configured for radial flow, the first valve surface would preferably be radially inward when the less strongly adsorbed gas fraction has much higher density that the more strongly adsorbed fraction, and the first valve surface would preferably be radially outward when the less strongly adsorbed gas fraction has much lower density than the more strongly adsorbed fraction. Hence, for hydrogen purification in a radial flow embodiment, the feed gas would preferably be admitted to (and the higher molecular weight impurity fraction as heavy product is exhausted from) the first valve surface at an outer radius, while the hydrogen as first product gas is delivered from the second valve surface.
[0013] The present invention also includes the alternatives of (1) layered or laminated thin sheet adsorbers and (2) the centrifugally stabilized fine particle granular adsorbers to enable operation at exceptionally high cycle frequency. PSA cycle frequencies to at least 100 cycles per minute are practicable within the present invention, and will enable process intensification so that high productivity can be realized from compact modules. Cycle frequencies more rapid than about 50 cycles per minute will be achieved preferably with the layered thin sheet adsorbers, with the flow path in flow channels tangential to and between adjacent pairs of adsorbent loaded sheets, to obtain lower frictional pressure drop at high frequency than granular adsorbent.
[0014] Preferably, the increments between adjacent pressure levels are sized so that the gas flows entering or exiting the module are substantially steady in both flow velocity and pressure. As a result, the module can be operated with centrifugal or axial flow compressors and expanders, for most favourable efficiency and capital cost economies of scale. To reduce throttling losses, it is also preferred that the function compartments are shaped to provide uniform gas flow through the flow paths and/or the valve surfaces include sealing strips having tapered portions for providing uniform gas flow through the flow paths.
[0015] Since the orifices providing the valving function are immediately adjacent to the ends of the flow paths, the dead volume associated with prior art distribution manifolds is substantially reduced. Also, since the compartments communicating with the first and second valve surfaces are external to the valving function, the compartments do not contribute to dead volume of the adsorbers. As a result, high frequency pressure/vacuum swing adsorption is possible.
[0016] Also, in contrast to prior art PSA devices whose pressure vessels are subject to pressure cycling and consequent fatigue loading, the pressure vessel of the present invention operates under substantially static stresses, because each of the compartments operates under steady pressure conditions. Mechanical stresses on the rotor and its bearings are relatively small, because only small frictional pressure drops (at most equal to the interval between adjacent intermediate pressures) apply in the flow direction, while transverse pressure gradients between the adsorber elements are also small owing to the large number of elements. These features are important, since pressure vessel fatigue is a major concern and limitation in the design of PSA systems, especially working with corrosive gases or hydrogen at higher pressure or higher cycle frequency.
[0017] Further, by providing multiple closely spaced intermediate pressure levels, with substantially constant flow and pressure at each level, the present invention facilitates energy efficient application of multistage feed compressors and vacuum pumps (including centrifugal or axial compression machines) for feed compression, heavy product exhaust and heavy reflux compression; as well as multistage expanders (including radial inflow turbines, axial turbines and partial admission impulse turbines). Positive displacement (reciprocating piston, rotary piston, or progressive cavity such as screw or scroll machines) compression and expansion machinery may also be applied within the scope of the invention, particularly when adapted to deliver gas at multiple intermediate delivery pressures and/or to intake gas at multiple intermediate inlet pressures. The invention enables use of single shaft machines to provide all compression and expansion functions for a plurality of modules in parallel, as well as the combined use of motor driven and free rotor machines for more flexible modularization and splitting of stages.
[0018] The inventive concept of split stream centrifugal machinery is a desirable option for the described PSA process which requires various enthalpies in separate fluid streams at differing total pressures. The split stream machine has multiple inlet flows at multiple enthalpies, and/or multiple exit flows at multiple enthalpies, for a single centrifugal or radial flow impeller. The differing changes in enthalpy or total pressure are achieved by having a different change in radius, or differing blade angles, for each flow across the impeller. A split stream compressor has one inlet but numerous outlets at different total pressures or enthalpy levels from a single impeller. A split stream exhauster may be a vacuum pump or an expander, and will have multiple inlets and a single outlet at different total pressures or enthalpy levels for a single impeller. Also useful in the present invention is a split stream light reflux expander having a number of inlets and the same number of outlets, at different total pressures or enthalpy levels for a single impeller.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The preferred embodiments of the present invention will now be described, by way of example only, and with reference to the drawings, in which like reference numerals indicate like elements, and in which:
[0020] [0020]FIG. 1 is a sectional view of a rotary PSA module according to the invention;
[0021] [0021]FIG. 2 is the stator of the module of FIG. 1;
[0022] [0022]FIG. 3 is the rotor of the module of FIG. 1;
[0023] [0023]FIG. 4 is an axial section of the module of FIG. 1;
[0024] [0024]FIG. 5 shows an alternative adsorber configuration using layered adsorbent sheets;
[0025] [0025]FIG. 6 shows a typical PSA cycle according to the invention;
[0026] [0026]FIG. 7 shows a PSA cycle with heavy reflux;
[0027] [0027]FIG. 8 shows a PSA apparatus with a single rotary module and energy recovery;
[0028] [0028]FIG. 9 shows a vacuum PSA (VPSA) for oxygen separation from air;
[0029] [0029]FIG. 10 shows a VPSA apparatus without light reflux energy recovery;
[0030] [0030]FIG. 11 shows a PSA apparatus adapted to receive two feed gas mixtures, and with recompression of tail gas;
[0031] [0031]FIG. 12 shows a PSA apparatus with heavy reflux;
[0032] [0032]FIG. 13 shows a PSA apparatus with a free rotor tail gas compressor or vacuum pump, powered by energy recovery;
[0033] [0033]FIG. 14 shows another embodiment of a PSA apparatus with a free rotor compressor;
[0034] [0034]FIG. 15 shows a VPSA apparatus with 4 modules;
[0035] [0035]FIG. 16 shows a PSA apparatus with 5 modules;
[0036] [0036]FIG. 17 shows a simplified schematic of a VPSA cycle for oxygen production, using a split stream air compressor, a split stream vacuum pump as the countercurrent blowdown exhauster, and a split stream light reflux expander powering a product oxygen compressor;
[0037] [0037]FIG. 18 shows a radial flow rotary PSA module;
[0038] [0038]FIG. 19 shows an axial flow rotary PSA module;
[0039] [0039]FIG. 20 shows a double axial flow rotary PSA module;
[0040] [0040]FIG. 21 shows the first valve face of the embodiment of FIG. 19;
[0041] [0041]FIG. 22 shows the second valve face of the embodiment of FIG. 19;
[0042] [0042]FIG. 23 shows an adsorber wheel configurations based on laminated adsorbent sheet adsorbers for the embodiment of FIG. 19;
[0043] [0043]FIG. 24 shows a multistage centrifugal compressor with impulse turbine expanders for the light reflux and countercurrent blowdown;
[0044] [0044]FIG. 25 shows the light reflux impulse turbine runner with four nozzles;
[0045] [0045]FIG. 26 is an unrolled view of the light reflux expander impulse turbine;
[0046] [0046]FIG. 27 is an unrolled view of the countercurrent blowdown expander impulse turbine;
[0047] [0047]FIG. 28 shows a split stream axial compressor with three stages; and
[0048] [0048]FIG. 29 shows a composite pellet with zeolite material coated on a high specific gravity inert core, for centrifugally stabilized granular adsorbers in radial flow embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0049] [0049]FIGS. 1, 2, 3 and 4
[0050] A rotary module 10 according to the invention is shown in FIGS. 1, 2, 3 and 4 . The module includes a rotor 11 revolving about axis 12 in the direction shown by arrow 13 within stator 14 . FIG. 4 is an axial section of the module 10 , defined by arrows 15 and 16 in FIG. 1. FIG. 1 is a cross-section of the module 10 , defined by arrows 17 and 18 in FIG. 4. FIG. 2 is the sectional view of the rotor 11 repeated from FIG. 1, with the stator deleted for clarity. FIG. 3 is the sectional view of the stator 14 repeated from FIG. 1, with details of the rotor deleted for clarity.
[0051] In general, the apparatus of the invention may be configured for flow through the adsorber elements in the radial, axial or oblique conical directions relative to the rotor axis. For operation at high cycle frequency, radial flow has the advantage that the centripetal acceleration will lie parallel to the flow path for most favourable stabilization of buoyancy-driven free convection, as well as centrifugal clamping of granular adsorbent with uniform flow distribution. As shown in FIG. 2, the rotor 11 is of annular section, having concentrically to axis 12 an outer cylindrical wall 20 whose external surface is first valve surface 21 , and an inner cylindrical wall 22 whose internal surface is second valve surface 23 . The rotor has (in the plane of the section defined by arrows 15 and 16 in FIG. 4) a total of “N” radial flow adsorber elements 24 . An adjacent pair of adsorber elements 25 and 26 are separated by partition 27 which is structurally and sealingly joined to outer wall 20 and inner wall 22 . Adjacent adsorber elements 25 and 26 are angularly spaced relative to axis 12 by an angle of [360°/N].
[0052] Adsorber element 24 has a first end 30 defined by support screen 31 and a second end 32 defined by support screen 33 . The adsorber may be provided as granular adsorbent, whose packing voidage defines a flow path contacting the adsorbent between the first and second ends of the adsorber.
[0053] First aperture or orifice 34 provides flow communication from first valve surface 21 through wall 20 to the first end 30 of adsorber 24 . Second aperture or orifice 35 provides flow communication from second valve surface 23 through wall 22 to the second end 31 of adsorber 24 . Support screens 31 and 33 respectively provide flow distribution 32 between first aperture 34 and first end 30 , and between second aperture 35 and second end 32 , of adsorber element 24 . Support screen 31 also supports the centrifugal force loading of the adsorbent.
[0054] As shown in FIG. 3, stator 14 is a pressure housing including an outer cylindrical shell or first valve stator 40 outside the annular rotor 11 , and an inner cylindrical shell or second valve stator 41 inside the annular rotor 11 . Outer shell 40 carries axially extending strip seals (e.g. 42 and 43 ) sealingly engaged with first valve surface 21 , while inner shell 41 carries axially extending strip seals (e.g. 44 and 45 ) sealingly engaged with second valve surface 23 . The azimuthal sealing width of the strip seals is greater than the diameters or azimuthal widths of the first and second apertures 34 and 35 opening through the first and second valve surfaces.
[0055] A set of first compartments in the outer shell each open in an angular sector to the first valve surface, and each provide fluid communication between its angular sector of the first valve surface and a manifold external to the module. The angular sectors of the compartments are much wider than the angular separation of the adsorber elements. The first compartments are separated on the first sealing surface by the strip seals (e.g. 42 ). Proceeding clockwise in FIG. 3, in the direction of rotor rotation, a first feed pressurization compartment 46 communicates by conduit 47 to first feed pressurization manifold 48 , which is maintained at a first intermediate feed pressure. Similarly, a second feed pressurization compartment 50 communicates to second feed pressurization manifold 51 , which is maintained at a second intermediate feed pressure higher than the first intermediate feed pressure but less than the higher working pressure.
[0056] For greater generality, module 10 is shown with provision for sequential admission of two feed mixtures, the first feed gas having a lower concentration of the more readily adsorbed component relative to the second feed gas. First feed compartment 52 communicates to first feed manifold 53 , which is maintained at substantially the higher working pressure. Likewise, second feed compartment 54 communicates to second feed manifold 55 , which is maintained at substantially the higher working pressure. A first countercurrent blowdown compartment 56 communicates to first countercurrent blowdown manifold 57 , which is maintained at a first countercurrent blowdown intermediate pressure. A second countercurrent blowdown compartment 58 communicates to second countercurrent blowdown manifold 59 , which is maintained at a second countercurrent blowdown intermediate pressure above the lower working pressure. A heavy product compartment 60 communicates to heavy product exhaust manifold 61 which is maintained at substantially the lower working pressure. It will be noted that compartment 58 is bounded by strip seals 42 and 43 , and similarly all the compartments are bounded and mutually isolated by strip seals.
[0057] A set of second compartments in the inner shell each open in an angular sector to the second valve surface, and each provide fluid communication between its angular sector of the second valve surface and a manifold external to the module. The second compartments are separated on the second sealing surface by the strip seals (e.g. 44 ). Proceeding clockwise in FIG. 3, again in the direction of rotor rotation, light product compartment 70 communicates to light product manifold 71 , and receives light product gas at substantially the higher working pressure, less frictional pressure drops through the adsorbers and the first and second orifices. According to the angular extension of compartment 70 relative to compartments 52 and 54 , the light product may be obtained only from adsorbers simultaneously receiving the first feed gas from compartment 52 , or from adsorbers receiving both the first and second feed gases.
[0058] A first light reflux exit compartment 72 communicates to first light reflux exit manifold 73 , which is maintained at a first light reflux exit pressure, here substantially the higher working pressure less frictional pressure drops. A first cocurrent blowdown compartment 74 (which is actually the second light reflux exit compartment), communicates to second light reflux exit manifold 75 , which is maintained at a first cocurrent blowdown pressure less than the higher working pressure. A second cocurrent blowdown compartment or third light reflux exit compartment 76 communicates to third light reflux exit manifold 77 , which is maintained at a second cocurrent blowdown pressure less than the first cocurrent blowdown pressure. A third cocurrent blowdown compartment or fourth light reflux exit compartment 78 communicates to fourth light reflux exit manifold 79 , which is maintained at a third cocurrent blowdown pressure less than the second cocurrent blowdown pressure.
[0059] A purge compartment 80 communicates to a fourth light reflux return manifold 81 , which supplies the fourth light reflux gas which has been expanded from the third cocurrent blowdown pressure to substantially the lower working pressure with an allowance for frictional pressure drops. The ordering of light reflux pressurization steps is inverted from the ordering or light reflux exit or cocurrent blowdown steps, so as to maintain a desirable “last out-first in” stratification of light reflux gas packets. Hence a first light reflux pressurization compartment 82 communicates to a third light reflux return manifold 83 , which supplies the third light reflux gas which has been expanded from the second cocurrent blowdown pressure to a first light reflux pressurization pressure greater than the lower working pressure. A second light reflux pressurization compartment 84 communicates to a second light reflux return manifold 85 , which supplies the second light reflux gas which has been expanded from the first cocurrent blowdown pressure to a second light reflux pressurization pressure greater than the first light reflux pressurization pressure. Finally, a third light reflux pressurization compartment 86 communicates to a first light reflux return manifold 87 , which supplies the first light reflux gas which has been expanded from approximately the higher pressure to a third light reflux pressurization pressure greater than the second light reflux pressurization pressure, and in this example less than the first feed pressurization pressure.
[0060] Additional details are shown in FIG. 4. Conduits 88 connect first compartment 60 to manifold 61 , with multiple conduits providing for good axial flow distribution in compartment 60 . Similarly, conduits 89 connect second compartment 80 to manifold 81 . Stator 14 has base 90 with bearings 91 and 92 . The annular rotor 11 is supported on end disc 93 , whose shaft 94 is supported by bearings 91 and 92 . Motor 95 is coupled to shaft 94 to drive rotor 11 . The rotor could alternatively rotate as an annular drum, supported by rollers at several angular positions about its rim and also driven at its rim so that no shaft would be required. A rim drive could be provided by a ring gear attached to the rotor, or by a linear electromagnetic motor whose stator would engage an arc of the rim. Outer circumferential seals 96 seal the ends of outer strip seals 42 and the edges of first valve surface 21 , while inner circumferential seals 97 seal the ends of inner strip seals 44 and the edges of second valve surface 23 . Rotor 11 has access plug 98 between outer wall 20 and inner wall 22 , which provides access for installation and removal of the adsorbent in adsorbers 24 .
[0061] A further most important benefit of the invention in radial flow embodiments arises in purification of very low molecular weight gases such as hydrogen and helium to remove higher molecular weight impurities. Here, the light product is separated radially inward, while the heavy impurities are separated radially outward by the centrifugal PSA apparatus of the present invention. In all PSA systems, dispersive effects including axial dispersion, uneven bed packing, thermal gradients and wall flow channeling all tend to spread the concentration gradient in the bed so as to degrade separation performance. But the strong centripetal acceleration field of the present invention will induce a buoyant stratification of the purified light fraction radially inward of the separated heavy fraction, thus opposing dispersive effects and enhancing separation performance. This important desirable effect is present whether granular adsorbent or laminated sheet supported adsorbent is used, as along as the flow direction in the adsorbent bed is radially inward from the first end to the second end of the bed.
[0062] In air separation with the feed presented to the outer radius of the adsorbers, the buoyancy effect due to the greater molecular weight of oxygen compared to nitrogen would be modestly adverse. The molecular weight difference between hydrogen and its impurities (other than helium) is far greater and in the desired direction. Some process embodiments of the present invention include the feature of heating the oxygen light reflux gas, for the main objects of thermally enhancing expansion energy recovery, improving adsorption/desorption kinetics, and shifting the optimal operating pressure range from vacuum to positive superatmospheric pressure conditions. Heating the light reflux oxygen sufficiently will create a radial thermal gradient, so that the second end of the adsorbers (at an inner radius) will be hotter than the first end of the adsorbers (at an outer radius). In a rapidly rotating rotor of the invention, this thermal gradient will enhance the convective stability of the mass transfer front in the adsorbers, and will tend to compensate the adverse effect of oxygen being more dense than nitrogen at equal temperature. The present invention thus can provide radial stabilization of the mass transfer front by establishing a radial density gradient either of lower molecular weight of the gas contacting the adsorbent radially inward, or by a thermal gradient of higher temperature radially inward.
[0063] Alternatively, convective stability in air separation applications may be enhanced by operating with the feed applied to an inner radius of radial flow rotating adsorbers, while the oxygen as second product is withdrawn from an outer radius.
[0064] [0064]FIG. 5
[0065] An attractive alternative to the use of granular adsorbent is obtained by forming the adsorbent material with a suitable reinforcement matrix into thin adsorbent sheets, and layering the adsorbent sheets with spacers to form a layered sheet contactor with flow channels between adjacent pairs of sheets. The adsorber elements may then be installed as angularly spaced rectangular blocks within the rotor and between the first and second valve faces, with the adsorbent sheets as substantially flat sheets extending parallel to the plane defined by the axis of the rotor and a radius from the axis through the rectangular block, and the flat adsorbent sheets being layered with flow channels between them to form the rectangular block. The flow channels also lie in planes parallel to the sheets and to the plane defined by the axis of the rotor and a radius from the axis through the rectangular blocks, and may be configured for either axial flow or radial flow. In the axial flow case, the first and second valve surfaces would be provided as flat discs perpendicular to and concentric with the axis of rotation. In the radial flow case, represented by FIGS. 1 - 4 , the first and second valve surfaces are provided as inner and outer cylindrical surfaces bounding the annular rotor within which the adsorber elements are mounted.
[0066] A section 110 of rotor 11 has been identified in FIG. 2 between the curved lines with endpoints 111 and 112 , and 113 and 114 . FIG. 5 shows section 110 in detail, with the laminated sheet embodiment of the adsorbers.
[0067] The laminate sheets 115 lie in the radial plane and are layered to form the adsorber elements 24 as rectangular blocks. Each sheet 115 comprises reinforcement material, e.g. a glass fiber or metal wire matrix (woven or non-woven) on which the adsorbent material (e.g. zeolite crystallites is supported by a suitable binder (e.g., clay, silicate or coke binders). Typical thickness of an adsorbent sheet may be about 100 microns. The sheets 115 are installed with spacers on one or both sides to establish flow channels between adjacent pairs of sheets. The flow channels define the flow path approximately in the radial direction between first end 30 and second end 32 of the flow path in each adsorber element. Typical channel height would be about 50% to 100% of the adsorbent sheet thickness.
[0068] The adsorbent sheets comprise a reinforcement material, preferably glass fibre, but alternatively metal foil or wire mesh, to which the adsorbent material is attached with a suitable binder. For air separation to produce enriched oxygen, typical adsorbents are X, A or chabazite type zeolites, typically exchanged with calcium or lithium cations. The zeolite crystals are bound with silica, clay and other binders within the adsorbent sheet matrix.
[0069] Satisfactory adsorbent sheets have been made by coating a slurry of zeolite crystals with binder constituents onto the reinforcement material, with successful examples including non-woven fiber glass scrims, woven metal fabrics, and expanded aluminum foils. Spacers are provided by printing or embossing the adsorbent sheet with a raised pattern, or by placing a fabricated spacer between adjacent pairs of adsorbent sheets. Alternative satisfactory spacers have been provided as woven metal screens, fiber glass scrims, and metal foils with etched flow channels in a photolithographic pattern.
[0070] Typical experimental sheet thicknesses have been 150 microns, with spacer heights in the range of 100 to 150 microns, and adsorber flow channel length approximately 20 cm. Using X type zeolites, excellent performance has been achieved in oxygen separation from air at PSA cycle frequencies in the range of 50 to 100 cycles per minute.
[0071] [0071]FIGS. 6 and 7
[0072] [0072]FIG. 6 shows a typical PSA cycle according to the invention, while FIG. 7 shows a similar PSA cycle with heavy reflux recompression of a portion of the first product gas to provide a second feed gas to the process.
[0073] In FIGS. 6 and 7, the vertical axis 150 indicates the working pressure in the adsorbers and the pressures in the first and second compartments. Pressure drops due to flow within the adsorber elements are neglected. The higher and lower working pressures are respectively indicated by dotted lines 151 and 152 .
[0074] The horizontal axis 155 of FIGS. 6 and 7 indicates time, with the PSA cycle period defined by the time interval between points 156 and 157 . At times 156 and 157 , the working pressure in a particular adsorber is pressure 158 . Starting from time 156 , the cycle for a particular adsorber (e.g. 24 ) begins as the first aperture 34 of that adsorber is opened to the first feed pressurization compartment 46 , which is fed by first feed supply means 160 at the first intermediate feed pressure 161 . The pressure in that adsorber rises from pressure 158 at time 157 to the first intermediate feed pressure 161 . Proceeding ahead, first aperture passes over a seal strip, first closing adsorber 24 to compartment 46 and then opening it to second feed pressurization compartment 50 which is feed by second feed supply means 162 at the second intermediate feed pressure 163 . The adsorber pressure rises to the second intermediate feed pressure.
[0075] First aperture 34 of adsorber 24 is opened next to first feed compartment 52 , which is maintained at substantially the higher pressure by a third feed supply means 165 . Once the adsorber pressure has risen to substantially the higher working pressure, its second aperture 35 (which has been closed to all second compartments since time 156 ) opens to light product compartment 70 and delivers light product 166 .
[0076] In the cycle of FIG. 7, first aperture 34 of adsorber 24 is opened next to second feed compartment 54 , also maintained at substantially the higher pressure by a fourth feed supply means 167 . In general, the fourth feed supply means supplies a second feed gas, typically richer in the more readily adsorbed component than the first feed gas provided by the first, second and third feed supply means. In the specific cycle illustrated in FIG. 7, the fourth feed supply means 167 is a “heavy reflux” compressor, recompressing a portion of the heavy product back into the apparatus. In the cycle illustrated in FIG. 6, there is no fourth feed supply means, and compartment 54 could be eliminated or consolidated with compartment 52 extended over a wider angular arc of the stator.
[0077] While feed gas is still being supplied to the first end of adsorber 24 from either compartment 52 or 54 , the second end of adsorber 24 is closed to light product compartment 70 and opens to first light reflux exit compartment 72 while delivering “light reflux” gas (enriched in the less readily adsorbed component, similar to second product gas) to first light reflux pressure let-down means (or expander) 170 . The first aperture 34 of adsorber 24 is then closed to all first compartments, while the second aperture 35 is opened successively to (a) second light reflux exit compartment 74 , dropping the adsorber pressure to the first cocurrent blowdown pressure 171 while delivering light reflux gas to second light reflux pressure letdown means 172 , (b) third light reflux exit compartment 76 , dropping the adsorber pressure to the second cocurrent blowdown pressure 173 while delivering light reflux gas to third light reflux pressure letdown means 174 , and (c) fourth light reflux exit compartment 78 , dropping the adsorber pressure to the third cocurrent blowdown pressure 175 while delivering light reflux gas to fourth light reflux pressure letdown means 176 . Second aperture 35 is then closed for an interval, until the light reflux return steps following the countercurrent blowdown steps.
[0078] The light reflux pressure let-down means may be mechanical expanders or expansion stages for expansion energy recovery, or may be restrictor orifices or throttle valves for irreversible pressure let-down.
[0079] Either when the second aperture is closed after the final light reflux exit step (as shown in FIGS. 6 and 7), or earlier while light reflux exit steps are still underway, first aperture 34 is opened to first countercurrent blowdown compartment 56 , dropping the adsorber pressure to the first countercurrent blowdown intermediate pressure 180 while releasing “heavy” gas (enriched in the more strongly adsorbed component) to first exhaust means 181 . Then, first aperture 34 is opened to second countercurrent blowdown compartment 58 , dropping the adsorber pressure to the first countercurrent blowdown intermediate pressure 182 while releasing heavy gas to second exhaust means 183 . Finally reaching the lower working pressure, first aperture 34 is opened to heavy product compartment 60 , dropping the adsorber pressure to the lower pressure 152 while releasing heavy gas to third exhaust means 184 . Once the adsorber pressure has substantially reached the lower pressure while first aperture 34 is open to compartment 60 , the second aperture 35 opens to purge compartment 80 , which receives fourth light reflux gas from fourth light reflux pressure let-down means 176 in order to displace more heavy gas into first product compartment 60 .
[0080] In FIG. 6, the heavy gas from the first, second and third exhaust means is delivered as the heavy product 185 . In FIG. 7, this gas is partly released as the heavy product 185 , while the balance is redirected as “heavy reflux” 187 to the heavy reflux compressor as fourth feed supply means 167 . Just as light reflux enables an approach to high purity of the less readily adsorbed (“light”) component in the light product, heavy reflux enables an approach to high purity of the more readily adsorbed (“heavy”) component in the heavy product.
[0081] The adsorber is then repressurized by light reflux gas after the first and second apertures close to compartments 60 and 80 . In succession, while the first aperture 34 remains closed at least initially, (a) the second aperture 35 is opened to first light reflux pressurization compartment 82 to raise the adsorber pressure to the first light reflux pressurization pressure 190 while receiving third light reflux gas from the third light reflux pressure letdown means 174 , (b) the second aperture 35 is opened to second light reflux pressurization compartment 84 to raise the adsorber pressure to the second light reflux pressurization pressure 191 while receiving second light reflux gas from the second light reflux pressure letdown means 172 , and (c) the second aperture 35 is opened to third light reflux pressurization compartment 86 to raise the adsorber pressure to the third light reflux pressurization pressure 192 while receiving first light reflux gas from the first light reflux pressure letdown means 170 . Unless feed pressurization has already been started while light reflux return for light reflux pressurization is still underway, the process (as based on FIGS. 6 and 7) begins feed pressurization for the next cycle after time 157 as soon as the third light reflux pressurization step has been concluded.
[0082] The pressure variation waveform in each adsorber would be a rectangular staircase if there were no throttling in the first and second valves. In order to provide balanced performance of the adsorbers, preferably all of the apertures are closely identical to each other.
[0083] The rate of pressure change in each pressurization or blowdown step will be restricted by throttling in ports (or in clearance or labyrinth sealing gaps) of the first and second valve means, or by throttling in the apertures at first and second ends of the adsorbers, resulting in the typical pressure waveform depicted in FIGS. 6 and 7. Alternatively, the apertures may be opened slowly by the seal strips, to provide flow restriction throttling between the apertures and the seal strips, which may have a serrated edge (e.g. with notches or tapered slits in the edge of the seal strip) so that the apertures are only opened to full flow gradually. Excessively rapid rates of pressure change would subject the adsorber to mechanical stress, while also causing flow transients which would tend to increase axial dispersion of the concentration wavefront in the adsorber. Pulsations of flow and pressure are minimized by having a plurality of adsorbers simultaneously transiting each step of the cycle, and by providing enough volume in the function compartments and associated manifolds so that they act effectively as surge absorbers between the compression machinery and the first and second valve means.
[0084] It will be evident that the cycle could be generalized by having more or fewer intermediate stages in each major step of feed pressurization, countercurrent blowdown exhaust, or light reflux. Furthermore, in air separation or air purification applications, a stage of feed pressurization (typically the first stage) could be performed by equalization with atmosphere as an intermediate pressure of the cycle. Similarly, a stage of countercurrent blowdown could be performed by equalization with atmosphere as an intermediate pressure of the cycle.
[0085] [0085]FIG. 8
[0086] FIGS. 8 - 15 are simplified schematics of PSA systems using the module 10 of FIGS. 1 - 4 as the basic building block, and showing the connections from the first and second manifolds of the module to machinery for compression and expansion of gases in typical applications. In FIGS. 8 - 15 , the reference numerals of the first and second manifolds are as defined for FIG. 3.
[0087] [0087]FIG. 8 is a simplified schematic of a PSA system for separating oxygen from air, using nitrogen-selective zeolite adsorbents. The light product is concentrated oxygen, while the heavy product is nitrogen-enriched air usually vented as waste. The cycle lower pressure 152 is nominally atmospheric pressure. Feed air is introduced through filter intake 200 to a feed compressor 201 . The feed compressor includes compressor first stage 202 , intercooler 203 , compressor second stage 204 , second intercooler 205 , compressor third stage 206 , third intercooler 207 , and compressor fourth stage 208 . The feed compressor 201 as described may be a four stage axial compressor or centrifugal compressor with motor 209 as prime mover coupled by shaft 210 , and the intercoolers are optional. With reference to FIG. 6, the feed compressor first and second stages are the first feed supply means 160 , delivering feed gas at the first intermediate feed pressure 161 via conduit 212 and water condensate separator 213 to first feed pressurization manifold 48 . Feed compressor third stage 206 is the second feed supply means 162 , delivering feed gas at the second intermediate feed pressure 163 via conduit 214 and water condensate separator 215 to second feed pressurization manifold 51 . Feed compressor fourth stage 208 is the third feed supply means 165 , delivering feed gas at the higher pressure 151 via conduit 216 and water condensate separator 217 to feed manifold 53 . Light product oxygen flow is delivered from light product manifold 71 by conduit 218 , maintained at substantially the higher pressure less frictional pressure drops.
[0088] The apparatus of FIG. 8 includes energy recovery expanders, including light reflux expander 220 (here including four stages) and countercurrent blowdown expander 221 (here including two stages), coupled to feed compressor 201 by shaft 222 . The expander stages may be provided for example as radial inflow turbine stages, as full admission axial turbine stages with separate wheels, or as partial admission impulse turbine stages combined in a single wheel as illustrated in FIGS. 17 - 20 below.
[0089] Light reflux gas from first light reflux exit manifold 73 flows at the higher pressure via conduit 224 and heater 225 to first light pressure letdown means 170 which here is first light reflux expander stage 226 , and then flows at the third light reflux pressurization pressure 192 by conduit 227 to the first light reflux return manifold 87 . Light reflux gas from second light reflux exit manifold 75 flows at the first cocurrent blowdown pressure 171 via conduit 228 and heater 225 to second light reflux pressure letdown means 172 , here the second expander stage 230 , and then flows at the second light reflux pressurization pressure 191 by conduit 231 to the second light reflux return manifold 85 . Light reflux gas from third light reflux exit manifold 77 flows at the second cocurrent blowdown pressure 173 via conduit 232 and heater 225 to third light reflux pressure letdown means 174 , here the third expander stage 234 , and then flows at the first light reflux pressurization pressure 190 by conduit 235 to the third light reflux return manifold 83 . Finally, light reflux gas from fourth light reflux exit manifold 79 flows at the third cocurrent blowdown pressure 175 via conduit 236 and heater 225 to fourth light reflux pressure letdown means 176 , here the fourth light reflux expander stage 238 , and then flows at substantially the lower pressure 152 by conduit 239 to the fourth light reflux return manifold 81 .
[0090] Heavy countercurrent blowdown gas from first countercurrent blowdown manifold 57 flows at first countercurrent blowdown intermediate pressure 180 by conduit 240 to heater 241 and thence to first stage 242 of the countercurrent blowdown expander 221 as first exhaust means 181 , and is discharged from the expander to exhaust manifold 243 at substantially the lower pressure 152 . Countercurrent blowdown gas from second countercurrent blowdown manifold 59 flows at second countercurrent blowdown intermediate pressure 182 by conduit 244 to heater 241 and thence to second stage 245 of the countercurrent blowdown expander 221 as second exhaust means 183 , and is discharged from the expander to exhaust manifold 243 at substantially the lower pressure 152 . Finally, heavy gas from heavy product exhaust manifold 61 flows by conduit 246 as third exhaust means 184 to exhaust manifold 243 delivering the heavy product gas 185 to be vented at substantially the lower pressure 152 .
[0091] Heaters 225 and 241 raise the temperatures of gases entering expanders 220 and 221 , thus augmenting the recovery of expansion energy and increasing the power transmitted by shaft 222 from expanders 220 and 221 to feed compressor 201 , and reducing the power required from prime mover 209 . While heaters 225 and 241 are means to provide heat to the expanders, intercoolers 203 , 205 and 207 are means to remove heat from the feed compressor and serve to reduce the required power of the higher compressor stages. The haters and intercoolers are optional features of the invention.
[0092] If light reflux heater 249 operates at a sufficiently high temperature so that the exit temperature of the light reflux expansion stages is higher than the temperature at which feed gas is delivered to the feed manifolds by conduits 212 , 214 and 216 , the temperature of the second ends 35 of the adsorbers 24 may be higher than the temperature of their first ends 34 . Hence, the adsorbers have a thermal gradient along the flow path, with higher temperature at their second end relative to the first end. This is an extension of the principle of “thermally coupled pressure swing adsorption” (TCPSA), introduced by Keefer in U.S. Pat. No. 4,702,903. Adsorber rotor 11 then acts as a thermal rotary regenerator, as in regenerative gas turbine engines having a compressor 201 and an expander 220 . Heat provided to the PSA process by heater 225 assists powering the process according to a regenerative thermodynamic power cycle, similar to advanced regenerative gas turbine engines approximately realizing the Ericsson thermodynamic cycle with intercooling on the compression side and interstage heating on the expansion side.
[0093] In the instance of PSA applied to oxygen separation from air, the total light reflux flow is much less than the feed flow because of the strong bulk adsorption of nitrogen. Accordingly the power recoverable from the expanders is much less than the power required by the compressor, but will still contribute significantly to enhanced efficiency of oxygen production. By operating the adsorbers at moderately elevated temperature and using strongly nitrogen-selective adsorbents such as Ca—X, Li—X or calcium chabazite zeolites, a PSA oxygen generation system can operate with favourable performance and exceptional efficiency. While higher temperature of the adsorbent will reduce nitrogen uptake and selectivity, the isotherms will be more linear. Effective working capacity in superatmospheric pressure PSA cycles may be enhanced by operation in TCPSA mode with an elevated temperature gradient in the adsorbers. Working with adsorbents such as Ca—X and Li—X, recent conventional practice has been to operate ambient temperature PSA at subatmospheric lower pressures in so-called “vacuum swing adsorption” (VSA), so that the highly selective adsorbents operate well below saturation in nitrogen uptake, and have a large working capacity in a relatively linear isotherm range. At higher temperatures, saturation in nitrogen uptake is shifted to more elevated pressures, so the optimum PSA cycle higher and lower pressures are also shifted upward. For satisfactory operation of the apparatus of FIG. 8, the typical operating temperature of the second ends of the adsorbers may be approximately 50° C. for Ca—X or Li—X, and 100° to 150° C. for calcium chabazite.
[0094] If high energy efficiency were not of highest importance, the light reflux expander stages and the countercurrent blowdown expander stages could be replaced by restrictor orifices or throttle valves for pressure letdown, as illustrated in FIG. 10. The schematic of FIG. 8 shows a single shaft supporting the compressor stages, the countercurrent blowdown or exhaust expander stages, and the light reflux stages, as well as coupling the compressor to the prime mover. However, it should be understood that separate shafts and even separate prime movers may be used for the distinct compression and expansion stages within the scope of the present invention.
[0095] It should also be understood that the number of compression stages and the number of expansion stages (as well as the number of vacuum pump stages in the embodiment of FIG. 9 below) may be varied within the scope of the invention. Generally and for equal stage efficiency of the compressor or expander type chosen, a larger number of stages will improve the PSA process efficiency, since the irreversible equalization expansions over the first and second orifices will be performed over narrower pressure intervals. However, the improvement in efficiency for each additional stage will diminish as the number of stages is greater.
[0096] [0096]FIG. 9
[0097] [0097]FIG. 9 shows a vacuum PSA (VPSA) system for oxygen separation from air. Intermediate pressure 158 of FIG. 6 is now nominally atmospheric pressure. Lower pressure 152 and higher pressure 151 may respectively be approximately 0.5 and 1.5 times atmospheric pressure. Feed compressor first stage 202 becomes directly the first feed means feeding manifold 48 . Likewise, compressor second stage 204 and third stage 206 operate as the second feed means 162 and third feed means 165 respectively. The condensate separators are omitted for simplicity.
[0098] A multistage vacuum pump 260 is driven by shaft 222 , and assisted by light reflux expander 220 . The vacuum pump may for example be a multistage centrifugal or axial compression machine, or it may be provided by rotary positive displacement machinery adapted to accept inlet gas at multiple suction pressures. First stage vacuum pump 261 (acting as third exhaust means 184 ) draws nitrogen-enriched air from the heavy product exhaust manifold 61 at substantially the lower pressure, and delivers this gas through intercooler 262 at the second countercurrent blowdown pressure 182 to second stage vacuum pump 263 (acting as second exhaust means 182 ) which also draws heavy gas from the second countercurrent blowdown manifold 59 at the same pressure. The combined heavy gas discharged from vacuum pump 260 is combined with heavy gas discharged by conduit 240 (acting as first exhaust means 181 ) to form the heavy product 185 delivered to atmosphere (equal to the first countercurrent blowdown pressure) by conduit 243 .
[0099] [0099]FIG. 10
[0100] [0100]FIG. 10 shows a VPSA apparatus similar to that of FIG. 9, but with the light reflux pressure letdown means 170 , 172 , 174 and 176 provided respectively by throttle orifices 270 , 272 , 274 , and 276 . The throttle orifices may be fixed orifices, or may be throttle valves with a control actuator 277 for coordinated adjustment of their orifice aperture. Control actuator 277 provides means to adjust the rate of pressure letdown for each light reflux step, so that the process may be adjusted for operation at a different cycle frequency or a different ratio of the higher and lower working pressures. It should be noted that adjustable nozzles (similar to the above adjustable throttles with controller 277 ) may be alternatively used in conjunction with expansion turbines used for each of the light reflux (or countercurrent blowdown expander stages.
[0101] [0101]FIG. 11
[0102] [0102]FIG. 11 shows a PSA apparatus adapted to receive two feed gas mixtures, and with recompression of the heavy product gas. A suitable application would be hydrogen recovery from petroleum refinery offgases, e.g. hydrotreater purge gases typically containing light hydrocarbon gases with 30% to 70% hydrogen. Frequently, several offgases of differing hydrogen concentration are available at elevated feed pressures in the range of 10 to 20 atmospheres. Using typical adsorbents, e.g. activated carbon or zeolites, the hydrocarbon impurities will be much more readily adsorbed than hydrogen, so the purified hydrogen will be the light product delivered at the higher working pressure which may be only slightly less than the feed supply pressure, while the impurities will be concentrated as the heavy product and will be exhausted from the PSA process as “PSA tail gas” at the lower working pressure. The tail gas is often either flared or used as fuel gas.
[0103] For hydrogen duty, positive displacement expansion and compression machinery (e.g. twin screw machines) may be preferred because of the low molecular weight of the gas. Such machines may be adapted in accordance with the invention with extra inlet and/or discharge ports to accept and deliver gas at multiple intermediate pressures.
[0104] Performance and productivity of PSA hydrogen recovery from refinery offgases (with the adsorbers working at near ambient temperature) will be greatly enhanced by operating with the lower working pressure as low as possible and preferably near atmospheric pressure. However, the tail gas is usually delivered at a pressure of at least 5 or 6 atmospheres, for disposal to the refinery fuel gas header. Compression costs, particularly for combustible gases under refinery safety constraints, may be prohibitively high.
[0105] The apparatus of FIG. 11 is configured to accept first and second feed gas mixtures, the first having a higher concentration of the less readily adsorbed component (e.g. hydrogen) while the second is more concentrated than the first feed gas mixture in the more readily adsorbed fraction. The first feed gas is supplied at substantially the higher working pressure by first infeed conduit 280 to first feed manifold 53 , while the second feed gas is supplied at substantially the higher working pressure by second infeed conduit 281 to first feed manifold 55 . Each adsorber receives the second feed gas after receiving the first feed gas, so that the concentration profile in the adsorber is monotonically declining in concentration of the more readily adsorbed component along its flow path from first end 34 to second end 35 of the flow path in adsorber element 24 . All but the final pressurization steps are here achieved with light reflux gas. The final feed pressurization (from the third light reflux pressurization pressure 192 directly to the higher pressure 151 ) is achieved as the first end of each adsorber is opened to compartment 52 communicating to manifold 53 . Additional feed pressurization steps could readily be incorporated as in the embodiment of FIG. 8.
[0106] In this embodiment, the tail gas (heavy product) is discharged from second product delivery conduit at a higher pressure than the lower working pressure, in this example being approximately the first countercurrent blowdown pressure 180 of FIG. 6 with conduit 240 being first exhaust means 181 . Tail gas is recompressed by tail gas compressor 290 , with compressor first stage 291 being the third exhaust means 184 compressing the first product gas from exhaust manifold 61 via conduit 246 , and delivering the first product gas after first stage compression through intercooler 292 to compressor second stage 293 which itself is the second exhaust means compressing second countercurrent blowdown gas from manifold 59 via conduit 244 .
[0107] [0107]FIG. 12
[0108] [0108]FIG. 12 shows a PSA apparatus with heavy reflux to obtain either higher enrichment and purity of the more readily adsorbed component into the heavy product, or higher yield (recovery) of the less readily adsorbed component into the light product. This apparatus may also be configured to deliver the heavy product at elevated pressure, here approximately the higher working pressure so that both product gases are delivered at about the higher pressure.
[0109] The apparatus of FIG. 12 has infeed conduit 300 to introduce the feed gas at substantially the higher pressure to first feed manifold 53 . As in the example of FIG. 11, adsorber pressurization is achieved mainly by light reflux, with a final feed pressurization step through manifold 53 .
[0110] A multistage heavy reflux compressor 301 has a first stage 302 as third exhaust means 184 of FIG. 7, drawing heavy gas by conduit 246 from first product exhaust manifold 61 , and compressing this gas through intercooler 303 to second stage 304 . Heavy reflux compressor second stage 304 as second exhaust means 183 also draws heavy gas from second countercurrent blowdown manifold 59 through conduit 244 , and delivers this gas by intercooler 305 to third stage 306 which as first exhaust means 181 also draws heavy gas from first countercurrent blowdown manifold 57 through conduit 240 , and delivers this gas by intercooler 307 to fourth stage 308 which attains substantially the higher working pressure of the PSA cycle. The heavy reflux compressor is driven by prime mover 209 through shaft 210 , and by light reflux expander 220 through shaft 309 .
[0111] The compressed heavy gas is conveyed from compressor fourth stage 308 by conduit 310 to condensate separator 311 , from which the heavy product is delivered by conduit 312 which is externally maintained at substantially the higher pressure less frictional pressure drops. Condensed vapours (such as water or liquid hydrocarbons) are removed through conduit 313 at substantially the same pressure as the heavy product in conduit 312 . The remaining heavy gas flow, after removal of the first product gas, flows by conduit 314 to the second feed manifold 55 as heavy reflux to the adsorbers following the feed step for each adsorber. The heavy reflux gas is a second feed gas, of higher concentration in the more readily adsorbed component or fraction than the first feed gas.
[0112] [0112]FIG. 13
[0113] [0113]FIG. 13 shows a PSA apparatus with a free rotor tail gas compressor or vacuum pump, powered by energy recovery expanders analogous to a multistage turbocharger. Free rotor compressor 320 includes, on shaft 321 , tail gas compressor 322 (or vacuum pump 322 , if the lower pressure is subatmospheric) which is the third exhaust means 184 drawing heavy product gas or tail gas from exhaust manifold 61 . In this example, the heavy product gas is discharged from conduit 243 at the second countercurrent blowdown pressure 182 , which is above the lower pressure. Pressure 182 may here be atmospheric pressure, in which case the third exhaust means is a vacuum pump. Conduit 244 is the second exhaust means 183 . The first exhaust means 181 is expander 323 coupled to shaft 321 of free rotor compressor 320 . Expander 323 expands heavy gas flowing from manifold 57 through conduit 240 and optional heater 241 , and releases that gas to exhaust conduit 243 .
[0114] The light reflux expander 220 and the countercurrent blowdown expander 323 are both coupled to drive the tail gas compressor 322 by shaft 321 , with no other source of mechanical power required. The application of energy recovery (from light reflux and countercurrent blowdown) provides the alternative benefits of reducing the lower pressure so as to improve PSA (or VPSA) cycle performance, or raising the first product delivery pressure as may be required e.g. for tail gas disposal, without the requirement for an electric motor driven compressor. This feature would be particularly useful for hydrogen separation, where reducing the lower pressure greatly improves performance, while elevated tail gas pressures may be desired. Alternatively, a hydrogen PSA system could be operated with a subatmospheric lower pressure, while the tail gas is discharged at sufficiently above atmospheric pressure for combustion in a flare or furnace.
[0115] [0115]FIG. 14
[0116] [0116]FIG. 14 shows another embodiment using a free rotor compressor or turbocharger. In this embodiment, applied to oxygen separation from air, a motor driven first feed compressor 330 is driven by prime mover 209 through shaft 210 . Using the same nomenclature and reference numerals of feed compression stages as FIG. 8, feed compressor 330 includes feed compression first stage 202 and third stage 206 on shaft 210 driven by motor 209 . Free rotor second compressor 340 includes feed compression second stage 204 and fourth stage 208 on shaft 222 , driven by countercurrent blowdown expander 221 and light reflux expander 220 through shaft 222 . This configuration enables operation of a motor driven feed compressor with a limited number of stages (here 2 stages) to operate a PSA cycle with a larger number of feed supply pressures (here the three pressures 161 , 163 and 151 of FIG. 6), since the free rotor compressor has dual functions as means to boost feed pressure by application of thermally boosted expansion energy recovery, and means to split the stage intermediate pressures for supply to the PSA module.
[0117] [0117]FIG. 15
[0118] [0118]FIG. 15 shows a VPSA oxygen generation plant with 4 modules in parallel, each having a free rotor booster compressor powered by energy recovery expanders, and the entire apparatus having a single prime mover 350 which may for example be an electric motor or a gas turbine. Prime mover 350 drives first feed compressor 351 on shaft 352 . Feed compressor 351 has a first stage 353 drawing feed gas from infeed conduit 200 , and a third stage 354 . The second stage of feed compression is provided by the free rotor compressors of each module. The first feed compressor 351 in this embodiment also includes an exhaust vacuum pump 355 likewise coupled to shaft 352 .
[0119] The plant includes four identical modules 10 A, 10 B, 10 C and 10 D. In FIGS. 15 and 16, component nomenclature and reference numerals follow that established for FIGS. 1 - 14 , with a suffix A to D appended to the reference numerals for module components, and each component so identified with reference to any one module will be identically found in each of the other modules. The first manifolds are identified with reference to module 10 D as 48 D and 51 D for feed pressurization, 53 D for feed supply at the higher pressure, 57 D and 59 D for countercurrent blowdown, and 61 D for exhaust at the lower pressure. The second manifolds are identified with reference to module 10 C as 71 C communicating to light product delivery manifold 360 and delivery conduit 218 , light reflux exit manifolds 73 C, 75 C, 77 C and 79 C, and light reflux return manifolds 81 C, 83 C, 85 C and 87 C.
[0120] The identical free rotor compressor for each module will be described with reference to module 10 B. Free rotor compressor assembly 370 B includes feed compression second stage 371 B and vacuum pump 372 B, both coupled by shaft 373 B to light reflux expander 220 B. Feed gas compressed by feed compressor first stage 353 is conveyed by feed manifold 376 in parallel to the first feed pressurization manifold (e.g. 48 D) of each module, and to the inlet of feed compression second stage (e.g. 371 B) of the free rotor compressor assembly (e.g. 370 B) of each module which delivers further compressed feed pressurization gas to the second feed pressurization manifold (e.g. 51 D) of each module. Feed gas compressed to the higher pressure by third feed compressor stage 354 is conveyed by feed manifold 377 in parallel to the first feed supply manifold (e.g. 53 D) of each of the modules. Heavy gas at the lower pressure is drawn from the heavy compartment (e.g. 61 D) of each module through vacuum exhaust manifold 378 to exhaust vacuum pump 355 as the third exhaust means. Countercurrent blowdown gas from the first countercurrent blowdown manifold (e.g. 57 D) of each module is discharged by e.g. conduit 240 B as first exhaust means, while countercurrent blowdown gas from the second countercurrent blowdown manifold (e.g. 59 D) of each module is exhausted by vacuum pump (e.g. 372 B) of the free rotor compressor assembly as second exhaust means, delivering the heavy tail gas to the module heavy product or waste gas exhaust, e.g. 243 B.
[0121] [0121]FIG. 16
[0122] [0122]FIG. 16 shows a PSA apparatus with 5 modules 10 A- 10 E. In this embodiment, the prime mover, all compressor stages and all expander stages are directly mechanically coupled (e.g. on a single shaft) following the embodiment and component descriptions of FIG. 8, with the only difference being the connection in parallel of multiple modules.
[0123] [0123]FIG. 17
[0124] In this example, sealing faces 21 and 23 are respectively provided as hard-faced ported surfaces on the first and second valve stators 40 and 41 . Sliding seals 380 are provided on rotor 11 between each adsorber 24 and its neighbours, to engage both sealing faces 21 and 23 in fluid sealing contact. Seals 380 may have a wear surface of a suitable composite material based on PTTE or carbon, and should be compliantly mounted on rotor 11 so as to compensate for wear, deflections and misalignment. Ports 381 may be sized, particularly at the leading edge of each compartment, to provide controlled throttling for smooth pressure equalization between adsorbers and that compartment, as each adsorber in turn is opened to that compartment.
[0125] Split stream vacuum pump 260 receives the countercurrent blowdown and exhaust flow in three streams receiving exhaust gas at incrementally reduced pressures from countercurrent blowdown compartment 56 , compartment 58 and compartment 60 . The combined exhaust gas is discharged as heavy product gas. In this example, initial feed pressurization is performed from atmosphere, so a first feed pressurization conduit 382 admits feed air directly from inlet filter 200 to first feed pressurization compartment 46 at substantially atmospheric pressure. The first discharge port of feed compressor 201 now communicates to second feed pressurization compartment 50 . The compressor is shown as a split stage machine with inlet 391 , and three discharges 392 , 393 and 394 at incrementally higher pressures.
[0126] In the option of light reflux pressure letdown with energy recovery, a split stream light reflux expander 220 is provided to provide pressure let-down of four light reflux stages with energy recovery. The light reflux expander provides pressure let-down for each of four light reflux stages as illustrated. As indicated by dashed lines 395 , the stages may optionally be compartmentalized within the light reflux expander to minimize mixing of gas concentration between the stages. The light product purity will tend to decline from the light reflux stages of higher pressure to those of lower pressure, so that a desirable stratification of the light reflux can be maintained if mixing is avoided.
[0127] Light reflux expander 220 is coupled to drive light product pressure booster compressor 396 by shaft 397 . Compressor 396 receives the light product from compartment 70 , and delivers light product (compressed to a delivery pressure above the higher pressure of the PSA cycle) from delivery conduit 218 . Since the light reflux and light product are both enriched oxygen streams of approximately the same purity, expander 220 and light product compressor 396 may be hermetically enclosed in a single housing similar to a turbocharger.
[0128] [0128]FIG. 18
[0129] [0129]FIG. 18 shows a radial flow rotary PSA module 500 , contemplated for tonnage oxygen generation. With reference to FIG. 17, this view may be interpreted as an axial section through compartments 54 and 70 at the higher pressure, and compartments 80 and 60 at the lower pressure. Arrows 501 and 502 respectively indicate the feed and exhaust flows. Rotor 11 has a first end plate 510 with stub shaft 511 supported by bearing 512 in first bearing housing 513 , which is integral with first valve stator 40 . Rotor 11 is attached at assembly joint 514 to a second end plate 515 with stub shaft 516 supported by bearing 517 in second bearing housing 518 , which is attached at assembly joint 519 to first valve stator 40 .
[0130] Rotor 11 is driven by motor 95 connected to stub shaft 511 by shaft 94 penetrating housing 513 through shaft seal 522 . First end plate 510 has no perforations that might compromise purity of the light product gas by leakage from the first valve surface to the second valve surface. Second end plate 515 is penetrated at bushing 530 by the second valve stator. Second valve stator 41 is a stationary pintle within rotor 11 , with guide bushings 530 and 532 , and is attached to the second bearing housing 518 at assembly face 534 . Bearings 512 and 517 may be much smaller in diameter than the outer diameter of rotor 11 at sealing face 21 . A shaft seal 535 is provided between shaft 516 and bearing 517 , to prevent contamination of the light product gas by leakage from chamber 536 adjacent the first valve sealing face 21 to chamber 537 adjacent the second valve sealing face 23 .
[0131] Preferably, seal 535 is tight against leakage so that product purity is not compromised. By configuring this seal at smaller diameter than the valve sealing faces, frictional torque from shaft seal 535 is greatly reduced than if this seal were at the full rotor diameter. Leakage across seals in the first valve face is much less important, because moderate leakage across those seals simply reduced the volumetric efficiency of the process. Similarly, moderate leakage across the seals in the second valve face may be tolerated, as the concentration of light reflux gases and the light product gas that may leak across those seals is almost identical. Because moderate leakage across seals in the first valve surface (including circumferential seals 96 ), and across seals in the second valve surface (including circumferential seals 97 ), can be accepted, all of those seals may be designed for relatively light mechanical engagement to minimize frictional torque. In fact, use of narrow gap clearance seals or labyrinth seals with zero mechanical rubbing friction is an attractive option especially for larger capacity modules operating at high cycle frequency (e.g. 50 or 100 cycles per minute) where seal leakage flows would have a minimal effect on overall efficiency. Preferably, the seals in the first and second valve faces have consistent performance and leakage, so that all “N” adsorbers experience the same PSA cycle flow and pressure regime as closely as possible, without being upset by variations in leakage between the adsorbers.
[0132] Hence an important benefit of the present invention is that close tolerance sealing is only required on one dynamic rotary seal, shaft seal 535 , whose diameter has been made much smaller than the rotor diameter to reduce the sealing perimeter as well as mechanical friction power loss. For a given rotary seal section and loading, rubbing friction power loss at given RPM is proportional to the square of the sealing face diameter.
[0133] Because of the compactness (similar to an automotive turbocharger) of a “turbocompressor” oxygen booster as described for FIG. 17above, it is possible to install a split stream light reflux expander 220 with close-coupled light product compressor 396 inside the light valve stator. Compressed oxygen product is delivered by conduit 218 .
[0134] [0134]FIG. 19
[0135] [0135]FIG. 19 shows an axial flow rotary PSA module 600 for smaller scale oxygen generation. The flow path in adsorbers 24 is now parallel to axis 601 . A better understanding will be obtained from FIGS. 20, 21 and 22 , which are cross sections of module 600 in the planes respectively defined by arrows 602 - 603 , 604 - 605 , and 606 - 607 . FIG. 19 is an axial section of module 600 through compartments 54 and 70 at the higher pressure, and compartments 60 and 80 at the lower pressure. The adsorber rotor 11 contains the “N” adsorbers 24 in adsorber wheel 608 , and revolves between the first valve stator 40 and the second valve stator 41 . Compressed feed air is supplied to compartment 54 as indicated by arrow 501 , while nitrogen enriched exhaust gas is exhausted from compartment 60 as indicated by arrow 502 .
[0136] At the ends of rotor 11 , circumferential seals 608 and 609 bound first sealing face 21 , and circumferential seals 610 and 611 bound second sealing face 23 . The sealing faces are flat discs. The circumferential seals also define the ends of seals between the adsorbers, or alternatively of dynamic seals in the sealing faces between the stator compartments. Rotor 11 has a stub shaft 511 supported by bearing 512 in first bearing housing 513 , which is integral with first valve stator 40 . Second valve stator 41 has a stub shaft engaging the rotor 11 with guide bushing 612 .
[0137] A flanged cover plate 615 is provided for structural connection and fluid sealing enclosure between the first valve stator 40 and the second valve stator 41 . Rotor 11 includes seal carrier 618 attached at joint 619 to adsorber wheel 608 , and extending between the back of second valve stator 41 and cover plate 615 to sealing face 621 which is contacted by dynamic seal 625 . Seal 625 prevents contamination of the light product gas by leakage from chamber 626 adjacent the first valve sealing face 21 to chamber 627 adjacent the second valve sealing face 23 .
[0138] Seal 625 needs to be tight against leakage that could compromise product purity. By this seal to a smaller diameter than the valve faces outer diameter, frictional torque from this seal is greatly reduced than if this seal were at the full rotor diameter. The circumferential perimeter exposed to leakage is also reduced. As in FIG. 18, the light reflux pressure letdown means, illustrated as a split stream light reflux expander 220 with close-coupled light product compressor 396 , may be installed inside the light valve stator.
[0139] [0139]FIG. 20
[0140] [0140]FIG. 20 shows an axial flow rotary PSA module 650 with twin adsorber wheels. The same reference numerals are used as in FIG. 19 for the first adsorber wheel 608 , and primed reference numerals are used for the second adsorber wheel 608 ′, which are assembled together as rotor 11 . Module 650 has two first valve faces 21 and 21 ′, each with a full set of feed supply and second product exhaust compartments. External manifolds will be provided to supply feed fluid to each pair of feed compartments and to withdraw exhaust fluid from each pair of exhaust compartments. Module 650 has two second valve faces 23 and 219 ′, which share a common set of compartments for light product delivery, light reflux exit and return, and purge. Arrows 651 indicate the flow direction in compartment 221 , and arrows 652 indicate the flow direction in compartment 70 .
[0141] Rotor 11 is driven by shaft 94 coupled to the first adsorber wheel 608 . The adsorber wheels 408 and 608 ′ are attached at joint 655 . Flanged cover plate 615 of FIG. 19 is here replaced by the first valve stator 40 ′ for the second adsorber wheel 608 ′, in the role of connecting the first valve stator 40 and second valve stator 41 to form an enclosed housing for the module. A small diameter dynamic seal 660 is mounted adjacent bushing 612 ′, to prevent leakage between the first and second valve faces.
[0142] Embodiment 650 enables a doubled capacity rating for the twin axial wheel configuration compared to the single wheel embodiment 600 .
[0143] [0143]FIG. 21
[0144] [0144]FIG. 21 shows the first valve face 21 of embodiment 600 of FIG. 19, at section 602 - 603 , with fluid connections to a split stream feed compressor 201 and a split stream countercurrent blowdown expander 221 . Arrow 670 indicates the direction of rotation by adsorber rotor 11 . The open area of valve face 21 ported to the feed and exhaust compartments is indicated by clear angular segments 46 , 50 , 52 , 56 , 58 , 60 corresponding to those compartments, between circumferential seals 608 and 609 . The closed area of valve face 21 between compartments is indicated by cross-hatched sectors 675 and 676 . Typical closed sector 675 provides a transition for an adsorber, between being open to compartment 56 and open to compartment 58 . Gradual opening is provided at the leading edges 677 and 678 of compartments, so as to achieve gentle pressure equalization of an adsorber being opened to a new compartment. Much wider closed sectors (e.g. 676 ) are provided to substantially close flow to or from one end of the adsorbers when pressurization or blowdown is being performed from the other end.
[0145] Sealing between compartments at typical closed sectors (e.g. 675 ) may be provided by rubbing seals on either stator or rotor against a ported hard-faced sealing counter face on the opposing rotor or stator, or by narrow gap clearance seals on the stator with the area of the narrow sealing gap defined by the cross hatched area of the nominally closed surface. Rubbing seals may be provided as radial strip seals, with a self-lubricating solid material such as suitable PTFE compounds or graphite, or as brush seals in which a tightly packed brush of compliant fibers rubs against the counter face.
[0146] If the rubbing seals are on the rotor (between adjacent adsorbers), cross-hatched sectors 675 and 676 would be non-ported portions of the hard-faced sealing counter face on the stator. If the rubbing seals are on the stator, the ported hard-faced counter face is on the rotor valve face. Those rubbing seals could be provided as full sector strips for narrow closed sectors (e.g. 675 ). For the wider closed sectors (e.g. 676 ), narrow radial rubbing seals may be used as the edges 678 and 679 , and at intervals between those edges, to reduce friction in comparison with rubbing engagement across the full area of such wide sectors.
[0147] Clearance seals are attractive, especially for larger scale modules with a very large number “N” of adsorbers in parallel. The leakage discharge coefficient to or from the clearance gap varies according to the angular position of the adsorber, thus providing gentle pressure equalization as desired. The clearance gap geometry is optimized in typical nominally closed sectors (e.g. 675 ) so that the leakage in the clearance gap is mostly used for adsorber pressure equalization, thus minimizing through leakage between compartments. The clearance gap may be tapered in such sectors 675 to widen the gap toward compartments being opened, so that the rate of pressure change in pressure equalization is close to linear. For wide closed sectors (e.g. 676 ) the clearance gap would be relatively narrow as desired to minimize flows at that end of adsorbers passing through those sectors.
[0148] For all types of valve face seals described above, it is preferable that consistent performance be achieved over time, and that all “N” adsorbers experience the same flow pattern after all perturbations from seal imperfections. This consideration favours placing rubbing seals on the stator so that any imperfections are experienced similarly by all adsorbers. If the seals are mounted on the rotor between adsorbers, it is preferable that they are closely identical and highly reliable to avoid upsetting leakages between adjacent adsorbers.
[0149] To compensate for misalignment, thermal distortion, structural deflections and wear of seals and bearings, the sealing system should have a suitable self-aligning suspension. Thus, rubbing seal or clearance seal elements may be supported on elastomeric supports, bellows or diaphragms to provide the self-aligning suspension with static sealing behind the dynamic seal elements. Rubbing seals may be energized into sealing contact by a combination of elastic preload and gas pressure loading.
[0150] Clearance seals require extremely accurate gap control, which may be established by rubbing guides. Clearance seal gap control may also be achieved by a passive suspension in which the correct gap is maintained by a balance between gas pressure in the gap of a clearance seal segment, and the pressures of adjacent compartments loading the suspension behind that segment. For seal elements between blowdown compartments, a simple passive self-adjusting suspension should be stable. Active control elements could also be used to adjust the clearance seal gap, with feedback from direct gap height measurement or from the pressure gradient in the gap. Active control may be considered for seal elements between pressurization compartments, for which the simple passive control may be unstable.
[0151] [0151]FIG. 22
[0152] [0152]FIG. 22 shows the second valve face 23 of embodiment 600 of FIG. 19, at section 604 - 605 , with fluid connections to a split stream light reflux expander 220 and light product booster compressor 396 . Fluid sealing principles and alternatives are similar to those of FIG. 21. Similar principles and alternatives apply to radial flow and axial flow geometries, respectively sealing on cylindrical or disc faces.
[0153] [0153]FIG. 23
[0154] Adsorber wheel 608 may use radially aligned rectangular flat packs of adsorbent laminate, as shown in FIG. 5 for radial flow. FIG. 23 shows an alternative adsorber wheel configuration for the embodiment of FIG. 19, at section 606 - 607 . As in FIG. 5, the adsorbers 24 are again formed of a pack of rectangular adsorbent sheets with spacers, but with the sheets here curved arcs rather than flat. With this configuration, the ports and seals in valve faces 21 and 23 would desirably be configured as corresponding curved arcs. Voids between the circularly curved adsorber packs are filled by separators 684 . Such circularly curved adsorber packs may be made by forming the adsorbent sheets with spacers in a spiral roll on a circular cylindrical mandrel, and then cutting the spiral roll longitudinally to obtain the desired packs. Packing density may be further improved by forming the adsorber sheets to a spiral rather than circular curve.
[0155] FIGS. 24 - 27
[0156] [0156]FIG. 24 shows a multistage centrifugal compressor 400 with impulse turbine expanders for the light reflux and countercurrent blowdown, configured to provide the feed compressor stages 202 , 204 , 206 and 208 , the countercurrent blowdown expander stages 242 and 245 , and the light reflux expander stages 226 , 230 , 234 , and 238 of FIG. 8. Prime mover 209 drives shaft 402 , supported in compressor casing 403 by bearings 404 and 405 on axis 406 . Shaft 402 carries compressor first stage impeller 411 , second stage impeller 412 , third stage impeller 413 and fourth stage impeller 414 , exhaust impulse turbine runner 415 and light reflux impulse turbine runner 416 .
[0157] Feed air from PSA plant inlet 200 enters suction port 420 to suction scroll 421 to the inlet 422 of impeller 411 . Impeller 411 discharges the air to first stage diffuser 425 and first stage collector scroll 426 , which directs the first stage compressed air to the inlet of the second stage impeller 412 . Impeller 412 discharges the air to second stage diffuser 430 and second stage collector scroll 431 , from which second stage delivery port 432 discharges a portion of the feed air as pressurization gas at the second stage pressure to conduit 212 . Similarly, the feed air is compressed by the third and fourth stage impellers 413 and 414 , discharging air at the third stage pressure from third stage delivery port 436 communicating to conduit 214 , and at the fourth stage pressure from fourth stage delivery port 440 .
[0158] The multistage centrifugal compressor 400 provides the stages of feed compressor 201 in FIG. 8. Multistage vacuum pumps, as required in the embodiment of FIG. 9, may similarly be provided as conventional centrifugal stages. For a large multiple module plant, for example as described in FIG. 16, the exhaust and light reflux expander turbines may be provided as multistage radial inflow turbines whose stages would be mechanically similar to the centrifugal stages of FIG. 24. In larger plants, expander stages may also be provided as full admission axial turbine stages, similar to gas turbine stages.
[0159] For particular advantage in smaller plant capacities, considerable simplification is obtained in the embodiment of FIGS. 24 - 27 by using partial admission impulse turbines for countercurrent blowdown and light reflux expansion, with each expander stage occupying a sectoral arc of the corresponding turbine on a single runner wheel. This approach is practicable because the stages for each turbine expand gases of approximately similar composition across adjacent pressure intervals.
[0160] [0160]FIG. 25 is a section of FIG. 24, defined by arrows 451 and 452 , across the plane of light reflux impulse turbine runner 416 . FIG. 24 is a section of FIG. 25, in the plane indicated by arrows 453 and 454 . Runner 416 rotates about axis 406 in the direction indicated by arrow 455 . Runner 416 has blades 456 mounted on its rim. FIG. 26 is a projected view of the light reflux expander impulse turbine, unrolled around 360° of the perimeter of the impulse turbine as indicated by the broken circle 458 with ends 459 and 460 in FIG. 25.
[0161] The light reflux turbine has four nozzles serving the four 90° quadrants of the runner to provide the four expansion stages, including first nozzle 461 receiving flow from port 462 communicating to conduit 224 , second nozzle 463 receiving flow from port 464 communicating to conduit 228 , third nozzle 465 receiving flow from port 466 communicating to conduit 232 , and fourth nozzle 467 receiving flow from port 468 communicating to conduit 236 .
[0162] The first stage light reflux flow from nozzle 461 impinges blades 456 , and is collected in diff-user 471 and discharged at the reduced pressure by port 472 communicating to conduit 227 . Similarly the light reflux flow from nozzle 463 is collected in diff-user 473 and flows by port 474 to conduit 231 , the light reflux flow from nozzle 465 is collected in diffuser 475 and flows by port 476 to conduit 235 , and the light reflux flow from nozzle 467 is collected in diffuser 477 and flows by port 478 to conduit 239 . To minimize interstage leakage losses, the channel gap 479 between the casing 403 and blades 456 of runner 416 is appropriately narrow between quadrants.
[0163] The exhaust expander turbine, or countercurrent blowdown expander turbine, has two stages. Its sectional arrangement is similar to that depicted in FIG. 25, except that two rather than four nozzles and diffusers are required for the two exhaust stages. FIG. 27 is an unrolled projection around exhaust turbine runner 415 as indicated by broken circle 458 for the light reflux turbine. The exhaust turbine has impulse blades 480 on runner 415 . Nozzle 481 receives the first countercurrent blowdown stream by port 482 communicating to conduit 240 , while nozzle 483 receives the second countercurrent blowdown stream by port 484 communicating to conduit 244 . Nozzles 481 and 483 have guide vanes 485 and 486 , and direct the countercurrent blowdown flows to impinge on blades 480 in opposite half sectors of the turbine 415 . After deflection by blades 480 , the expanded flow from nozzle 481 is collected in diffuser 491 , and is passed to collector ring manifold 492 . The flow from nozzle 483 likewise passes the blades 480 and is collected in diffuser 493 joining manifold 492 to deliver the combined low pressure exhaust flow by exhaust port 494 which is connected to the discharge 243 .
[0164] [0164]FIG. 28
[0165] [0165]FIG. 28 shows a three stage axial flow split stream compressor 700 . While it is known in the prior art to divert minor bleed flows between stages of multistage axial flow compressors or expanders, compressor 700 has nested annular diffusers for splitting fractionally large intermediate flows from the main flow between stages.
[0166] Compressor 700 may represent split stream compressor 201 of FIG. 4, and has a scroll housing 701 with feed inlet 391 , first discharge port 392 , second discharge port 393 and third discharge port 394 . Rotor 702 is supported by bearings 703 and 704 with shaft seals 705 and 706 within housing 701 , and is driven by motor 209 through shaft 210 . The rotor supports first stage rotor blades 711 , second stage rotor blades 712 , and third stage rotor blades 713 .
[0167] Housing 701 includes an inlet scroll 721 distributing feed gas from inlet 391 to annular feed plenum 722 , with the flow direction indicated by arrow 723 . The feed flow enthalpy is increased by first stage blades 711 , with static pressure recovery by first stage stator blades 724 mounted in first stage stator ring 725 . The feed flow enthalpy is further increased by second stage blades 712 , with static pressure recovery by second stage stator blades 726 mounted in second stage stator ring 727 ; and finally by third stage blades 713 , with static pressure recovery by third stage stator blades 728 mounted in third stage stator ring 729 .
[0168] Second stage stator ring 727 has a smaller diameter than first stage stator ring 725 , defining an annular area of annular first stage diffuser 731 which delivers the first intermediate feed pressurization flow to collector scroll 732 and thence to first discharge port 392 as indicated by arrow 733 . Similarly, third stage stator ring 729 has a smaller diameter than second stage stator ring 727 , defining an annular area of annular second stage diffuser 734 which delivers the first intermediate feed pressurization flow to collector scroll 735 and thence to second discharge port 393 as indicated by arrow 736 . The fraction of flow entering the first and second stage annular diffusers is substantially equal to the ratio of the annular area of those diffuser inlets to the annular flow area of that stage between its stator ring and the rotor 702 .
[0169] The flow delivered by the third stage passes stator blades 728 into third stage diffuser 737 , and in collector scroll 738 into discharge port 394 as indicated by arrow 739 . Stator rings 725 , 727 and 729 are respectively supported by partitions 741 , 742 and 743 separating the inlet and discharge scrolls.
[0170] It will be evident that additional stages could be added with more paired sets of rotor blades and stator blades, with the option of including or not including an annular diffuser for diverting an intermediate flow stream between any adjacent pair of stages. It will also be evident that the structure of compressor 700 could be applied to a split stream axial flow vacuum exhauster or expander, by reversing the flow directions indicated by arrows 723 , 733 , 736 , and 739 , so that port 394 would be a first inlet, port 393 a second inlet, and port 392 a third inlet for each of three inlet streams at incremental total pressures, and with port 391 the discharge port for the combined total flow.
[0171] [0171]FIG. 29
[0172] [0172]FIG. 29 shows a composite adsorbent pellet 800 , useful in the practice of the present invention with the radial flow configuration of FIGS. 4, 5, 6 and 18 , in the alternative of using granular packed bed adsorbers 24 .
[0173] Granular adsorbent beds cannot be operated in prior art PSA devices at very high cycle frequency without excessive pressure drops leading to incipient fluidization and resulting attrition. The present apparatus in the radial flow configuration provides a centripetal acceleration field which may be greater than the ordinary gravitational field. This provides a desirable “centrifugal clamping” effect to stabilize the adsorbent bed, and thus facilitate safe operation at higher cycle frequency. However, the specific gravity of conventional macroporous zeolite adsorbent pellets is only about 0.75, thus limiting the effect of centrifugal clamping. While the use of rotating granular adsorbent beds in radial flow configurations is well known in the above cited prior art, operating conditions that would provide useful centrifugal clamping have not been disclosed. Thus, Boudet et al in U.S. Pat. No. 5,133,784 contemplate a maximum cycle frequency and rotor speed of 20 RPM, which with their mentioned rotor outer radius of 1 meter would provide a maximum centripetal acceleration of less than half the acceleration of gravity at the outer radius. The adsorbent beds, within the rotor and closer to the axis, are subject to a much smaller centripetal acceleration.
[0174] Ballasted composite pellet 800 has an inert core 801 of a dense material, surrounded by a coating 802 of macroporous zeolite material similar to the material of conventional adsorbent pellets. The core material may be selected for high density, high heat capacity, high thermal conductivity and compatibility for adhesion to zeolite binders as well as for thermal expansion. Suitable core materials include transition metal oxides, most simply iron oxide, as well as solid iron or nickel-iron alloys.
[0175] If the diameter of core 801 is e.g. 790 microns, and the radial thickness of coating 802 is e.g. 105 microns so that the overall diameter of a spherical pellet 800 is 1 mm, the volume of the pellet is then 50% inert and 50% active macroporous adsorbent. In a packed bed using such composite pellets, the active volume of adsorbent has been reduced by 50%, while the fractional bed voidage of the active material has been increased from the typical 35% of spherical granular media to approximately 50%. This might seem to be an inferior packed bed, with half as much useful material and reduced effective selectivity performance because of the high effective void fraction. Unexpectedly, this can be a superior packed bed, because pressure drop and mass transfer resistance are both reduced, so that the PSA cycle can be operated at higher cycle frequency without excessive pressure drop and without risk of fluidization. At the same cycle frequency, pressure drops are reduced by the smaller flows in proportion to the smaller active adsorbent inventory for the same voidage channels, while mass transfer through the macropores only has to take place through a relatively thin shell. The inert material also acts as thermal ballast to isothermalize the adsorber against thermal swings due to heat of adsorption.
[0176] While the higher void fraction will reduce product yield at specified purity in the uneconomic regime of very low cycle frequency, product yield and productivity are actually enhanced in the economic regime of higher cycle frequency. Degradations of product yield and process energy efficiency (at specified product purity) will result from mass transfer resistance and pressure drop, and those degradations are more severe for the conventional bed than for the present inventive granular adsorber of composite pellets.
[0177] Such composite pellets are very useful in the radial flow embodiment of the rotary adsorber module, since the heavy composite pellets are centrifugally stabilized very positively, even as mass transfer resistance and pressure drop are reduced. Such composite pellets will also be very useful in axial flow embodiments, as well as non-rotary adsorbers, with vertically oriented flow path. Again, cycle frequency can be increased, while performance can be enhanced in terms of productivity, yield and efficiency at the most economic operating point. Consider FIGS. 4 and 18 to be vertical views of radial flow embodiments. The vertical axis embodiment of FIG. 4 will benefit from centrifugal stabilization if its rotor radius and cycle frequency are high enough. The horizontal axis embodiment of FIG. 18 will have centripetal acceleration assisting the gravitational field to suppress fluidization in the feed production step with upward flow from compartment 54 to compartment 70 at higher pressure, while the centripetal acceleration will assist pressure drop in the purge step with upward flow from compartment 80 to compartment 60 at lower pressure to prevent downward collapse of the adsorbers at the top of their rotational orbit. The adsorbent beds are supported at their first end (radially outside) by a first set of screens, and retained against collapsing when the rotor is stopped by a second set of screens at their second end (radially inside). Hence, the adsorbent beds are centrifugally clamped on the first screens by centripetal acceleration with the rotor acting as a centrifuge.
[0178] While composite pellets 800 are shown in FIG. 29 as spherical, other geometries are also attractive. For example, cylindrical composite pellets might be made by dip-coating the zeolite and binder slurry onto steel rods, which are then cut into short lengths.
[0179] The centrifugal clamping aspect of the present invention allows operation of granular adsorbent beds with much higher than conventional flow friction pressure gradients while still positively preventing any particle movement and attrition. In turn, this allows use of smaller adsorbent grain sizes, also enabling a very shallow radial bed depth which reduces total pressure drop. With the small adsorbent granule size reducing the mass transfer diffusional resistance, high PSA cycle frequencies become practicable. Closing the logical argument, high cycle frequencies correspond to the high rotational speed needed for centrifugal clamping.
[0180] The foregoing description of the preferred embodiments of the invention is intended to be illustrative of the present invention. Those of ordinary skill will be able to make certain additions, deletions or modifications to the described embodiments without departing from the spirit or scope of the invention as defined by the appended claims.
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A rotary module for implementing a high frequency pressure swing adsorption process comprises a stator and a rotor rotatably coupled to the stator. The stator includes a first stator valve surface, a second stator valve surface, a plurality of first function compartments opening into the first stator valve surface, and a plurality of second function compartments opening into the second stator valve surface. The rotor includes a first rotor valve surface in communication with the first stator valve surface, a second rotor valve surface in communication with the second stator valve surface, and a plurality of flow paths for receiving adsorbent material therein. Each flow path includes a pair of opposite ends, and a plurality of apertures provided in the rotor valve surfaces and in communication with the flow path ends and the function ports for cyclically exposing each said flow path to a plurality of discrete pressure levels between the upper and lower pressures for maintaining uniform gas flow through the first and second function compartments.
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BACKGROUND
[0001] It is not uncommon today to find residential neighborhoods which have underground utilities, in addition to the usual underground water/sewer service. In these neighborhoods, the electric, gas, and communication services (telephone, fax, cable television, Internet, etc.) are all installed underground, and there are no upright power poles to be seen. There are advantages to underground utility services. For example, in high wind storms, or ice storms, in an underground utility neighborhood, there are no power poles or wires subject to high wind and/or ice damage and/or collapse.
[0002] In these neighborhoods, when a new communication cable is to be connected, for example, to a particular residence, that cable is buried in a trench in the ground typically between a “hand-hole” located near the street and the particular residence to which the cable is to be connected. The depth of the trench is typically seven inches, or so. Obviously, buried cable installation is not limited to single family dwellings and it can be applied to apartment buildings as well as to non-residential buildings such as industrial buildings.
[0003] These trenches are usually dug by hand, at least for individual residences. In the course of digging these trenches for cable installation, such as fiber optic cable or copper-wire cable installation, it is not unusual to be confronted with an immovable obstacle such as a concrete sidewalk, a stone wall, a series of large rocks in the nature of a wall, decorative landscape concrete edgings, etc. These are problematic situations that slow down any underground installation process, and the cable installer must come up with a “work-around” (or, more precisely, a “work-under”) solution to the obstacle problem. There is a need for an easily applied and effective solution to this underground-pathway obstruction problem and the disclosed subject matter of the instant application teaches and claims such a solution.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a schematic top view of an exemplary surface-visible, underground-pathway-obstruction such as a sidewalk with a flexible conduit positioned there-under;
[0005] FIG. 2 is a schematic elevation front view of an exemplary cross-section of the sidewalk of FIG. 1 , with a flexible conduit positioned there-under;
[0006] FIG. 3 is a functional block diagram of an exemplary system for configuring a pathway under a surface-visible, underground-pathway-obstruction;
[0007] FIG. 4 is an exemplary schematic diagram of the hose to conduit adapter of FIG. 3
[0008] FIG. 5 is a flowchart depicting an exemplary method of fiberoptic or other cable underground installation; and
[0009] FIG. 6 is an exemplary schematic diagram showing how fiberoptic cable can be lashed for pulling it through a resultant tunnel fashioned under a ground surface obstruction.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0010] In this description, the same reference numeral in different Figs. is referring to the same entity. Reference numerals of each Fig. start with the same number as the number of that Fig. For example, FIG. 3 has numerals in the “300” category and FIG. 4 has numerals in the “400” category, etc. Thus, if discussing an entity in a Fig. having a particular reference numeral not starting with the same number as that Fig. one can easily refer back to the appropriate Fig.
[0011] Exemplary embodiments include system and method for facilitating underground installation of communication cable such as fiberoptic cable or copper wire cable. If an obstruction, such as a sidewalk, is encountered crossing paths with an intended trench path in which communication cable is intended to be buried, the systems and methods permit the erosion, or washing-away, or loosening-up, of soil underneath the sidewalk, along an intended underground route, through which the communication cable is passed.
[0012] In other words, a trench may first be hand-formed starting from the location of a communication signal source, such as, for example, a hand-hole located at the street in front of a residence, to the first-encountered side of the sidewalk obstruction. The trench is continued from the other side of the sidewalk obstruction to the residence. Applicant's erosion, or hydraulic-pressure, technique, whereby the soil is loosened under the sidewalk along a particular underground route, permits the communication cable to be easily fed under the sidewalk through that loosened-up, or eroded, underground route or tunnel from the formed trench on one side of the sidewalk to the formed trench on the other side of the sidewalk. There is no requirement that the trench be formed prior to the underground route or pathway under the sidewalk, and the underground pathway can be formed first.
[0013] FIG. 1 is a schematic top view of a surface-visible, underground-pathway-obstruction such as a sidewalk with a flexible conduit positioned there-under according to an exemplary embodiment. Sidewalk 101 represents a surface-visible obstruction to a trench (trench not shown in this Fig.). In other words, sidewalk 101 prevents a continuous trench, approximately 6-12 inches deep, from being dug, usually by hand using shovels or similar tools, from one side, e.g., side “A” of sidewalk 101 to side “B” thereof.
[0014] Flexible conduit identified as 102 ( a ) and 102 ( b ) is a continuous conduit with sections 102 ( a ) lying on top of the ground, one section on either side of the sidewalk, and with sections 102 ( b ) lying under the ground and depicted in dashed-line-format. Sections 102 ( b ) also pass underneath sidewalk 101 . Therefore, locations 103 and 104 signify the two places where above-ground conduit section 102 ( a ) transitions to below ground conduit section 102 ( b ). This depicts the conduit after it has been passed under the sidewalk.
[0015] Referring to FIG. 2 , a schematic elevation front view of a cross-section of the sidewalk 101 of FIG. 1 is shown, exposing flexible conduit 102 which is positioned there-under according to an exemplary embodiment. Sidewalk 101 is shown as partially submerged below ground surface 201 into underground 202 . Output end P of flexible conduit 102 is shown at the right of the drawing, the opposite end of the conduit being its input end. Input and output ends of the conduit are used in reference to inflow and outflow, respectively, of water therethrough, to be described below. Water flow direction 205 is shown.
[0016] FIG. 3 is a functional block diagram of a system for configuring a pathway under a surface-visible, underground-pathway-obstruction in accordance with according to an exemplary embodiment. A source of water pressure 301 is shown at the left of FIG. 3 . This source can come from a home water supply which, in turn, receives water from a public source such as a municipal reservoir or from a private water source such as a well drilled on the property of that home.
[0017] The source of the water is not of particular significance, but the pressure of the water that is applied is relevant to their operational success. In other words, well-water pressure may be insufficient to allow efficient operation. But that pressure can be boosted by a mechanism (not shown) similar to that used for power-washing outdoor decks, house siding, etc., if needed. Typical water pressure from municipal supplies is generally adequate, but that pressure can also be increased by the same mechanism noted herein, if needed. The pressure needed for proper operation of embodiments disclosed herein is a function of the compactness of the soil to be eroded—the more compacted the soil such as hard clay, the more pressure required.
[0018] Water pressure source 301 is connected to a typical garden hose 302 , which homeowners use for lawn-watering and other similar chores. The other end of that hose is connected to a hose-to-conduit-adapter 303 (hereinafter “adapter 303 ”). Adapter 303 connects to conduit 304 and forms a water-proof interface between the garden hose and conduit 304 . Adapter 303 can be constructed from standard metal plumbing and/or plastic plumbing hardware. Adapter 303 can include a shutoff valve to be used by a cable installer to turn on/off water flow there-through.
[0019] Detail of adapter 303 is shown in FIG. 4 which is an exemplary schematic diagram of the hose to conduit adapter of FIG. 3 . Adapter 303 has typical garden hose coupling 401 on its left side for normal coupling to a standard garden hose. Adapter has compression fitting 402 on its right side, to properly engage and make water tight the interface between itself and flexible conduit 304 . In addition adapter 303 has valve 403 , manually adjustable, to control water flow and shut-off such flow if need be.
[0020] Returning to FIG. 3 , conduit 304 may be formed from a flexible plastic tube having inner diameter similar to, or typically less than, the inner diameter of the garden hose to which it is attached by adapter 303 . Conduit 304 is formed in a manner that gives it a permanent bias or curve; in other words, if lying flat on the ground without external constraint imposed on the conduit, it can assume a curve in the manner shown. In addition, other conduits can be brought to a job-site and made available for use by a cable installer, these other conduits having a more severe curve-bias, even to the extent that the conduit is “coiled.” These various strengths of bias or curvature can be useful in different applications as a function of ground soil density actually encountered at a particular job site, distance to be traversed underground, and other factors. In other words, for a short underground distance, compared to the distance of a sidewalk width, and in a highly compacted soil, it may be advantageous to try a tightly-coiled conduit to achieve an underground path consistent with the size of the barrier in its path, as shall be more fully described below. The output end P of the conduit can be tipped with a rim of hard metal such as steel, and the rim can have a sharp cusp formed into it, the cusp pointing in the direction of water flow, to facilitate operation.
[0021] Briefly, in operation, an underground cable installation team may have certain team members who are responsible for digging the above-referenced trench and for traversing any ground surface obstacles that are encountered. When encountering an obstruction, e.g., a sidewall(, one of these team members, an installer, after connecting flexible conduit to a water supply, can grab flexible conduit 304 and press the sharp metal rim into the soil at one side of the sidewalk. The water can then be turned-on, allowing a pressure stream of water to be applied against the ground surface. Simultaneously, a steady force is applied by the installer to the flexible conduit, pushing against the soil. The conduit, thereby, follows the direction of the water stream which is eroding, or loosening, the soil in its path.
[0022] An experienced installer can guide, wiggle, push and/or orient the flexible conduit, thereby working the metal-rimmed output end of the conduit through the soaked underground soil until the metal rim pops-up through the ground surface on the opposite side of the sidewalk. Another variable under control of the installer is the water pressure, which can be increased/decreased to achieve the desired result. In the event that the flexible conduit passes under the sidewalk, but does not emerge on its own, the installer can always dig a hole on the opposite side of the sidewalk at the approximate place where the emergence was expected, and capture the conduit by that technique, as a last resort.
[0023] FIG. 5 is a flowchart depicting the above-described method or technique of fiberoptic cable underground installation in more detail. In act 501 , the installer attaches water hose 302 to source of water pressure 301 . In act 502 , the installer attaches flexible conduit 304 to the hose via adapter 303 . In act 503 , the installer presses the flexible conduit output and, in particular embodiments, the hard metal rim attached to the conduit output, against ground surface 201 nearby sidewalk 101 . In act 504 , someone opens a water flow valve, either at the dwelling on the property from which the water is supplied, or at the adapter 303 , or both, to cause water flow through conduit 304 to penetrate the ground at the place where it is being pressed by the conduit output P.
[0024] In act 505 , the installer works the conduit under the obstruction with intentions of achieving an emergence on the other side of the obstruction 101 . In question box 506 , the query is made: has the conduit emerged? If not, another question box 507 answers the question: is progress being made? If yes, a return to question box 506 occurs to query the emergence of the conduit end. But, if not, the algorithmic process moves to act 508 which allows, if needed, a pressure adjustment to the water supply; the flow can be increased by opening the garden hose to fully-open and/or a pressure washing apparatus (not shown) can be connected to the garden hose upstream from adapter 303 to radically increase available water pressure to loosen heavily compacted underground soil. After that, acts 505 and 506 are repeated to see if the conduit emerges.
[0025] If conduit 304 does emerge on the other side of the obstruction, then in act 509 one end of the fiber optic cable (or other telecommunications cable) that is being installed on this property is tied or lashed to the output end of the flexible conduit. In act 510 , the installer pulls the conduit back out of the underground passage in the opposite direction from that in which it was inserted, thereby dragging the fiber optic cable into and through the underground tunnel or passage to the other side of the obstruction. Thus, the cable is now traversed under the obstruction and it can then be detached from the conduit. In act 51 1 , the cable can then be pulled thereunder to whatever length is needed to make the appropriate optical or electrical connection from hand-hole to dwelling structure. If a trench has been dug, the cable is then appropriately buried in the trench, and if not, the trench is then dug at that time with cable burial following.
[0026] FIG. 6 is a schematic diagram showing how fiberoptic cable can be lashed/tied for underground installation, in accordance with the description of the previous paragraph. FIG. 6 shows a portion of conduit 304 near its output end P, after it has emerged from underground per the discussion above. Fiber optic cable 601 is shown physically attached to conduit 304 by lashing or tie 603 . Lashing 603 can be a twist wire-tie or made from nylon cord or from any other strong, suitable material. In addition, conduit 304 can be grooved near end P on its outer circumferential surface to form a frictional surface or a detent to facilitate the binding between the conduit and the cable. Alternatively, an adhesive tape, such as electrical insulating tape can be wound around the cable and conduit, tightly, to enable the pull-through operation to properly conclude. In this instance the direction of pull-through is direction 602 as shown in FIG. 6 .
[0027] In the preceding specification, various preferred embodiments have been described with reference to the accompanying drawings. It will, however, be evident that various modifications and changes may be made thereto, and additional embodiments may be implemented, without departing from the broader scope of the invention as set forth in the claims that follow. For example, in a first alternative technique, a fiberoptic or other cable can be attached to the flexible conduit at the adapter end, instead of at the conduit's output end, after removing the adapter, and the conduit can be pulled out of the underground tunnel in the same direction in which it was inserted, thereby dragging the fiberoptic cable behind it into and through the tunnel. In another alternative technique, where a copper-wire cable is being installed, after removal of the conduit from the hose-to-conduit-adapter 303 , that cable can be inserted directly into and through the conduit itself, before the conduit is removed from its above and below ground position; after emergence of the copper wire cable, the conduit sleeve can then be pulled out of the ground, leaving the cable in proper place. Accordingly, the specification and drawings are accordingly to be regarded in an illustrative rather than restrictive sense.
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A technique for aiding an underground communications cable installer in the installation such cable in underground utilities neighborhoods. The technique manages the problem presented by a surface-visible, underground-pathway obstruction such as a sidewalk, which lies across the path of installation. The technique, or method, is useful with any kind of cable, such as fiberoptic cable or copper wire cable. Hydraulic water pressure is applied through a biased, flexible conduit to erode a pathway under the obstruction from ground surface on one side to ground surface on the opposite side of the obstruction, thereby forming a tunnel under the obstruction through which the cable can be easily pulled. In alternative embodiments, the cable can be inserted directly into and through the conduit while it is underground, the conduit then acting as a sleeve for the cable which is subsequently removed prior to burying the cable in a trench dug from street-located handhole to house. Special apparatus connects a water hose to the flexible conduit (PVC plastic) to provide watertight operation while allowing manual flow control.
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FIELD OF THE INVENTION
The present invention relates to the field of textile fabrics, and to methods of manufacturing same. In particular, the present invention provides a novel knitted fabric heaving good moisture absorption capabilities, combined with excellent breathability and a dry touch.
BACKGROUND OF THE INVENTION
The fabric of the present invention is particularly suited to applications in which it is desired to provide a body-contacting fabric surface covering a moisture absorbing layer. A typical product requiring such a combination is a bed pad, or an incontinence garment. Conventionally, fabrics for these products have been manufactured by quilting together a face fabric such as a hydrophobic polyester knit and a soaker layer such as a non-woven hydrophillic needlepunch. Material manufactured in this way is capable of absorbing a large amount of moisture, but does not feel dry to the touch, because the face fabric, while hydrophilic, lies directly on the soaker material. Accordingly, if the soaker material is saturated, a wet feel will be transmitted to the surface of the face fabric. Moreover, such quilted material is costly to manufacture since it requires two separate manufacturing processes, one for each of the soaker and the face materials, and a separate quilting operation.
There have been attempts made, in the textile industry, to provide a fabric with a hydrophilic face and a hydrophillic face, thereby to produce a material capable of absorbing a significant quantity of moisture, while remaining dry to the touch. In U.S. Pat. No. 5,065,600 (Byles) a textile fabric with opposed absorbent and non-absorbent layers is described, which comprises a hydrophilic yarn formed in a raised surface construction at one face of the fabric, and a hydrophilic yarn formed in a dense extended pile at the opposite face of the fabric, and a ground yarn between these two layers formed in a dimensionally stable construction. Dry feel is provided by the raised surface construction of the hydrophilic yarn layer. The disadvantage of such a construction, however, is that it does not provide a significant volume in association with the hydrophilic yarn layer, because the ground yarn layer is relatively flat. Accordingly, moisture accumulating in the hydrophillic layer may tend to migrate to the hydrophilic layer, especially if subjected to tactile pressure.
Other knitted fabrics attempting to take advantage of the different properties of hydrophilic and hydrophillic yarns or filaments and/or yarns of varying denier are described in Canadian Patent No. 2,170,976 and U.S. Pat. No. 4,733,546. Knitted fabrics utilizing a stitch that spaces apart a front and back face of a fabric for providing an insulating layer or high loft feel to a fabric are described in Canadian Patent No. 2,115,505 and U.S. Pat. No. 5,385,036. The prior art does not, however, describe a knit fabric with a hydrophilic face spaced from a hydrophobic face by low density columnar stitches extending between the two faces to provide a relatively voluminous space between the two for water retention and air circulation.
The object of the present invention, therefore, is to provide a lightweight, highly absorbent knitted fabric.
A further object is to provide a knitted fabric with a highly absorbent, hydrophilic face, and a dry feeling hydrophobic face, spaced apart from one another by a low density, but relatively thick layer of columnar stitches. The low density layer of columnar stitches provides a space for air circulation between the hydrophilic and hydrophobic faces, and provides additional space for retention of excess moisture when the holding capacity of the hydrophilic layer is completely utilized. In this way, even at full capacity for holding moisture, the hydrophobic dry face of the fabric is held out of contact with the accumulated moisture, and will maintain a dry feel to the touch.
In a broad aspect, then, the present invention relates to a knitted fabric comprising a layer of hydrophilic yarn on one face of said fabric, a layer of hydrophilic yarn on the opposite face of said fabric, and a pillar stitched, low density layer of yarn extending between and joining said hydrophillic and hydrophilic yarn.
BRIEF DESCRIPTION OF THE DRAWINGS
In drawings that illustrate the present invention by way of example:
FIG. 1 is a cross-sectional view of a fabric according to the present invention;
FIG. 2 is a top view of the technical front of the fabric of the present invention;
FIGS. 3a, 3b and 3c are stitch pattern diagrams for three exemplary embodiments of the present invention;
FIG. 4 is a cross-sectional view of an incontinent pad utilizing the fabric of the present invention, coated with PVC.
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2, the basic three dimensional structure of the fabric of the present invention is illustrated. The fabric comprises a hydrophobic technical back face 2, made from hydrophobic yarn such as a 1/150/34 denier textured polyester. The selection of a suitable hydrophobic yarn is considered a matter of choice for one skilled in the art.
The technical front face 1 is a hydrophilic yarn, such as a 1/150/200 denier textured polyester yarn. The selection of a suitable hydrophilic yarn is also considered a matter of choice for one skilled in the art.
The technical front 1 and back 2 are joined by a layer 3 of tuck stitches in a pillar arrangement as illustrated. The pillar tuck stitches are made from a 1/220/60 denier flat polyester yarn, or such other suitable yarn, as will be an obvious matter of choice to one skilled in the art and apprised of the teaching of the present application.
The fabric of the present invention is knit on a circular knitting machine such as an FDR Rib machine, with a thirty inch diameter, 1320 needles, 6 feeds and 14 cuts. A typical knitting pattern to produce the fabric of the present invention will be:
Feed #1: Tuck all long butt needles, dial and cylinder;
Feed #1: Knit all long butt needles; dial only;
Feed #3: Knit all long butt needle; cylinder only;
Feed #4: Knit all short butt needles; dial only;
Feed #5: Knit all short butt needles; cylinder only;
repeated, with five courses per repeat, twelve courses per revolution, with the machine identified. FIGS. 3a, 3b and 3c illustrate diagrammatically other patterns that may be utilized to produce the fabric of the present invention.
Referring to FIG. 4, a preferred use of the fabric of the present invention is illustrated. After the fabric of the present invention is knit, following the examples cited above, or other patterns that will be obvious to one skilled in the art who is apprised of the present invention, it is hot air tentered under no tension, and then coated on its technical front (hydrophilic layer) with PVC or any other suitable waterproof polymer, following which a finishing layer, for instance of knit jersey is applied to the face of the PVC. This combination is eminently suited for the manufacture of bed pads, or incontinence garments, where a water proof layer, such as will be provided by the PVC, is desired.
Other uses for the fabric of the present invention include use as a thermally insulating fabric. In this regard, the fabric is especially useful for sportswear for use in active winter sports like cross country skiing. This type of sport will cause a participant to perspire freely even at very low temperatures like -15° C. It is very desirable to wick perspiration from the skin before it causes chills. Moreover, the fabric of the present invention will permit perspiration to be removed while at the same time allowing air to circulate in the middle, pillar stitch layer of the fabric, keeping the wearer warm and well ventilated.
The fabric of the present invention also has potential uses in protective clothing, medical garments, footwear liners and socks, bedding and filtration.
It is to be understood that the examples described above are not meant to limit the scope of the present invention. It is expected that numerous variants will be obvious to the person skilled in the field of knitting and fabric engineering without any departure from the spirit of the invention. The appended claims, properly construed, form the only limitation upon the scope of the invention.
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A knitted fabric comprises a layer of hydrophillic yarn on one face of the fabric, a layer of hydrophobic yarn on the opposite face of the fabric. A pillar stitched, low density layer of yarn extends between and joins the hydrophillic and hydrophobic yarn layers.
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BACKGROUND OF THE INVENTION
The present invention relates to improvements in self-straining bolts.
Self-straining bolts are known for example from British patent specification No. 1,382,192 which shows a bolt having a central bore which is closed at one end. The bolt is stressed by inserting a rod along the bore into contact with the closed end and applying jacking forces, at the opposite end of the bolt, between the bolt and rod in such a manner as to tension and stretch the shank of the bolt and apply a corresponding compression force to the rod. The clearance created by stretching the bolt is taken up by shims or adjustment of a nut and the jacking forces are then relieved, leaving the bolt under tension. The rod may then be removed.
OBJECT OF THE INVENTION
An object of the invention is to provide a self-straining bolt construction in which substantially the entire cross-section of the bolt is solid and under tension and which may be tensioned by a tensioning head which is not required to bear against the work in which the bolt is being installed. It is further desirable that the tensioning head should not project laterally beyond the outer perimeter of the area of pressure-transmitting contact between the bolt and the work.
BRIEF DESCRIPTION OF THE INVENTION
According to the present invention there is provided a compound bolt comprising a hollow shank and a core member within the shank, the shank and core member being secured to each other at or adjacent a first end of the bolt assembly, releasable transfer means at or adjacent the second end of the assembly for transferring tension forces from the core member to the hollow shank, the core member being capable of withstanding in compression the normal tensile force generated in the shank in use when such force is transferred thereto by the transfer means and having coupling means at or adjacent the second end for applying tensile and compressive forces to the core member.
Also according to the present invention there is provided a method of establishing a tensioned compound bolt connection between two spaced regions comprising the steps of pre-tensioning a hollow bolt shank by pre-compressing a core member in the shank, positioning the shank and core member assembly in the required position for the bolt connection without end play; releasing the pre-compression in the core member, whereby the pre-tension of the hollow shank is applied between the two regions, applying tension to the core member by exerting reaction against the shank, creating a play-free force transmitting path between the two ends of the tensioned core member and corresponding ends of the hollow shank, and releasing the tension applied externally to the core member so that the tension in the core member is applied in the direction compress the shank.
By making use of the invention, it is possible to establish a high tension bolted connection by using bolt tightening devices which do not project beyong the circumscribed cylinder around the head or load transmitting flange of the bolted connection. This arrangement is particularly desirable with large highly-stressed closely-pitched bolts or studs used for example in securing the casings of large steam turbines which operate at high temperatures. The present method of tightening such bolts is by thermal means in which the bolt or stud is rapidly elongated by inserting an electrical heating element into a centrally drilled hole in the core of the bolt or stud.
When the bolt has increased its length by the required amount, the nut is secured down and measurements made through the centrally drilled hole indicate the true extension achieved in the bolt or stud and hence the true tension achieved in the bolt or stud. However, this method is time-consuming and there is always a danger that the rapid heating from the core of the bolt or stud will cause cracking due to plastic deformation of the bolt material resulting from the very high termal stress gradients which such heating causes. To achieve uniform tightening around a complete turbine casing, it is often necessary to repeat this time-consuming operation two or three times on each bolt or stud.
The present invention avoids the need for any thermal stressing of the bolts or studs but instead makes use of hydraulic stressing techniques (which have been proved by wide experience in other fields) while at the same time, avoiding the need for any equipment of greater diameter than the head of the bolt or stud which is to be tightened.
DESCRIPTION OF THE DRAWING
An embodiment of the invention will now be described by way of example with reference to the accompanying drawing in which the single figure shows one compound bolt together with tensioning apparatus therefor in axial section and the two adjacent bolts in elevation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following description and in the claims, reference is made to "compound bolts"; it will of course be understood that this term is used generically for the sake of simplicity and will include compound studs where appropriate.
The compound bolt shown in the drawing comprises a hollow tubular shank 1 which is both internally and externally screw-threaded at its first or lower end at 2 and 3 respectively and has an integral circular flange 4 which forms the base of an externally screw-threaded head portion 5 for the bolt.
A core member in the form of a solid rod 6 has its lower end screw-threaded and in tight engagement with the threads 2 at the lower end of the hollow shank 1. The rod 6 is somewhat longer than the shank 1 so that it projects above the top of the head 5 and the upper end portion of the rod above the flange 4 is screw-threaded at 8 and has engaged thereon a cylindrical nut 9 the upper part of which projects above the head 5 and is formed with blind castellations 10 while the lower part of the nut 9 is received in a counterbore 11 in the shank head 5.
The tensioning apparatus for the compound bolt comprises a generally cylindrical housing 21 the lower end of which is internally screw-threaded to engage with the external threads on the shank head 5. The diameter of the head 21 is equal to the diameter of the shank head flange 4.
An internal flange 22 extends inwards from the housing 21 to make sliding contact with cylindrical surface 23 on a combined piston and nut 24 which has internal screw-threads engaged on the upper part of the threads 8 on the rod 6 and has its external cylindrical surface 25 in sliding contact with the inner wall surface of the housing 21 above the flange 22. There is thus defined an annular chamber 26 containing a tire or load-cell 27 made of nitrile rubber which has a connection 28 for receiving a high pressure hydraulic supply.
The top surface of the radially inner part of the piston nut 24 is substantially flush with the top surface of the rod 6 and the two form a seating for a diaphragm 29 which may be formed by a stack of thin discs of nitrile rubber. An end cap 30 has external screw-threads engaged in internal screw-threads in the upper part of the housing 21 and has a central connector 32 for delivering high pressure hydraulic fluid to the upper side of the diaphragm 29.
At the level of the blind castellations or notches 10, the housing 21 is formed with horizontal arcuate slots 33 through which a suitable tommy-bar or the like can be inserted to engage the notches 10 for manipulation of the nut 9.
Installation and fitting of each compound bolt are as follows:
Before installation in the work W, the compound bolt is preassembled and pre-tensioned in the workshop. First, the rod 6 is screwed firmly home by means of its screw-threads into the screw-threads 2 in the lower part of the shank 1. The nut 9 is then engaged on the screw-threads 8 on the upper part of the rod 6.
Next the pressure head cylinder 21 complete with the nitrile load cell 27 and pressure connection 28 is firmly screwed down onto the bolt flange face 4. The nut 24 is now screwed home until the upper surface is flush with the end of rod 6, a micrometer depth reading R 1 between the upper lip of the pressure head cylinder 21 and the top surface of the rod 6 is taken to provide a datum.
The nitrile rubber diaphragm 29 is then inserted and the top plate 30 is screwed home firmly. A hydraulic pressure of 35,000 p.s.i. is now applied through connector 32 elongating the bolt shank 1 and reducing its diameter. The isolating valve (not shown) is closed, trapping the hydraulic pressure within the head. The bolt is now screwed into place in the work W as shown, being nipped up by a hammer and metal drift engaged in appropriate notches 36 in the flange 4. The isolating valve is opened-releasing the hydraulic pressure and the top plate 30 and the nitrile diaphragm 29 are removed. A repeat of this micrometer reading R 2 will give the actual value of the bolt as R 2 -R 1 .
If, as in the case of the drawing, a ring of bolts is being installed, it may be desired that the final tensioning operation on a plurality of bolts should take place simultaneously. For this purpose, all connections 32 of individual tensioning heads for each of the bolts to be simultaneously tensioned are connected together as are the connections 28. Then, the isolating valve controlling all the connectors 32 is opened simultaneously releasing the pressure as a result of which the shank 1 contact in length thereby applying a uniform load to the work W. The micrometer depth gauge readings for each bolt should then be taken again and recorded after checking that they are within prescribed limits.
The or each isolator valve connection is then removed from the connector 32 and applied to the connector 28 and the top plate 30 and nitrile diaphragm 29 are also removed. The high working pressure of about 35,000 p.s.i. is then applied to pressurise the annular pressure cell or tyre 27 thereby stretching the rod 6. The micrometer depth gauge reading R is again taken (R 3 ) and the tension in rod 6 is represented by R 3 -R 2 . With the hydraulic pressure maintained at the working pressure, each nut 9 is screwed down on the threads 8 into contact with the bottom of the counterbore 11 by hand, using a suitable tommy-bar engaged through the slots 33 into the notches 10.
By releasing the pressure in the load cells 27, the load which was transmitted by the load cells is now transmitted through the nuts 9 again to the heads 5 and flanges 4 of the bolt shanks. A further micrometer reading (R 4 ) will indicate whether there has been any loss of tightening strain when the load is transferred to nut 9. The loss should in fact be not more than one thousandth of an inch if the unit has been adequately nipped up and there are normal machining errors on the screw-threads and the mating faces of unit and landing.
The or each tensioning head may now be removed by disconnecting the hydraulic pipe from the connection 28 by unscrewing them, unscrewing the piston nut 24 and then finally unscrewing the outer casing 21 from the bolt head 5.
Removal of a bolt is effected by re-assembling the tensioning head onto the head 5 of the bolt in question, applying the high loading fluid pressure to the load cell or tyre 27, unscrewing the nut 9 by hand by means of the tommy-bar passed through the slots 33 until the nut 9 touches the underside of the piston nut 24, applying the high fluid pressure through the connector 32 and thereafter closing the isolator valve, using the hammer and drift to slacken off the bolt by means of the notches 36, completely unscrewing the bolt in question and removing the bolt and tensioning head assembly for further work as required.
As can be clearly seen in the drawing, the housings 21 of the tensioning heads do not come into contact with the work W and are situated within the imaginary circumscribing cylinder of the flanges 4. As a result of nominal clearance only is required between adjacent flanges 4 and tensioning head housings 21.
It will be noted that the assembly comprising the shank 1 and the rod 6 are fully loaded to a high level of controlled stress.
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A self-straining bolt comprises a hollow shank having a flanged and screw-threaded head at one end, a core member, a rod within the shank and secured to the other end of the shank a nut in screw-threaded engagement with the core bears against the shank at the said one end. The bolt is tensioned by means of a tensioning head comprising two coaxial jacking means, one for tensioning the hollow shank by bearing on the core member and the other for tensioning the core member by bearing on the shank head.
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This application is a Continuation-in-part of U.S. application Ser. No. 09/217,581, filed Dec. 22, 1998, which is a regular national application claiming priority from provisional application Ser. No. 60/068,668, filed Dec. 23, 1997. The entirety of both are incorporated herein by reference.
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
The present invention generally relates to a gaseous blend of O x , and a method for applying the gaseous blend of O x , that can be utilized to significantly reduce the biological load on consumer products such as food products, botanicals and cosmetic ingredients, which have traditionally been treated with commercial sterilants or fumigants such as ethylene oxide, propylene oxide, methyl bromide, hydrogen phosphide, steam (heat), irradiation, and the like.
BACKGROUND OF THE TECHNOLOGY
A number of commercial fumigants are presently used to treat foodstuffs and other stored commodities. The most widely used fumigants are methyl bromide, hydrogen phosphide, and hydrogen cyanide. As disclosed in U.S. application Ser. No. 09/217,581, many of these compounds pose hazardous conditions for application personnel and can form deleterious residues in the foodstuffs and commodities that are treated. Furthermore, some of the traditional fumigants have been identified with the formation of carcinogens and mutagens which thus limit the products that can be treated.
U.S. Pat. Nos. 5,897,841 and 6,027,667 disclose the use of CO 2 as a carrier gas for phosphine fumigant.
U.S. Pat. No. 4,889,708 discloses a mixture of phosphine and CO 2 and the use thereof to fumigate stored produce, such as grains and other commodities.
U.S. Pat. No. 4,200,656 discloses the use of CO 2 as a carrier for methyl bromide in fumigation.
U.S. Pat. No. 4,998,377 discloses the use of CO 2 as a carrier for methyl bromide and hydrogen phosphide in fumigation.
U.S. Pat. No. 5,678,352 discloses the use of CO 2 as a carrier for toxic agents such as methyl bromide during fumigation.
U.S. Pat. No. 4,989,3 63 discloses application of CO 2 in pesticidal quantities for fumigation. The process disclosed in U.S. Pat. No. 4,989,363 require administration of the CO 2 for a period of time of at least about 5 days.
Other procedures that have been developed to treat products utilize heat, ionizing radiation, and other chemical compounds. All of these procedures are potentially detrimental to the products' nutritional, physical and/or chemical attributes and thus make them undesirable. Insects and other pests damage to food products and other commodities account for billions of dollars of losses in the United States annually. Traditionally, a number of fumigants have been utilized to control these pests by their application under air tight tarpaulins, in sealed rooms and in steel chambers. All three primary gaseous fumigants; i.e., methyl bromide, hydrogen phosphide and hydrogen cyanide, are facing major regulatory restrictions and/or total phase out agreements over the next few years. With these limitations in mind, the search for effective alternatives has evolved the use of materials such as methyl iodide and sulfonyl fluoride. Unfortunately, these alternatives have limitations due to factors such as worker exposure, halogen content and damage to certain commodities.
Ozone (O 3 ) and its primary active component, atomic oxygen, have been used in water and commodity sterilization for about 100 years. However, as discussed in more detail below, prior treatment methods using O 3 would be ineffective for many applications.
U.S. application Ser. No. 09/217,581 discloses a method and apparatus that uses a gaseous mixture of oxygen-containing gases, i.e., O 3 , O 2 and O 1 , hereinafter referred to as O x , to reduce biological loads on consumer products to eliminate pathogens while maintaining product stability.
As an advancement to the invention disclosed in application Ser. No. 09/217,581, the present inventors have surprisingly discovered that for a number of consumer products, O x biological burden reduction is even more effective at two distinct temperature ranges. With the appropriate adjustments to other parameters, both temperature ranges can be used for enhanced microbiological reduction and insect control, The present inventors have thus discovered that O x 's effectiveness as a fumigant can be maintained and in some cases enhanced while increasing the treatment temperature. When the temperature is increased, certain other O x treatment parameters must also be adjusted away from those originally used for microbiological reduction.
SUMMARY OF THE INVENTION
It is desirable to treat a wide variety of consumer products in a cost effective manner. The gaseous blend of O x , and method of the present invention permit fumigation (hereinafter referred to as “biological burden reduction” of a product in its original container (e.g., burlap bag, fiber drum, kraft paper bag, plastic bag, etc.)). Thus, double handling, product loss, and post treatment contamination are reduced.
The gaseous blend of the present invention consists at least in part of O 3 .
The method of the present invention utilizes the gaseous blend of O x in a technologically advanced treatment system that overcomes the limitations formerly encountered with O 3 treatment on biological burden. Prior O 3 treatmnents include, for example, (1) the submersion of an article to be treated in ozone-containing water and the bubbling of ozonated water over the article (see, e.g., U.S. Pat. No. 4,517,159 to Karlson and U.S. Pat. No. 4,640,872 to Burleson); and (2) the static treatment of medical devices and food products with gaseous ozone (see, e.g., U.S. Pat. No. 3,179,017 to Shapiro et al., U.S. Pat. No. 5,069,880 to Karlson, and U.S. Pat. No. 5,120,512 to Masuda.) Systems utilizing such as described above have encountered several limitations. The incorporation of ozone gas into water and then submersion of items(s) to be sterilized or the spraying of ozone treated water onto the surface of item(s) to be sterilized limit the process to products that can be soaked in water. The few gaseous uses of ozone have been limited to the surface treatment of medical devices and the like due to the lack of adequate penetration into compacted products. Thus, although these past processes have proven the efficacy of ozone as a sterilant, the limitation of the use of ozone as a surface treatment has not presented ozone as a reliable sterilant or fumigant for products contained within commercial containers.
In addition to the generation of the ozone molecule, the present invention also utilizes the quenching effect of other inert gases to assist ozone generation, thereby increasing the stability of the O x radicals. Argon and carbon dioxide (CO 2 ) can be used in the method of the present invention to achieve these factors. Furthermore, the presence of atmospheric nitrogen has been utilized in the food industry for many years to protect sensitive oils and fats from oxidative rancidity. Small quantities of nitrogen can be used in the method of the present invention to assist in the protection of sensitive food components as well as assisting in the stabilization of the O x generation.
Accordingly, it is an object of the present invention to provide a gaseous blend of O x and a method for applying the gaseous blend of O x for reducing biological burden from consumer products.
It is another object of the present invention to provide a gaseous blend of O x and method for applying the gaseous blend of O x for reducing biological burden from consumer products in a safe manner.
It is thus an object of the present invention to eliminate the health risks that are associated with the reduction of biological burden from consumer products.
It is a further object of the present invention to provide a simple, efficient and economical gaseous blend of O x and a method for applying the gaseous blend of O x for reducing biological burden from consumer products that can be used at the site of production and/or packaging of such products.
In accordance with the above and other objects, the inventive gaseous blend consists of at least O 3 . The inventive method for applying the gaseous blend comprises applying a continuous stream of O x gas to a material at a specified temperature. The first temperature range is 45° F. to 60° F. The second temperature range is 90° F. to 130° F. In conjunction with temperature, adjustments to other parameters proves beneficial depending on the commodity being treated and organism being targeted. With the eventual elimination of methyl bromide as a fumigant, development of alternative treatment methods has become very important. The present inventors have discovered that O x 's effectiveness as a fumigant can be maintained and in some cases enhanced while increasing the treatment temperature. When the temperature is increased, certain other O x treatment parameters must also be adjusted away from those originally used in application Ser. No. 09/217,581 for microbiological reduction.
The continuous stream of O x gas is prepared in an O x generation cell, which contains a means for generating the O x gas at a pressure less than about 20 lbs/in 2 , for example, one or more of the following: corona discharge, high frequency electrical discharge, ultraviolet light, x-ray, radioactive isotope and electron beam.
As discussed herein, N 2 , CO 2 and/or Ar may be added during O x treatment. The addition of 0%-70% N 2 , 20%-100% CO 2 and/or 1%-18% Ar increases the generation of an O x quenching effect. Penetration of O x into the material being treated is thus enhanced. In addition, argon is unique among the (inert) Noble Gases, in that it is soluble in both water and organic liquids. (The Merck Index Eleventh Edition). This characteristic theoretically enables argon to become a glue of sorts. Argon is capable of attaching to gases without reacting thereto. Argon thus assists in O x quenching by attaching to the O x molecules and preventing the O x molecules from colliding into each other. Argon also loosely binds hydrophilic and hydrophobic materials, thus allowing one to be diffused through the other, without reacting with either. This characteristic is useful in accelerating the diffusion of O x into and through hydrophilic materials such as fats, oils and cell walls.
An apparatus such as that disclosed in application Ser. No. 09/217,581, may be used to carry out the method of the invention.
The apparatus disclosed in application Ser. No. 09/217,581 comprises:
(a) a biological burden reduction chamber;
(b) a vacuum pump coupled to the biological burden reduction chamber;
(c) an O x generation cell, wherein the O x generation cell contains a means for generating O x at pressure less than about 20 lbs./in 2 using, for example, one or more of the following: corona discharge, high frequency electrical discharge, ultraviolet light, x-ray, radioactive isotope and electron beam;
(d) a first control valve coupled to the biological burden reduction chamber and the O x generation cell, wherein the first control valve is capable of permitting O x to be drawn from the O x generation cell into the biological burden reduction chamber; and
(e) a second control valve coupled to the biological burden reduction chamber, wherein the second control valve is capable of withdrawing O x contained within the biological burden reduction chamber out of the biological burden reduction chamber.
Water vapor may be introduced to the gaseous O x to maintain an appropriate humidity level, i.e., between about 20% and 98% relative humidity, and, more preferably between about 40% and 75% relative humidity. The appropriate humidity level is dependent upon the ambient humidity and upon the product being treated. For example, granular and powered products require a relatively low humidity level to prevent growth of mold and yeast thereon. However, depending on the length of treatment time, any vacuum that may be created during the process removes humidity, thus requiring the addition of humidity. The O x gas may then be passed through a commercially available catalytic destruct unit to eliminate any residual O 3 and O 1 before the gas stream is discharged to the atmosphere.
The present invention is also directed to treated consumer products that result from use of the present inventive gaseous blend of O x and method.
Additional objects and attendant advantages of the present invention will be set forth in the description and examples that follow, or may be learned from using the gaseous blend or practicing the method of the present invention. These and other objects and advantages may be realized and attained by means of the features, instrumentalities and/or combinations particularly described herein. It is also to be understood that the foregoing general description and the following detailed description are only exemplary and explanatory and are not to be viewed as limiting or restricting the invention as claimed.
The invention itself, together with further objects and attendant advantages, will best be understood by reference to the following detailed description, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart showing an embodiment of a method for using a continuous flow of O x to reduce biological burden in accordance with the method of the present invention.
FIG. 2 is a schematic showing one example of an apparatus for using a continuous flow of O x to reduce biological burden in accordance with the method of the embodiment in FIG. 1 .
FIG. 3 is a graph comparing permeation of O x gas for (a) VVP+CO 2 , +O x in accordance with an embodiment of the method of the invention, (b) VVP+O x in accordance with an embodiment of the method the invention, and (c) static+O x in accordance with conventional use of gaseous O x in a static fashion.
In the following description, like parts are designated by like reference numerals throughout the figures.
DESCRIPTION OF PREFERRED EMBODIMENTS
All patents, patent applications and literatures that may be cited herein are incorporated herein by reference.
The antibacterial potential of O 3 has been recognized for many years. O 3 is widely used as a disinfectant for sewage treatment and for purification of drinking water. It has, however, failed to gain acceptance as a biological burden reduction treatment for consumer goods. The primary reason for this failure is that the O 3 molecule is highly unstable and quickly reverts to O 2 if it does not encounter a susceptible substrate with which to react. O 3 also has the capacity to react with a broad array of substrates and would be expected to react with packaging materials surrounding the items being sterilized. This further reduces the number of O 3 molecules available to react with and inactivate microbial contaminants.
Previous attempts to use O 3 as a biological burden reduction treatment include the reliance upon filling a sterilization chamber with O 3 and exposing the materials to be treated in static fashion for various periods of time without replenishment of O 3 See for example, U.S. Pat. Nos. 3,719,017 and 5,069,880. Under these conditions, the concentration of O 3 within the chamber would be expected to rapidly decrease to a level below that required for effective biological burden reduction due to the short half life of O 3 , which is typically less than 20 minutes. A further disadvantage of the static exposure technology is the reliance on simple diffusion to promote permeation of the O 3 molecules through packaging materials and into interstices of the materials being treated. Thus, such methods do not achieve adequate permeation into the material being treated.
The present invention, which has been designated “dynamic O x biological burden reduction,” offers significant advances over the prior static biological burden reduction technology in that it provides a continuous flow of O x , i.e., between about 0.03% and 16%, throughout the treatment cycle and promotes rapid permeation of O x through packaging materials and into the voids and interstices of the materials undergoing treatment. Continuous operation of the vacuum pump and O x generator during biological burden reduction ensures that the concentration of O x remains essentially the same throughout the process by constantly supplying newly generated O x molecules to replace those molecules which have spontaneously degraded to inactive O 2 and those which have reacted during the process.
Dynamic O x biological burden reduction provides significant cost advantages over existing biological burden reduction technology. The most significant savings derive from the fact that the O x biological burden reducing gas may be generated on site, during the process.
Because O x is not flammable or explosive, facilities need not include damage-limiting construction or explosion-proof equipment. Another advantage of dynamic O x biological burden reduction is that scrubbing will be easily accomplished using existing technology. Moreover, O 3 is classified by the U.S. Food and Drug Administration as a generally recognized as safe “GRAS” substance.
The dynamic O x biological burden reduction process of the invention has proven successful in the treatment of a wide variety of materials, including spices, flavorings, and packaging materials.
Referring to FIG. 3, which is a graph comparing permeation O x gas for (a) VVP+CO 2 +O x in accordance with an embodiment of the method of the invention, (b) VVP+O x in accordance with an embodiment of the method the invention and (c) static+O x in accordance with conventional use of gaseous O x in a static fashion. The static flow of gas (c) demonstrated a limited permeation, which quickly stopped altogether. The (VVP) process (a) and (b), on the other hand, demonstrated a continuous progression through the packed column; completely depleting the chemical indicator. This embodiment enhances the permeability of O x gases into commercially sized containers of granular and powdered food components. The observation of treatment in accordance with the invention to live insects and microbiological and chemical indicators has been utilized to measure the incorporation of lethal doses of O x into these containers. Via comparative data (see FIG. 3 ), a static flow of O x bearing gas (curve (c)) has proven ineffective in driving the O x into the containers. This embodiment utilizes a process herein described as the Vacuum Vapor Phase Dynamic Flow (VVP). In theory, and supported by empirical data, VVP acts as the driving force to enhance permeation of the O x gases by two factors. The first factor is the molecular acceleration of the O x gases due to the flashing of the concentrated O x gas into the reduced pressure treatment chamber. This creates a driving force at a molecular level that continuously forces the O x gases into the product being treated. The second factor is the resulting reduction of molecules within the reduced pressure treatment chamber which reduces the incidence of molecular collision of the O x gases. Molecular collision of the O x gases causes rapid degradation of the O 3 and O 1 radicals present therein, thereby reducing the gases effectiveness. Without the VVP process, the O x gas flow could only be utilized as a surface treatment of non-amorphous materials, therefore, the VVP process expands the capabilities of the present invention to process virtually any type of product in-situ, thus eliminating the need to repackage the product after treatment.
The method of the present invention avoids many of the limitations of previous practices by avoiding the need for water sprays and/or water immersion of the substrate to be treated. Many products such as spices, flour-based products, sugar-based products, cosmetic bases, herbs, and botanicals, which are sensitive to high levels of moisture, can be treated using the method of the present invention. The method of the present invention also avoids the need to open conventional commercial packaging before treatment, thus avoiding unnecessary product degradation and loss. The product may be treated in situ utilizing conventional processing. Previous methods have required the product to be agitated, blended, bubbled, or re-packaged during or immediately upon completion of the treatment. Due to the increased permeation of the VVP process and the O x gas mixture, these damaging handling practices are avoided. The extended half life of the O x radicals allows the active portions of the treatment gas to fully penetrate the substrate and act upon offending organisms. In combination with carbon dioxide, the stabilized O x gas mixture is further enhanced by the increased respiration rates of the offending organism(s) while in the presence of the permeated O x gases.
Referring to FIG. 2, an apparatus that may be used to practice an embodiment of the method if the invention includes a biological burden reduction chamber 1 equipped with a gasketed door 2 that can be opened to accommodate placement of material 3 within the biological burden reduction chamber 1 and tightly closed and latched. The biological burden reduction chamber 1 permits a vacuum tight seal during the process. The chamber 1 is connected via piping and appropriate control valves 4 to a vacuum pump 5 and separately to a generator of O x 6 , which, in turn is connected to a gas washer 14 and an air preparation regulated feed gas supply 15 . The biological burden reduction chamber 1 is jacketed by coils of metal tubing 11 through which heated or chilled water generated by a temperature control (e.g., glycol) system 7 may be pumped to regulate the temperature within the chamber 1 during the biological burden reduction process. The entire biological burden reduction process may be controlled and monitored by a programmable industrial process controller 8 . The chamber 1 is also connected to a water vapor source 12 to provide humidity control.
According to an embodiment of the invention, material 3 for which biological burden is to be reduced is placed within the biological burden reduction chamber 1 and the door 2 is closed and latched. The process is then initiated by activating the process controller 8 , which has previously been programmed with the appropriate process parameters such as pressure, the specified temperature and humidity. The controller 8 first activates the vacuum pump 5 and ancillary valves 4 to reduce the biological burden reduction chamber pressure to a preset level between, e.g., 0 and 15 psia depending on the pressure sensitivity of the product being treated, to introduce via the water vapor source 12 the desired humidity, and to maintain a desired temperature via the temperature control system 7 . After the appropriate vacuum level has been reached, the controller 8 initiates biological burden reduction by activating the O x generator 6 and opening a control valve 10 , allowing the washed O x stream to be drawn into, through and out of the chamber 1 by the pressure differential. The vacuum pump 5 and O x generator 6 operate continuously during the process.
Exposure to the O x gas mixture may be varied in time from several minutes to several hours, depending on the material being treated. Once the biological burden reduction phase is complete, the vacuum pump 5 and O x generator 6 are inactivated and fresh air is allowed to enter the chamber 1 via the air purge valve 13 . All O x gases may then be passed through a commercially available catalytic destruct unit 9 which eliminates any residual O 3 and O 1 before the gas stream is discharged to the atmosphere. The treated material 3 can then be removed from the chamber 1 and is ready for use following appropriate tests to confirm biological burden reduction.
EXAMPLES
The present invention will be further illustrated by the following non-limiting Examples.
Example 1
The method of the invention is carried out using the VVP process as described above at a specified temperature range of 90° F. to 130° F. According to this example, the following adjustments to the VVP process for fumigation are made:
Vacuum Vapor
8-10 psia for pressure sensitive commodities like
Phase (VVP)
fresh fruits and vegetables, such as: papayas,
oranges, grapes, squash, bell peppers, and tomatoes.
0-6 psia for non pressure sensitive commodities like
spices and dehydrated vegetables, such as: black
pepper, cloves, nutmeg, diced bell peppers, minced
onion and garlic.
Exposure Time
0.5 to 3 hours.
O 3 concentration
500 to 15,000 ppm.
Feed Gas Blend
Concentration of oxygen (O 2 ), 0 to 100%.
Concentration of carbon dioxide (CO 2 ), 1-100%.
No adjustment for nitrogen (N 2 ), 0-70%.
No adjustment for Argon (Ar), 1-18%.
Temperature
90° F. to 130° F.
Humidity Control
Typically on the dryer side of the same non-
condensing range of 40% to 70% RH, control is less
critical, due to shorter treatment times.
Commodity Treated
Granulated Raw Sugar
Target Organism
Book Mites
VVP
6 psia
Feed Gas Blend
O 2 87% CO 2 10% N 2 3%
O 3 Concentration
10,000 ppm
Humidity
40%
Temperature
90° F.
Treatment Time
2 Hr
Observation After
100% elimination
Treatment
As can be seen from the above example, book mites, the target organism, were eliminated from granulated raw sugar by 100% in accordance with the method of the invention.
In addition to the increased applications and effectiveness seen when treating at warmer temperatures, several economical benefits for utilizing adjusted O x fumigation parameters can be achieved. These benefits stem from reducing the construction specifications for fumigation specific equipment. Chamber construction may now be from mild steel or epoxy coated mild steel as opposed to the much more expensive stainless steel. This is because lower O x concentrations are inherently less corrosive. Thus, all of the support equipment required for O x processing, i.e., the O x generator, the vacuum pump, the temperature and humidity control systems, can all be down-sized, lowering both their capital and operational costs.
Additional advantages that result from using increased treatment temperature for microbiological reduction and disinfestation include reductions in post-treatment odor, color loss and burn damage caused by condensation spotting. When treating pressure sensitive commodities like fresh fruits and several vegetables for microbiological reduction, the parameter adjustments listed above for fumigation have proven very effective.
Example 2
The method of the invention is carried out using the VVP process as described above at a specified temperature range of 90° F. to 130° F. According to this example, when using increased process temperature for microbiological reduction of nonsensitive small particle size commodities like spices, psyllium and dehydrated vegetables, the following adjustments should also be made:
Vacuum Vapor Phase
No adjustment. 1 -6 psia
Exposure Time
No adjustment. 0.5-20 Hr.
O 3 concentration
1500 to 6000 ppm.
Feed Gas Blend
No adjustment for O 2 . 0-100%.
Concentration of CO 2 , 1-100%.
No adjustment for N 2 , 0-70%.
No adjustment for Argon (Ar), 1-18%.
Temperature
90° F. to 130° F.
Humidity Control
Typically on the dryer side of the same
non-condensing gas range. 60%-80% RH.
Commodity Treated
Psyllium Husk
Target Organism
1.2 × 10 6 Bacillus Subtilis Spores
VVP
6 psia
Feed Gas Blend
O 2 2% CO 2 95% N 2 3%
O 3 Concentration
3,000 ppm
Humidity
64%
Temperature
127° F.
Treatment Time
20 Hr
Observation After Treatment
100% elimination
As can be seen from the above example, bacillus subtilis spores, the target organism, were eliminated from psyllium husk by 100% in accordance with the method of the invention.
Example 3
According to another embodiment of the invention, the VVP process as described is carried out using a unique gaseous mixture comprised primarily of CO 2 as well as smaller concentrations of O 3 , O 2 and carbon monoxide (CO). The gaseous mixture is preferably fed through an ozone generator such as described above where a gaseous blend is formed consisting of CO 2 , O 3 , O 2 and CO. This gaseous blend assists in the stabilization of the O 3 molecules by dampening the molecular collision of the O 3 molecules, which would degrade this triatomic form of oxygen back to its diatomic form, atmospheric oxygen. Several benefits have been observed by generating this gaseous blend. The first benefit is to “tame” the O 3 so it has a chance to penetrate into the interstitial spaces of the product being treated. In addition, the CO 2 acts as a non-polar solvent to assist in the penetration of the gaseous blend into the commodities. By reducing the residual oxygen levels equal to or below normal atmospheric levels, the oxidative damage to the commodity is highly reduced. The presence of high levels of CO 2 has been shown to enhance the effects of fumigants by promoting increased respiration in insects, thereby allowing the infusion of the fumigant into the insect spiracles and coming into direct contact with the insect's bodily fluids.
As an alternative, the CO 2 can be mixed into an O 3 rich gas flow immediately after the ozone generator to assist in the formation of the gaseous blend. According to this technique, no CO is formed since no CO 2 molecules are cleaved. A disadvantage of this system is the increased amount of oxygen required to produce the O 3 in the generator, which subsequently allows the O 3 to degrade at an accelerated rate.
Fumigation Parameters:
Vacuum Vapor Phase
8-10 psia for pressure sensitive
commodities like fresh fruits
and vegetables.
0-6 psia for non pressure sensitive
commodities like spices and
dehydrated vegetables.
Exposure Time
0.5 to 3 hours.
O 3 concentration
500 to 1500 ppm.
Feed Gas Blend
Concentration of oxygen (O 2 ), 0 to 20%.
Concentration of carbon dioxide (CO 2 ),
80-100%.
Temperature
45° F. to 60° F. or 90° F. to 130° F.
Humidity Control
40% to 70% RH.
Commodity Treated
Fresh Whole Green Banana
Target Organism
Nevada Fire Ants
VVP
10 psia
Feed Gas Blend
O 2 0% CO 2 100%
O 3 Concentration
525 ppm
Humidity
40%
Temperature
115° F.
Treatment Time
30 min
Observation After Treatment
100% elimination
As can be seen from the above example, Nevada fire ants, the target organism, were eliminated from fresh whole green banana by 100% in accordance with the method of the invention.
Sterilization Parameters:
Vacuum Vapor
8-10 psia for pressure sensitive commodities like
Phase
fresh fruits and vegetables.
0-6 psia for non pressure sensitive commodities like
spices and dehydrated vegetables.
Exposure Time
0.5 to 20 hours.
O 3 concentration
500 to 8000 ppm.
Feed Gas Blend
Concentration of oxygen (O 2 ), 0 to 20%.
Concentration of carbon dioxide (CO 2 ), 80-100%.
Temperature
45° F. to 60° F. or 90° F. to 130° F.
Humidity Control
40% to 70% RH.
Commodity Treated
Fresh Whole Strawberries
Target Organism
E. Coli >10 6
VVP
10 psia
Feed Gas Blend
O 2 2% CO 2 98%
O 3 Concentration
1337 ppm
Humidity
40%
Temperature
112° F.
Treatment Time
60 min
Observation After
Post treatment <10
Treatment
As can be seen from the above example, E. coli , the target organism, was eliminated from fresh whole strawberries by a factor of more than 10 5 in accordance with the method of the invention.
The gaseous blend of O x and method for applying the gaseous blend of O x of the invention are thus an excellent substitute for commercial sterilants and fumigants in all of its current uses and is also useful for the treatment of many food ingredients on which use of commercial sterilants and fumigants is not permitted, including cocoa beans, grains, and edible gums.
The gaseous blend of O x and method for applying the gaseous blend of O x of the invention have been shown to be highly insecticidal and are therefore a useful substitute for certain current uses of methyl bromide, which, as discussed herein, are soon to be banned under the direction of the Montreal Protocols of 1997.
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A gaseous blend of O x and a method for significantly reducing the biological load on consumer products such as food products, botanicals and cosmetic ingredients is disclosed. The gaseous blend of O x consists at least in part of O 3 . The method involves applying a continuous stream of oxygen-containing, i. e., O x , gas to a material at a predetermined temperature, pressure and relative humidity. The continuous stream of O x gas is prepared in an O x generation cell, which contains a means for generating the O x gas at a pressure less than 20 lbs/in 2 using, for example, one or more of the following: corona discharge, high frequency electrical discharge, ultraviolet light, x-ray, radioactive isotope and electric beam.
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BACKGROUND OF THE INVENTION
The present invention relates to brick alignment poles used by bricklayers and more particularly to a system of such poles.
Such poles have been used for many years for assisting bricklayers in aligning courses of brick and commonly are known as "dead man" poles. An exemplary brick alignment pole can be found in U.S. Pat. No. 4,144,649, the disclosure of which is expressly incorporated herein by reference. The brick alignment pole in such patent is a versatile tool which has properly performed according to its description under most circumstances. A notable circumstance under which such alignment pole, as well as all other conventional corner alignment poles, does not entirely achieve its intended result is when the brick wall under construction is of sufficient length such that the line strung between the corner poles has a serious sway in it. Under these circumstances accurate horizontal measurement of an individual course of brick is not possible about the center of the wall between the two corner poles. Thus, there is a need in the art for some means of insuring that the line tensioned between the corner poles remains uniformly horizontal for its entire length.
BROAD STATEMENT OF THE INVENTION
The present invention solves the foregoing problem for a system of poles for aligning courses of brick of a brick wall being constructed as a facing for a building structure construction wall. In such system of poles there is a pole disposed at each corner of said wall, each corner pole including adjustable means for securing said pole at said corners, a mason's rule carried adjustably by each corner pole, and a line block adjustably carried by each corner pole wherein a line is tensioned between each line block of each corner pole. The improvement of the present invention comprises at least one pole disposed intermediate between said corner poles. The intermediate pole has adjustable means for securing the pole to the brick wall and/or the construction wall, a mason's rule adjustably carried by said intermediate pole, and an intermediate line block for insuring that the line remains tensioned between the corner line blocks. All of the line blocks are synchronously adjusted in vertical height so that the tensioned line defines the horizontal component of each course of brick being laid.
A further feature of the present invention, wherein it is desired that a vertical half-brick recess in the wall be constructed, is an intermediate line block and template assembly carried by the intermediate pole wherein such assembly not only ensures that the line remains tensioned between the corner line blocks but also provides an accurate guide for laying such vertical recessed brick portion of the wall without the need for resorting to plumb lines or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a broken elevational view of a portion of the improved pole system of the invention showing a corner pole and an intermediate pole, both being mounted in operable position on a construction wall, the actual distance between said poles being interrupted in this drawing;
FIG. 2 is a fragmentary sectional view taken along line 2--2 of FIG. 1;
FIG. 3 is a fragmentary sectional view taken along line 3--3 of FIG. 1;
FIG. 4 is a fragmentary view of the apparatus of FIG. 2 taken from the front of the pole as shown in FIG. 1;
FIG. 5 is a fragmentary view of the apparatus of FIG. 2 taken from the opposite side of the view shown in FIG. 2;
FIG. 6 is a fragmentary view of the apparatus of FIG. 2 taken from the rear side of the pole adjacent the brick wall as shown in FIG. 1; and
FIG. 7 is a fragmentary view of the apparatus of FIG. 3 taken from the opposite side of the view shown in FIG. 3.
FIG. 8 is a fragmentary sectional view of an alternative intermediate line guide.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is designed to be used with a construction wall wherein courses of brick are being laid to form a brick wall facing. This is shown in particular in FIG. 1 as sheathing 11 having brick 13 as a brick wall facing thereon. The conventional corner brick alignment pole 15 is shown in FIG. 1 and generally is conventional in fashion. The preferred corner brick alignment pole is that pole shown in applicant's U.S. Pat. No. 4,144,649. Other possible corner brick alignment poles which may be used in conjunction with the present invention include those poles shown in U.S. Pat. Nos. 1,872,860; 2,761,214; 2,949,673; 3,063,152; 3,104,468; and 3,349,494. As to the preferred corner brick alignment pole for use in conjunction with the present invention, it presently is preferred to replace the mason's rule securing means and the line block attaching means shown in U.S. Pat. No. 4,144,649 with scale retainer 19 and line block 21 as will be more particularly shown and described in detail later herein.
Intermediate pole 17 shown in FIG. 1 preferably is attached at its lower and upper ends in the same fashion as shown for the attachment of the preferred corner poles in U.S. Pat. No. 4,144,649. Briefly, as to such attachment means, intermediate pole 17 like corner pole 15 contains an arm pivotally attached to the lower portion of the pole which allows pivoting of the arm at times about a horizontal axis with respect to the pole and for rigidly holding the arm at times in place with respect to the pole, and means for attaching the arm to the brick wall. Near the upper end of the pole is a nail bar of substantial length which is slidably attached thereto by a transversely projecting extension of the nail bar and there are means for rigidly clamping the extension to the pole and for allowing the extension to slide to other positions. Also, there are means for securing the nail bar to the building structure construction wall. The nail bar is adjustable relative to the pole axis in the two dimensions of a plane perpendicular to the axis and the extension of the nail bar is bifrucated to slide on each side of the attaching means. The attaching means preferably comprise a threaded nut connected to a stud on the pole. Again, reference is made to U.S. Pat. No. 4,144,649 for further elaboration on the details of the means for attaching the corner poles and the intermediate pole to the brick wall and/or construction wall.
Pole 23 preferably is rectangular and hollow in shape, and is metallic in construction. Mason's rule 25 is attached to intermediate pole 23 by scale retainers 19 and assembly 27. Mason's rule 25 is conventional in having a plurality of measurements engraved thereon including measurements indicating the depth of one brick and interposed between such measurements of one brick it has measurements of spacing between the bricks and the mortar layer for the bricks. Scale retainer 19 is a square collet preferably constructed of metal and having a thumbscrew therethrough for securing rule 25 to pole 23. As was mentioned above, it is preferred that such scale retainers be used for the corner poles also. Assembly 27 is shown in detail in FIGS. 2-7 and will be described in detail in connection with such drawings.
Intermediate line block and template assembly 27 as shown in FIG. 2 is composed of intermediate line block 29 and template 31. Intermediate line block 29 has line guide channel 33 (see also FIG. 6) at its end closest to the brick wall for retaining the line 39 which runs between the two corner poles. Line 39 (see FIGS. 3 and 6) is secured in line guide channel 33 by line retainer 35 which preferably is the same type of material used for the line. Line retainer 35 is connected about one of its ends at screw 37 then through slot 38 (FIG. 3) through hole 49 in template 31 and thence to convex washer 47 (FIG. 7) which is attached to square collet 41, which collet with thumbscrew 45 adjustably retains assembly 27 to pole 23. Template 31 (see also FIG. 3) is designed to enable the brick layer to lay a vertical line of brick 13b recessed one-half brick width (or any other desired width) from brick 13a which forms the brick wall being constructed. Such template eliminates three plumb points and makes for easy and efficient laying of the recessed brick. When no recess is necessary, line block 29 may be used sans template 31 as shown in FIG. 8. Note that corner line block 21 (FIG. 1) can be the same as intermediate line block 29 of FIG. 8.
As shown in FIG. 3, assembly 27 is attached to pole 23 by means of square collet 41 which has a permanent nut 43 attached thereto for receiving thumbscrew 45 therein. The thumb screw may be tightened into pressure contact with pole 23 for securing the assembly in place. Square collet 41 additionally retains rule 25 at this point. The intermediate pole is designed in size so that line 39 is intended to be one-eighth of an inch from the outer face of brick 13. The space between the brick and pole 23 is designed to be one inch. Additionally, template 31 is designed so that the one-eighth inch spacing from such template to brick 13a and 13b is maintained at the desired one-eighth inch spacing. Intermediate line block 29 is attached to template 31 by means of screws 53 shown in FIG. 7. Square collet 41 is attached to intermediate line block 29 by means of screws 51 shown in FIG. 5. The vertical height of line guide channel 33 in intermediate line block 39 is synchronously adjusted with end blocks 21 by means of thumbscrew 45 in square collet 41 so that line 39 is maintained in a tensioned condition defining the horizontal component of each course of brick being laid. This is especially helpful when the brick wall being constructed is of very great length.
Intermediate line block 29 and template 41 preferably are constructed of wood, though other durable materials of construction such as high-impact plastic or metal is acceptable. All other components of the intermediate pole preferably are of suitable metal construction as is common practice for such items in the construction industry for maintaining their durability and reliability of service.
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Disclosed is a system of poles for aligning courses of brick of a brick wall wherein there is a pole disposed at each corner of said wall and at least one pole disposed intermediate between said corner poles, all of said poles containing line blocks which carry a tensioned line therebetween, the line block on the intermediate pole for ensuring that the line remains tensioned between said corner line blocks and all of said line blocks being synchronously adjusted in vertical height so that said tensioned line defines the horizontal component of each course of brick.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an on-vehicle power generation controller which is mounted on a vehicle and is driven by an internal combustion engine. More specifically, the present invention relates to an on-vehicle power generation controller capable of controlling power generation by employing a plurality of generators having the same structures.
2. Description of the Related Art
Among conventional on-vehicle power generation controllers, an on-vehicle power generation controller has been equipped with a controller for controlling turning on and off of a field current so as to adjust a generated voltage to a predetermined voltage. Also, while a plurality of the above-mentioned on-vehicle power generation controllers are employed, there have been known systems in which a plurality of generators are driven at the same time by a single engine so as to simultaneously generate electric power (refer to, for instance, JP 3061700 B and JP 04-38131 A).
FIG. 8 is a circuit diagram showing a generally available on-vehicle power generation controller. First of all, a description is made of operations of the on-vehicle power generation controller equipped with the below-mentioned controller with reference to FIG. 8 . That is, the controller controls turning on and off of a field current so as to adjust a generated voltage to a predetermined voltage, and to control power generating operations of a generator. The on-vehicle power generation controller shown in FIG. 8 includes a generator 1 , a rectifier 2 , and a controller 3 , and in addition, is externally equipped with a battery 4 and a key switch 5 .
In such a case that an engine (not shown) is started, when the key switch 5 is closed (turned ON), a current is supplied from the battery 4 via the key switch 5 to a terminal “R” of the controller 3 . As a result, a current is supplied via a resistor 304 and a diode 305 to a base terminal (base electrode) of a transistor 309 , so the transistor 309 is brought into a conductive state.
Then, because a base current of a transistor 310 flows through a resistor 308 , the transistor 310 is brought into a conductive state, and thus, a current is supplied via a resistor 311 to a zener diode 312 . Since this current flows, a power supply “A” having a constant voltage may be constructed, while the constant voltage constitutes a power supply voltage of the controller 3 .
Then, a comparator 317 is brought into an operable state by the power supply “A”. The comparator 317 compares a voltage of an input terminal (+) corresponding to a constant reference voltage value with a voltage of another input terminal (−) to control a field current on-off control transistor 301 . The above-mentioned reference voltage value as to the input terminal (+) is obtained by dividing the constant voltage of the power supply “A” by resistors 315 and 316 . The voltage of another input terminal (−) is obtained in such a manner that the voltage of the battery 4 is monitored via an external sensing terminal “S”, and the monitored-voltage is sub-divided by resistors 313 and 314 .
Since the generator 1 has not yet generated electric power until the engine is started, a voltage of the input terminal (−) corresponding to the divided voltage of the battery 4 becomes lower than the voltage of the input terminal (+), so a “Hi” signal (namely, signal having high level) is outputted from the comparator 317 . As a result, the field current on-off control transistor 301 is brought into a conductive state, so a field current flows through a magnetic field coil 102 , and thus, the generator 1 is brought into an electric power generatable condition.
Next, when the engine is started, the power generating operation by the generator 1 is commenced, so a voltage at an output terminal 201 of the rectifier 2 is increased. Since the output voltage of the rectifier 2 is increased, the battery 4 is charged, so the voltage of the battery 4 is increased. As a result, if both the voltage at the sensing terminal “S” of the battery 4 and the voltage of the input terminal (−) corresponding to the divided voltage are increased higher than the voltage of the input terminal (+) corresponding to the reference voltage, then an output signal of the comparator 317 becomes a “Lo” output (namely, output signal having low level), so this “Lo” output may cut off the transistor 301 . Since the transistor 301 is operated by such a cut off mode, the field current which has flown through the magnetic field coil 102 is decreased, so the output voltage of the generator 1 is lowered.
When the output voltage of the generator 1 is lowered and the voltage of the input terminal (−) of the comparator 317 becomes lower than the voltage of the input terminal (+) thereof, the comparator 317 again outputs the “Hi” signal, so the transistor 301 is brought into the conductive state. Since a series of the above-mentioned operation is repeatedly carried out, the output voltage of the generator 1 is adjusted and controlled to become the constant voltage value.
Also, the controller 3 is equipped with a terminal “M” for outputting a field current on-off control signal, by which signals can be outputted outside the controller 3 when the transistor 301 is conductive. As a result, the signals synchronized with the operations of the transistor 301 can be outputted from the terminal “M”, so the “Hi” signal is outputted from the terminal “M” when the transistor 301 is conductive, whereas the “Lo” signal is outputted from the terminal “M” when the transistor 301 is cut off.
In such a case where even maximum output power derived from one generator 1 is not sufficient for all of electric loads required by an engine, there are some possibilities that the plurality of generators 1 having the same structures may be operated with respect to a single engine. FIG. 9 is a structural diagram showing a conventional on-vehicle power generation controller under such a condition that the plurality of generators 1 are operated with respect to a single engine. In FIG. 9 , two on-vehicle power generation controllers containing two generators having the same structures are exemplified, while a first on-vehicle power generation controller is indicated as “G 1 ” and a second on-vehicle power generation controller is indicated as “G 2 .”
When the plurality of generators 1 constructed in the same manners are operated at the same time by a single engine so as to simultaneously generate electric power, conductive states of the transistors 301 provided in the respective controllers 3 are not identical to each other due to various sorts of factors, for instance, variations in adjusted voltages of the controllers 3 caused by manufacturing variations, differences of wiring lines between a battery and the power generation controllers, which are produced when the power generation controllers are mounted on the single engine.
FIG. 10 is a diagram showing operation waveforms at respective units employed in controllers in such a case where a plurality of generators having the same structures are driven at the same time by a single engine so as to simultaneously generate electric power. More concretely, the operation waveforms show states at the terminal “R”, the transistor 301 , and the terminal “M” employed in the controller 3 as to each of the two on-vehicle power generation controllers “G 1 ” and “G 2 ” previously shown in FIG. 9 .
As shown in FIG. 10 , due to the various factors, the conductive states of the transistors 301 provided in the respective controllers 3 are not identical to each other. As a result, there is such a problem that because the power generating conditions of the two generators are not equal to each other, the voltages become unstable.
Also, for instance, there is a problem that, in the case where such a condition that an electric power generating condition of only one generator is increased among a plurality of on-vehicle power generation controllers is continued, a lifetime of the one generator becomes short, as compared with lifetimes of other generators. Further, there is another problem that, in connection with the fluctuation of the lifetimes, longer times and higher costs are required for maintenance and the like, as compared with those of the conventional system.
As solving ideas for the above-mentioned problems, there have been proposed certain structures in which unbalanced conditions of the respective generators are to be adjusted (refer to, for instance, JP 3061700 B and JP 04-38131 A).
However, the conventional technologies have the below-mentioned problems.
That is, in the conventional technologies disclosed in JP 3061700 B and JP 04-38131 A, the structures of the on-vehicle power generation controllers are complex. As a result, the conventional technologies have such a problem that the costs as to the on-vehicle power generation controllers themselves are increased, or the structures as to the plurality of the generators are not made identical to each other.
SUMMARY OF THE INVENTION
The present invention has been made to solve the above-mentioned problems, and has an object to provide an on-vehicle power generation controller capable of uniformly maintaining balance of electric power generated by a plurality of generators, and also capable of realizing a less expensive controller structure.
An on-vehicle power generation controller according to the present invention includes a controller for adjusting a generated voltage to a predetermined voltage by controlling turning on and off of a field current so as to control an electric power generating operation of a generator. In a case where at least two on-vehicle power generation controllers are mounted with respect to a single engine, when respective generators corresponding to the at least two on-vehicle power generation controllers are operated at the same time, each of second and succeeding on-vehicle power generation controllers controls the electric power generating operation of each of the respective generators based upon a field current on-off control signal output in a first on-vehicle power generation controller.
According to the present invention, second and succeeding controllers perform power generation control operations based upon a field current on-off control signal outputted from a first controller. As a result, it is possible to realize the on-vehicle power generation controller capable of uniformly maintaining the balance of the electric power generated from the plurality of generators, and also capable of realizing a less expensive controller structure.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a circuit diagram of an on-vehicle power generation controller according to a first embodiment of the present invention;
FIG. 2 is a diagram showing operation waveforms at respective units of the on-vehicle power generation controller according to the first embodiment of the present invention in such a case where a plurality of generators having the same structures are driven at the same time by a single engine so as to simultaneously generate electric power;
FIG. 3 is a structural diagram of the on-vehicle power generation controller according to the first embodiment of the present invention in such a case where three generators are driven with respect to the single engine;
FIG. 4 is a structural diagram of an on-vehicle power generation controller according to a second embodiment of the present invention in such a case where three generators are driven with respect to a single engine;
FIG. 5 is a structural diagram of an on-vehicle power generation controller according to a third embodiment of the present invention in such a case where a plurality of generators are driven with respect to a single engine;
FIG. 6 is a circuit diagram showing a method of deriving a field current on-off control signal in an on-vehicle power generation controller according to a fourth embodiment of the present invention;
FIG. 7 is a circuit diagram showing another method of deriving the field current on-off control signal in the on-vehicle power generation controller according to the fourth embodiment of the present invention;
FIG. 8 is a circuit diagram of the generally available on-vehicle power generation controller;
FIG. 9 is a structural diagram of the conventional on-vehicle power generation controller in such a case where the plurality of generators are driven with respect to a single engine; and
FIG. 10 is a diagram showing the operation waveforms at the respective units of the controller in such a case where the plurality of generators having the same structures are driven at the same time by the single engine so as to simultaneously generate the electric power.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to drawings, a description is made of an on-vehicle power generation controller according to preferred embodiments of the present invention.
First Embodiment
FIG. 1 is a circuit diagram showing on-vehicle power generation controllers according to a first embodiment of the present invention. Namely, FIG. 1 shows a concrete circuit structure in such a case where two generators 1 a and 1 b are controlled. An internal basic structure of each of the on-vehicle power generation controllers is identical to the previously described structure of FIG. 8 . It should be noted that in the description of FIG. 1 and the below-mentioned descriptions, in order to distinguish two on-vehicle power generation controllers from each other, a suffix “a” has been applied to respective circuit elements employed in a first on-vehicle power generation controller, whereas another suffix “b” has been applied to respective circuit elements employed in a second on-vehicle power generation controller.
It should also be noted that although each internal structure as to a first controller 3 a and a second controller 3 b is identical to the internal structure of the previously described controller 3 shown in FIG. 8 , the former is omitted in FIG. 1 .
As shown in FIG. 9 , in the structure of the conventional technology in such a case where the plurality of on-vehicle power generation controllers are employed, the terminals “R” of the respective controllers 3 are commonly connected to the key switch 5 . In contrast to this conventional technology, in the structure of the first embodiment, as shown in FIG. 1 , a terminal “R” of the first controller 3 a is connected to the key switch 5 , whereas a terminal “R” of the second controller 3 b is connected to a terminal “M” for outputting a field current on-off control signal of the first controller 3 a.
Since the wiring lines of the on-vehicle power generation controllers are arranged in the above-mentioned manner, in the case where a transistor 301 a provided in the controller 3 a is brought into a conductive state because the first generator 1 a starts to generate electric power, a current is supplied from the terminal “M” of the first controller 3 a via a resistor 303 a to a terminal “R” of the second controller 3 b . As a result, only when the transistor 301 a of the first controller 3 a is in the conductive state, the second controller 3 b is operable, so a transistor 301 b is brought into a conductive state.
Conversely, when the transistor 301 a of the first controller 3 a is in the cut off state, the second controller 3 b is not operable, so the transistor 301 b is brought into the cut off state. As a result, conduction ratios as to the transistors 301 a and 301 b of the respective controllers 3 a and 3 b are controlled to become substantially equal to each other, so power generating balance of the two generators 1 a and 1 b can be uniformly maintained.
FIG. 2 is a diagram showing operation waveforms at respective units of the on-vehicle power generation controller according to the first embodiment of the present invention in such a case where the plurality of generators having the same structures are driven at the same time by a single engine so as to simultaneously generate electric power. More concretely, the operation waveforms show states as to the terminal “R”, the transistors 301 a and 301 b , and the terminal “M” employed in each of the two controllers 3 a and 3 b shown in FIG. 1 .
In comparison with the above-mentioned operation waveforms of the conventional technology as shown in FIG. 10 , in FIG. 2 , the conduction of the transistor 301 a employed in the first controller 3 a and the conduction of the transistor 301 b employed in the second controller 3 b occur at the substantially same timing. As a result, it can be seen that the power generating balance is kept uniform.
Since the terminals “R” as to the second and succeeding controllers are connected to the terminal “M” as to the first controller in the above-mentioned structural manner, even when a total number of generators mounted on a single engine is increased to 3 or more, the electric power generation can be controlled while the power generating balance can be uniformly maintained.
FIG. 3 is a structural diagram of the on-vehicle power generation controller according to the first embodiment of the present invention in such a case where three generators are driven with respect to a single engine. As described above, each of terminals “R” as to a second on-vehicle power generation controller “G 2 ” and a third on-vehicle power generation controller “G 3 ” is connected to a terminal “M” as to a first on-vehicle power generation controller “G 1 ”, so the conductions of the transistors with respect to all of these three on-vehicle power generation controllers “G 1 ”, “G 2 ”, and “G 3 ” can occur at the substantially same timing.
Although FIG. 3 exemplifies such a case where the three generators are mounted, even when the number of the generators is increased, the same control operation can be carried out. Also, because all of the structures of the on-vehicle power generation controllers “G 1 ”, “G 2 ”, and “G 3 ” themselves are identical to the structure of the conventional on-vehicle power generation controller, only external wiring lines are shown in FIG. 3 .
As described above, according to the first embodiment, the following structure has been employed: in the case where the plurality of generators having the same structures are employed to be driven by a single engine at the same time so as to simultaneously generate the electric power, the terminals “R” as to the second and succeeding controllers are connected to the terminal “M” as to the first controller. As a consequence, while the power generating balance of the plurality of generators can be uniformly maintained, the power generating operation can be controlled, so the power generating conditions of the plurality of generators can be stabilized.
In addition, because the power generating conditions of the plurality of generators can be balanced, deviations in product lifetimes may be decreased, so maintenance timing thereof can be readily judged. Moreover, the structures of the plurality of generators can be made identical to each other, and both the variations in adjusted voltages of the generators and the structures of the vehicle wiring lines do not need to be considered. Also, such a complex apparatus for adjusting the respective power generating conditions is no longer required, and the costs of the on-vehicle power generation controllers can be reduced.
In addition, the initiation signals of the generators other than the first on-vehicle power generation controller are connected to the signal output terminal as to the first on-vehicle power generation controller arranged at a close position thereto. As a result, the lengths of the wiring lines can be shortened, so the cost of the entire apparatus can be further decreased.
Second Embodiment
In a second embodiment of the present invention, a description is made of a structure of an on-vehicle power generation controller which is different from that of the previously described first embodiment in order to realize a control operation capable of uniformly maintaining balance of electric power generated by three or more generators. FIG. 4 is a structural diagram when three generators are driven at the same time with respect to a single engine in the second embodiment of the present invention.
In the above-mentioned first embodiment, the following structure of the on-vehicle power generation controller has been employed: in such a case where the plurality of generators having the same structures are driven by the single engine at the same time so as to simultaneously generate the electric power, the terminals “R” as to the second and succeeding controllers are connected to the terminal “M” as to the first controller. In contrast thereto, in this second embodiment, in such a case that the plurality of generators having the same structures are driven by the single engine at the same time so as to simultaneously generate electric power, each of the terminals “R” as to the second and succeeding controllers is connected to each of the corresponding terminals “M” of controllers provided at preceding stages thereof.
FIG. 4 is a structural diagram when three generators are driven with respect to the single engine in the second embodiment of the present invention. As shown in FIG. 4 , a terminal “R” as to a second on-vehicle power generation controller “G 2 ” is connected to a terminal “M” as to a first on-vehicle power generation controller “G 1 ” provided at a preceding stage thereof. Further, a terminal “R” as to a third on-vehicle power generation controller “G 3 ” is connected to a terminal “M” as to the second on-vehicle power generation controller “G 2 ” provided at a preceding stage thereof. Even in such a case where the on-vehicle power generation controllers “G 1 ”, “G 2 ”, and “G 3 ” are connected as described above, in the same manner as the connection shown in FIG. 3 in the first embodiment, transistor conductions with respect to all of these three on-vehicle power generation controllers “G 1 ”, “G 2 ”, and “G 3 ” can occur at the substantially same timing.
Although FIG. 4 exemplifies such a case where the three generators are mounted, even when the number of the generators is increased, the same control operation can be carried out. Also, because all of the structures of the on-vehicle power generation controllers “G 1 ”, “G 2 ”, and “G 3 ” themselves are identical to the structure of the conventional on-vehicle power generation controller, only external wiring lines are shown in FIG. 4 .
As described above, according to the second embodiment, in the case where the plurality of generators having the same structures are driven by the single engine at the same time so as to simultaneously generate the electric power, even when each of the terminals “R” as to the second and succeeding controllers is connected to each of the corresponding terminals “M” as to the controllers provided at the preceding stages thereof, a similar effect to that of the previously described first embodiment may be achieved.
Third Embodiment
In a third embodiment of the present invention, a description is made of a structure of an on-vehicle power generation controller which is different from those of the previously described first and second embodiments in order to realize a control operation capable of uniformly maintaining balance of electric power generated by a plurality of generators. FIG. 5 is a structural diagram of on-vehicle power generation controllers when the plurality of generators are driven at the same time with respect to a single engine in the third embodiment of the present invention. Namely, FIG. 5 exemplifies such a case where three generators are driven by the single engine.
In the previously described first and second embodiments, the voltage sensing terminals “S” as to all of the plurality of controllers are connected so as to monitor the voltage of the battery 4 . In contrast thereto, in this third embodiment, only a voltage sensing terminal “S” as to a first on-vehicle power generation controller “G 1 ” is connected so as to monitor a voltage of a battery 4 , whereas voltage sensing terminals “S” as to second and succeeding on-vehicle power generation controllers “G 2 ” and “G 3 ” are not connected to the battery 4 . Also, similar to the previously described first embodiment, terminals “R” as to the second and succeeding on-vehicle power generation controllers “G 2 ” and “G 3 ” are connected to the terminal “M” as to the first on-vehicle power generation controller “G 1 ”.
As described above, even when such a structure is made that the voltage-sensing monitor terminals of the second and succeeding controllers “G 2 ” and “G 3 ” are not connected, or even when such a structure is made that the second and succeeding controllers “G 2 ” and “G 3 ” do not have voltage adjusting functions themselves, because the second and succeeding controllers “G 2 ” and “G 3 ” employ the output signal from the terminal “M” of the first controller “G 1 ” which is operated while considering the voltage sensing function thereof, the second and succeeding controllers “G 2 ” and “G 3 ” can perform the same control operations (namely, control operations equipped with voltage sensing functions) as the control operation for the first controller “G 1 ”.
As described above, according to the third embodiment, even in such a case where the second and succeeding controllers “G 2 ” and “G 3 ” open the terminals “S” thereof, the output signal from the terminal “M” as to the first controller “G 1 ” is acquired by the terminals “R” of the second and succeeding controllers “G 2 ” and “G 3 ”, so the second and succeeding controllers “G 2 ” and “G 3 ” can perform the control operations having the voltage adjusting function provided in the first controller “G 1 ”. As a consequence, the second and succeeding controllers “G 2 ” and “G 3 ” themselves can be constructed in such a simple structure without having the voltage adjusting function (voltage monitoring function). Accordingly, the costs of the on-vehicle power generation controllers “G 2 ” and “G 3 ” can be further reduced.
It should also be noted that, with reference to FIG. 5 , the description has been made of the structure in which, similar to the previously described first embodiment, the terminals “R” as to the second and succeeding controllers “G 2 ” and “G 3 ” are connected to the terminal “M” as to the first controller “G 1 ”. However, similar to the previously described second embodiment, even when the terminals “R” as to the second and succeeding controllers are connected to the terminals “M” of the controllers provided at the preceding stages thereof, the same control operations (namely, control operations equipped with voltage sensing functions) as that for the first controller can be carried out, so a similar effect can be achieved.
Fourth Embodiment
In a fourth embodiment of the present invention, a description is made of various methods of deriving field current on-off control signals. In the on-vehicle power generation controllers according to the above-mentioned first to third embodiments, the field current on-off control signals are directly outputted from the field current on-off control transistor 301 via the resistor 303 to the terminals “M” thereof.
However, the methods of deriving the field current on-off control signal are not limited only to the above-mentioned control signal deriving method. FIG. 6 is a circuit diagram showing a method of deriving the field current on-off control signal according to the fourth embodiment of the present invention. As shown in FIG. 6 , it is possible to provide such a structure that the field current on-off control signal is directly outputted from a control signal portion of the field current on-off control transistor 301 via the resistor 303 to the terminal “M”.
Also, FIG. 7 is a circuit diagram showing another method of deriving the field current on-off control signal according to the fourth embodiment of the present invention. As shown in FIG. 7 , it is also possible to provide such a structure that the field current on-off control signal is directly outputted from another transistor 318 which is operated in the same manner as that of the above-mentioned field current on-off control transistor 301 via the resistor 303 to the terminal “M”.
As described above, according to the fourth embodiment, the field current on-off control signal can be derived to the external terminal by executing the various sorts of connecting methods. In addition, even when the field current on-off control signals derived by any one of these various sorts of connecting methods are employed, a similar effect to those of the previously described first to third embodiments can be achieved.
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Provided is an on-vehicle power generation controller capable of uniformly maintaining balance of electric power generated by a plurality of generators, and also capable of realizing a less expensive controller structure. The on-vehicle power generation controller includes a controller ( 3 ) which adjusts a generated voltage to a predetermined voltage by controlling turning on and off of a field current so as to control an electric power generating operation of a generator. In a case where at least two on-vehicle power generation controllers are mounted with respect to a single engine, when respective generators ( 1 a, 1 b ) corresponding to the at least two on-vehicle power generation controllers are operated at the same time, each of second and succeeding on-vehicle power generation controllers controls the electric power generating operation of each of the respective generators ( 1 a, 1 b ) based upon a field current on-off control signal output in a first on-vehicle power generation controller.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention disclosed and claimed herein generally pertains to a security locking apparatus and method for portable computers, wherein the invention provides enhanced adaptability. More particularly, the invention pertains to apparatus of the above type wherein a portable computer that is locked in place may be released by a program running on the computer. Even more particularly, the invention pertains to apparatus of the above type wherein a locked portable computer can be released either by a program running on the computer, or by manually unlocking a conventional security lock.
[0003] 2. Description of the Related Art
[0004] Laptop computers, notebook computers and other portable computer devices typically have high monetary value, often on the order of $1,000 or more. At the same time, portable computers are intentionally designed to be as mobile as possible, to enable users to easily move them from one location to another. Accordingly, it has been necessary to develop security locking systems for portable computers, to prevent their theft or other unauthorized removal from a site of use.
[0005] In conventional locking systems of the above type, locks typically consist of a cable terminated in a standardized “Universal Security Slot” (USS) locking tab. Nearly all laptop computers and docking stations made today incorporate a USS compatible slot. Security locking devices and cables that can be used with a USS compatible slot are referred to herein as “USS locking devices”. Such devices are available with either tamper-resistant keys or rotary combination locks.
[0006] A significant problem with USS locking devices is that they generally must be unlocked manually, in order to remove the computer from a current location. However, when the computer is used in and locked to a docking station or port replicator, there are often accessibility problems with unlocking the device for removal. For example, the portable computer may be positioned so that a keyhole or combination lock dial is awkward to reach, or is blocked by stationary adjacent structure. Moreover, if quick removal is required, even readily accessible locations of a USS locking device generally will still require using a key or dialing in a combination to release the computer. Frequently, neither of these methods is particularly quick or easy.
SUMMARY OF THE INVENTION
[0007] The invention generally provides an apparatus and method wherein a solenoid within a portable computer or docking station is used in connection with a conventional USS, and the solenoid may be controlled by a program running on the computer. Such solenoid, in its non-energized state, provides a slot compatible for use with manual USS locking devices of the types currently available. When energized, the solenoid expands the width of the USS slot, such that even a locked cable may be removed therefrom. Activation of the solenoid may be controlled by a computer security chip, such as is currently built into many or most laptop computers. A useful embodiment of the invention is directed to a portable computer security apparatus. Such apparatus includes a locking mechanism having a user interface and a locking element, wherein the locking element is movable from a lock mode to an unlock mode in response to operation of the user interface. The security apparatus further includes a component joined to the portable computer proximate to a slot disposed to receive the locking element, the component being adjustable between locking element hold and release configurations. The received locking element is fixably retained in the slot only when the locking element is in the locked mode, and the component is in the hold configuration. The apparatus further comprises a device that is actuated to adjust the slot, from the hold configuration to the release configuration, in response to a command generated by a specified program running on the computer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a block diagram showing a data processing system and solenoid that are contained in a portable computer and configured to implement an embodiment of the invention.
[0009] FIG. 2 is a flow chart depicting tasks or steps carried out by a program running on the computer of FIG. 1 , in implementing an embodiment of the invention.
[0010] FIGS. 3A and 3B depict information presented to a user in connection with certain steps shown in FIG. 2 .
[0011] FIG. 4 is a perspective view showing a portable computer for containing the data processing system and solenoid of FIG. 1 .
[0012] FIGS. 5 and 6 are views showing a USS locking device and compatible slot for the computer of FIG. 4 , and further showing the solenoid of FIG. 1 adjusting a mechanical component located at the slot entrance to hold and release positions, respectively.
[0013] FIGS. 7 and 8 show views taken along lines 7 - 7 of FIG. 5 and along lines 8 - 8 of FIG. 6 , respectively, in relation to the computer of FIG. 4 .
[0014] FIGS. 9 and 10 are views showing the device, slot and solenoid of FIGS. 5 and 6 , and further showing another embodiment of the mechanical component, adjusted to hold and release positions, respectively.
[0015] FIGS. 11 and 12 show views taken along lines 11 - 11 of FIG. 9 and lines 12 - 12 of FIG. 10 , respectively, in relation to the computer of FIG. 4 .
[0016] FIGS. 13 and 14 are views showing the locking device, slot and mechanical component of FIGS. 9 through 12 , wherein the mechanical component is adjusted to hold and release positions by a solenoid having a rotary, rather than a linear, actuator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] Referring to FIG. 1 , there is shown a block diagram of a generalized data processing system 100 , adapted for use in implementing an embodiment of the invention. System 100 exemplifies a data processing system that may be found in various types of portable computers, in which code or instructions for implementing the processes of the present invention may be located. The term “portable computer” is defined and used herein to mean any computer or data processing device that can be readily moved from one place to another, such as by a single user. Such term includes laptop computers, notebook and sub-notebook computers, hand-held computers, palmtops and personal digital assistants (PDA's), but is not limited to such devices.
[0018] Data processing system 100 usefully employs a peripheral component interconnect (PCI) local bus architecture. FIG. 1 shows a processor 102 and main memory 106 coupled through a host bridge 104 to a bus 108 . Host bridge 104 also includes a memory controller for processor 102 . FIG. 1 further shows bus 108 connected to a file storage adapter 110 , a local area network (LAN) adapter 112 and a video adapter 114 .
[0019] Referring further to FIG. 1 , there is shown a local I/O bus control 116 likewise connected to bus 108 . By means of a local bus 132 , a keyboard mouse adapter 118 , an integrated audio adapter 120 and a clock and CMOS memory 122 are respectively connected to I/O bus control 116 , and therethrough to other components of data processing system 100 .
[0020] A security control element 124 , also connected to I/O bus control 116 , is provided for use in implementing an embodiment of the invention, as described hereinafter in further detail. Security control 124 is coupled to operate a solenoid driver 126 , which is provided to selectively energize and de-energize a solenoid 128 or other linear or rotary actuator device. Solenoid 128 is provided with a plunger 130 or like elongated element, constrained to move linearly in response to successive energizations and de-energizations of solenoid 128 . Alternative embodiments may include a rotary solenoid provided with a rotational element which turns in response to successive energizations and de-energization of the solenoid.
[0021] Security control element 124 may include a biometric sensor or other security chip interfaces. Such devices are increasingly used to confirm that someone using or operating a computer is authorized to do so. A fingerprint access device would be one example of a biometric sensor that could be used in security control element 124 . Such device scans the fingerprint of a prospective user, and compares the scan with authorized user fingerprints. Other types of security chips or biometric sensors could be used in connection with security control element 124 .
[0022] In concert with the security chip or biometric sensor of security control 124 , a software user interface program is installed on data processing system 100 , for use in releasing a portable computer security lock. As described hereinafter in further detail, in connection with FIG. 2 , this lock release program is configured to allow a user to select or define a password, and also to specify a time period. When the user enters the password into system 100 and the password is verified, a signal is sent to security control 124 . If the user has also been confirmed or positively identified by the security chip, security control 124 would be operated to send an energization signal {acute over (α)} to the solenoid driver 126 . Driver 126 would then supply power to energize solenoid 128 , whereupon plunger 130 would be moved linearly or rotationally. The solenoid would remain energized for the time period specified by the user, which usefully could be on the order of 15 seconds. The solenoid 128 , under control of the security control 124 , remains powered for the set time duration, even if the system 100 enters standby mode or is shut down.
[0023] It will be seen that by providing the security control 124 , the solenoid 128 , and the lock release program installed to run on a portable computer, mechanical movement of element 130 can be generated by simply entering the password. As described hereinafter in connection with FIGS. 5-14 , the solenoid element with rotor or plunger 130 is coupled to vary a slot dimension for a conventional USS locking device, used to secure the computer to a docking station or other stationary structure. More particularly, energization of solenoid 128 moves rotor or plunger 130 to change or expand dimensions of the slot used to receive and retain the locking element of the USS device. The locking element may then be removed from the slot, to unlock or release the portable computer, even though the USS locking device remains in a locked condition. This removal action must be taken during the specified time period, or the solenoid rotor or plunger 130 will return to its de-energized position. Moreover, the means for unlocking the conventional USS device, such as a manual key or combination lock dial, can still be operated by a user to release the portable computer. It is thus seen that embodiments of the invention do not require any changes or modifications to a conventional USS locking device used therewith.
[0024] Referring to FIG. 2 , there is shown a flow chart illustrating respective steps taken by a user in interacting with a lock release program as described above, when such program is running on system 100 to control operation of solenoid 128 . After beginning a program sequence to unlock the portable computer security device, the program causes virtual buttons to appear on the computer monitor or other user interface. The program then waits for the user to select one of the virtual buttons as shown by function block 202 . Function blocks 204 - 206 indicate that three different buttons may be selected for directing the lock release program to perform one of three sequences. Selecting the OK button, as indicated by function block 204 , commences a sequence to energize solenoid 128 as described above. Selecting the Cancel button results in immediately exiting the program, as shown by function block 206 . Function block 208 indicates that selection of Configure button 208 commences a configuration dialogue sequence, as described hereinafter.
[0025] Referring to FIG. 3A , the three buttons associated with function blocks 204 - 208 are respectively represented as they appear to a user on a computer viewing screen. Thus, FIG. 3A depicts OK button 302 and the locations 304 and 306 of the Cancel and Configure buttons, respectively. FIG. 3A further shows a window 308 wherein the password is to be entered to energize the solenoid 128 . After the password has been inserted into window 308 , the OK button is operated to commence a lock release sequence. As is the case in most computer programs, keyboard keys may be used to provide an alternate user input means for button operation.
[0026] Referring further to FIG. 2 , decision block 210 indicates that after the lock release sequence has been started, the program determines whether or not the password is correct. If not, the sequence returns to its beginning at function block 202 . The screen shown in FIG. 3A will then reappear, to allow the user to enter the correct password. However, if the initial password is found to be correct at decision block 210 , a signal is generated to energize the solenoid 128 or other linear or rotary actuator, as described above. This is shown by function block 212 . Thereupon a timer is started, as indicated by function block 214 , to limit energization to the specified time period. Expiration of the time period is continually monitored, as shown by decision block 216 . Device 128 is de-energized or turned off when the period expires, as shown by function block 218 , and the sequence comes to an end. Blocks 216 and 218 may be implemented by the control program or security control element or both in implementation variations of this invention.
[0027] Referring again to FIG. 2 , function block 220 indicates that a configuration dialogue is opened, when the configure button is selected. This will enable a user to change the password or the time-out time, that is, the time that the solenoid is energized. After opening the configuration dialogue, the program causes virtual buttons pertaining to this sequence to appear on the viewing screen, as shown by function block 222 . The program then waits for the user to select one of the virtual buttons so presented. FIG. 3B indicates that both OK and Cancel buttons may be displayed allowing user selection at locations 310 and 312 , respectively. This is also shown by function blocks 224 and 226 of FIG. 2 . If the Cancel button is selected, the configuration dialog is closed. If the OK button is selected, decision block 228 of FIG. 2 indicates that the software program determines whether or not the password is to be changed.
[0028] Referring further to FIG. 3B , there are shown windows 314 - 318 , for respectively displaying the old password and entering and confirming a new password. Thus, if the password is to be changed or updated, the user carries out this task, represented in FIG. 2 by function block 230 , by entering the new password in both windows 316 and 318 .
[0029] FIG. 2 further shows a function block 232 following decision block 228 , wherein function block 232 pertains to updating the time out or time period of solenoid energization. Such time-out may be readily changed, by entering the new period at window 320 , shown in FIG. 3B . Thereafter, the configuration dialogue is closed, as indicated by function block 234 .
[0030] Referring to FIG. 4 , there is shown a laptop or other portable computer 400 , configured to contain respective components shown in FIG. 1 including data processing system 100 , security control 124 , solenoid driver 126 and solenoid 128 with its plunger 130 . Portable computer 400 is provided with a keyboard 402 and monitor 404 for use by a computer user or operator. FIG. 4 also shows a locking mechanism 406 , comprising a conventional USS locking device. Locking mechanism 406 is inserted into a USS compatible slot formed in portable computer 400 (not shown in FIG. 4 ) and is thus releasably locked to the computer.
[0031] FIG. 4 further shows one end of a flexible steel cable 408 firmly attached to locking mechanism 406 . An eye is formed in the other end of cable 408 , by means of a steel sleeve 414 . Accordingly, cable 408 can be looped through a hole or aperture formed through stationary structure 410 , as shown in FIG. 4 , in order to secure portable computer 400 to the structure 410 . Computer 400 thus cannot be removed from the location shown in FIG. 4 , without either cutting cable 408 or removing locking mechanism 406 from the computer. FIG. 4 shows a key 412 that can be used to manually unlock the mechanism 406 , in conventional manner, so that it can be removed. Alternatively, the solenoid 128 may be energized as described above, to expand the slot that holds locking mechanism 406 . The locking mechanism 406 may then be removed from engagement with computer 400 . Operation of the solenoid to expand the slot, in accordance with embodiments of the invention, is described hereinafter in further detail in connection with FIGS. 5-12 .
[0032] Referring to FIG. 5 , there is shown solenoid 128 and a plunger 500 in a de-energized mode, wherein the plunger is constrained to move linearly. There is further shown a spring 502 in a relaxed or unstressed condition. Spring 502 is joined to plunger 500 to receive forces therefrom and apply forces thereto, along the direction of plunger movement. It will be readily apparent that spring 502 will always act to return and maintain plunger 500 in the position shown in FIG. 5 , in the absence of any counter forces.
[0033] FIG. 5 further shows an end of plunger 500 attached to an adjustable mechanical component 504 by means of a pivotable pin 506 . Component 504 comprises elongated links 504 a and 504 b , each having one end joined to plunger 130 by pin 506 . The opposing ends of links 504 a and b are respectively joined to ends of arms 504 c and 504 d , by pivotable pins 508 a and 508 b . Arms 504 c and d are restrained to pivot about pivot points 510 a and 510 b , respectively. Arms 504 c and d are also respectively provided with slot edge members 512 a and 512 b , wherein the spacing between the two slot edge members is selectively adjusted by pivoting arms 504 c and 504 d.
[0034] Referring further to FIG. 5 , there is shown USS locking device 406 provided with a rotatable shaft 514 , and with a locking tab or locking element 518 . FIG. 5 shows the shaft 514 and locking element 518 extending downward into a slot 516 . It will be readily apparent that the width of the entrance to the slot, wherein the slot entrance is adjacent to locking device 406 , is determined by the spacing between slot edge members 512 a and 512 b . FIG. 5 and FIG. 7 together show that locking element 518 is elongated, and has a length greater than the spacing between edge members 512 a and b that is shown in FIGS. 5 and 7 . Thus, when locking element 518 and arms 504 c and d of component 504 are respectively positioned as shown in FIG. 5 , locking mechanism 406 cannot be removed from slot 516 . In a preferred embodiment, the spacing between the slot edge members 512 a and b shown in FIGS. 5 and 7 is equal to the width of the entrance to a USS compatible slot.
[0035] Referring further to FIG. 7 , it will be seen that if shaft 514 and locking element 518 are rotated by 90 degrees, locking element 518 can readily be removed from slot 516 . The shaft and locking element can be rotated, simply by unlocking the locking mechanism 406 using conventional manual means, such as key 412 .
[0036] Referring to FIGS. 6 and 8 together, there is shown solenoid 128 energized, whereby plunger 500 is moved downward as viewed in FIG. 6 . This action pivots arms 504 c and d of structure 504 to increase the spacing between slot edge members 512 a and 512 b . The increased spacing is large enough to allow locking element 518 to be withdrawn from slot 516 , even though locking mechanism 406 remains locked, and locking element 518 remains oriented as shown in FIGS. 6 and 8 . Thus, energizing solenoid 128 enables locking mechanism 406 to be released from computer 400 , even though locking mechanism 406 itself remains in a locked mode. Moreover, FIG. 6 shows spring 502 compressed as solenoid 128 is energized and the plunger 500 is moved. Accordingly, when solenoid 128 is de-energized, spring 502 will act to restore plunger 500 and component 504 to their normal positions or configurations, that is, to those shown in FIG. 5 .
[0037] Referring to FIG. 9 , there is shown solenoid 128 in a de-energized state, together with plunger 500 and spring 502 , as described above. FIG. 9 further shows the end of plunger 500 attached to an adjustable mechanical component 902 by means of a pivotable pin 904 . Component 902 comprises elongated links 902 a and 902 b , each having one end joined to plunger 500 by means of pin 904 . The opposing end of link 902 a is constrained to pivot about a pin 906 a , and the opposing end of link 902 b is joined to a sliding sub-component 902 c , by means of a pivotable pin 906 b . Component 902 further comprises a fixed or anchored sub-component 902 d , and sub-components 902 c and d are provided with slot edge members 908 a and 908 b , respectively. Sub-Component 908 a is constrained by conventional means, not shown, to sliding or translational movements toward or away from anchored sub-component 902 d . Thus, the spacing between slot edge members 908 a and 908 b is adjustable by moving sub-component 902 c to the right or left, as viewed in FIG. 9 .
[0038] Referring to FIGS. 9 and 11 together, there are shown slot edge members 908 a and b spaced apart to provide a width for the entrance to slot 516 that is compatible with a USS slot width. Accordingly, locking element 518 of locking mechanism 406 is retained in slot 516 by mechanical component 902 , when solenoid 128 is de-energized. The action of component 902 , with respect to solenoid 128 and locking mechanism 406 , is thus similar to the action of component 504 , described above.
[0039] Referring to FIG. 10 , there is shown solenoid 128 energized, whereby plunger 500 is moved downward and sliding sub-component 902 c is moved to the left, as viewed in FIG. 10 . Thus, the spacing between slot edge members 908 a and b becomes large enough for locking element 518 and mechanism 406 to be withdrawn from slot 516 . When solenoid 128 is de-energized, spring 502 will act to return plunger 130 and component 902 to the configuration shown by FIG. 9 .
[0040] Referring to FIGS. 13 and 14 , there is shown a rotor or rotary actuator 1302 for solenoid 128 , wherein solenoid 128 is configured to provide rotary movement to rotor 1302 , rather than linear movement to a plunger 500 as described above. More particularly, rotor 1302 is rotated through 180 degrees by solenoid 128 , whenever the solenoid is energized or de-energized, respectively. FIG. 13 shows rotor 1302 at its position when solenoid 128 is de-energized, and FIG. 14 shows rotor 1302 at its energized position.
[0041] Referring further to FIGS. 13 and 14 , there is shown a short link 1304 having an end fixably joined to rotor 1302 , by means of a pin 1306 . Accordingly, the short link 1304 rotates with rotor 1302 . The other end of short link 1304 is joined to an end of a link 1310 , by means of a pivotable pin 1308 . Accordingly, link 1310 reciprocates, or moves upwardly and downwardly as viewed in FIGS. 13 and 14 , as rotor 1302 is rotated between its energized and de-energized positions.
[0042] A spring 1312 joined to rotor 1302 is in a relaxed or unstressed condition, when rotor 1302 is in its de-energized position as shown in FIG. 13 . Thus, spring 1312 will store force when solenoid 128 is energized to move rotor 1302 and link 1310 to the positions thereof shown in FIG. 14 . Thereafter, when the solenoid is de-energized, spring 1312 will return rotor 1302 and link 1310 to their respective de-energized positions, shown in FIG. 13 .
[0043] FIGS. 13 and 14 further show the opposite end of link 1310 coupled to adjustable mechanical component 902 , by means of the pin 904 . Locking mechanism 406 , with its locking element 518 and shaft 514 , is arranged in relation to mechanical component 902 in like manner with the arrangement thereof shown in FIGS. 9-12 . Accordingly, when rotor 1302 is in its de-energized position, locking element 518 of locking mechanism 406 is retained in slot 516 by mechanical component 902 , as best shown by FIGS. 13 and 11 . When the solenoid is energized, rotor 1302 is rotated to move link 1310 downward, and to move sliding sub-component 902 c to the left, as viewed in FIG. 14 . Thus, the spacing between slot edge members 908 a and b becomes large enough for locking element 518 and mechanism 406 to be withdrawn from slot 516 , as shown in FIGS. 14 and 12 . When solenoid 128 is de-energized, spring 1312 will act to rotate rotor 1302 back to its de-energized position.
[0044] It is important to note that while the present invention has been described in the context of a fully functioning data processing system, those of ordinary skill in the art will appreciate that the processes of the present invention are capable of being distributed in the form of a computer readable medium of instructions and a variety of forms and that the present invention applies equally regardless of the particular type of signal bearing media actually used to carry out the distribution. Examples of computer readable media include recordable-type media, such as a floppy disk, a hard disk drive, a RAM, CD-ROMs, DVD-ROMs, and transmission-type media, such as digital and analog communications links, wired or wireless communications links using transmission forms, such as, for example, radio frequency and light wave transmissions. The computer readable media may take the form of coded formats that are decoded for actual use in a particular data processing system.
[0045] The description of the present invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
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A security apparatus and method is provided for a portable computer, wherein a solenoid within the portable computer is controlled by a specified program running on the computer. Activation of the solenoid is usefully enabled by a password or computer security chip. One embodiment, comprising a security apparatus, includes a locking mechanism such as a conventional manually operated USS locking device having a locking element. The security apparatus further includes a component positioned proximate to a slot disposed to receive the locking element, the component being adjustable to vary a dimension of the slot entrance between hold and release modes. The component is coupled to the solenoid and is actuated to adjust the slot entrance dimension, from the hold mode to the release mode, when the solenoid is energized in response to a command generated by the specified program running on the computer.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application discloses subject matter related to copending U.S. patent applications “HAMMERHEAD FLUID SEAL” (Ser. No. 11/146,801), “COMBINED BLADE ATTACHMENT AND DISK LUG FLUID SEAL” (Ser. No. 11/146,798) and “BLADE NECK FLUID SEAL” (Ser. No. 11/146,660), each filed on Jul. 7, 2005.
BACKGROUND OF THE INVENTION
[0002] (1) Field of the Invention
[0003] The invention relates to gas turbine engines, and more specifically to a cooled fluid sealing arrangement disposed between blades and vanes of such engines.
[0004] (2) Description of the Related Art
[0005] Gas turbine engines operate by compressing ambient air with a forward compressor, injecting a fuel, burning the air-fuel mixture in a central combustor and converting the energy of combustion into a propulsive force. Combustion gases exit the combustor through an annular duct, where the gases drive one or more axial stages of circumferentially distributed turbine blades. Each bladed stage transfers the combustion gas energy to a rotor attached to a central, longitudinal shaft. Interposed with the rotating blade stages are stationary vane stages affixed to radially outer casing structures, circumscribing the rotor. Two or more rotors may operate independently of one another and at differing speeds via concentric shafts. Gas turbine engines are flexible power plants that are typically used for powering aircraft, ships and generators.
[0006] In order to withstand combustion gas temperatures that regularly exceed 2000 degrees Fahrenheit and pressures exceeding 400 pounds per square inch absolute, turbine components such as blades, vanes and seals are cooled with lower-temperature, higher-pressure cooling air. The cooling air is bled from the compressors, then directed axially rearward and radially inward of the rotors to the turbine components, bypassing the combustor altogether. Once delivered to the turbine, a significant portion of the cooling air is directed radially outward to the blades, vanes and seals by the centrifugal force of the turning rotors. In order to achieve the greatest heat reduction benefit from the cooling air, the interfaces of the rotating blade stages and stationary vane stages must be effectively sealed.
[0007] The interfaces of the rotating blade stages and stationary vane stages are particularly difficult to seal due to the differences in thermal and centrifugal growth between the rotors and the cases. The high relative speeds, extremely high temperatures and pressures also present seal design challenges in the turbines. In the past, designers have attempted to seal the interfaces of the rotating blade stages and stationary vane stages with varying degrees of success.
[0008] An example of such a turbine seal is a labyrinth seal. In a typical blade to vane interface, a multi-step labyrinth seal, comprising stationary lands and rotating runners or knife-edges, restricts leakage of the cooling air radially outward, into the combustion gases. The runners project from annular supports, which are typically fastened to the rotor with bolted flanges and/or with snap fits. The supports are independent components, adding to the manufacturing costs and complexity of the turbine. The supports also contribute additional rotational mass to the rotors, which reduces the engine-operating efficiency. Also, the attachments at the interfaces of the supports and the rotors create an additional leakage path for the cooling air. Placement of the supports is influenced by adjacent components and typically does not optimize the distribution of the cooling air.
[0009] What is needed is a blade to vane interface seal that doesn't require separate seal support components, and also improves the apportioning of cooling air to the seal itself.
BRIEF SUMMARY OF THE INVENTION
[0010] In accordance with the present invention, there are provided rotor to stator interface seals for restricting leakage of cooling air and improving the apportioning of the cooling air to the seals.
[0011] Accordingly, a turbine rotor contains a first and a second stage of circumferentially distributed blades. The blade stages are separated axially from one another by an annular coupling located radially inboard of the blades, forming a chamber therebetween. Interposed between the blade stages is a stationary vane stage. The vane stage contains a land, facing radially inwardly. A ring projects axially from each of the first and second blade stages towards the vane stage. The rings radially cooperate with the land and together form the blade to vane interface seal. The coupling contains an aperture for radially introducing cooling air to the chamber for use in cooling the seal.
[0012] In another embodiment of an interface seal in accordance with the present invention, a turbine rotor contains a first and a second stage of circumferentially distributed blades. The blade stages are separated axially from one another by an annular coupling located radially inboard of the blades, forming a chamber therebetween. Interposed between the blade stages is a stationary vane stage. The vane stage contains a radially inwardly facing land. A ring projects axially from blade stages towards the vane stage. The rings radially cooperate with the land. The coupling contains an integral ring projecting radially outward and radially cooperating with the land. Together, the cooperating rings and land form the blade to vane interface seal. The coupling also contains an aperture for radially introducing cooling air to the chamber for use in cooling the seal. Although the aperture may be located anywhere along the axial length of the coupling, it is typically located forward of the vane stage.
[0013] Since the sealing rings are integral with the existing blades and couplings of the gas turbine engine, separate supports are not needed and are therefore eliminated. The elimination of separate supports reduces the rotational mass of the rotors, thus improving engine-operating efficiency. Also, by relocating the rings to the blades, cooling air leakage paths are eliminated and the cooling air apportioning to the seal is improved.
[0014] Other details of the present invention, as well as other objects and advantages attendant thereto, are set forth in the following detailed description and the accompanying drawings wherein like reference numerals depict like elements.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0015] FIG. 1 illustrates a simplified schematic sectional view of a gas turbine engine along a central, longitudinal axis.
[0016] FIG. 2 illustrates a partial sectional view of a low-pressure turbine of the type used in the engine of FIG. 1 .
[0017] FIG. 3 illustrates a detailed sectional view of a blade to vane interface seal embodiment of the type used in the turbine of FIG. 2 .
[0018] FIG. 4 illustrates a detailed sectional view of another blade to vane interface seal embodiment of the type used in the turbine of FIG. 2 .
[0019] FIG. 5 illustrates an isometric view of a turbine blade of the type used in the turbine of FIG. 2 .
[0020] FIG. 6 a illustrates a front view of a ring segment interface comprising a single chamfered edge.
[0021] FIG. 6 b illustrates a front view of a ring segment interface comprising double chamfered edges.
[0022] FIG. 6 c illustrates a front view of a ring segment interface comprising a single sloped edge.
[0023] FIG. 6 d illustrates a front view of a ring segment interface comprising dual sloped edges.
[0024] FIG. 6 e illustrates a front view of a ring segment interface comprising tangentially sloped wings.
[0025] FIG. 6 f illustrates a front view of a ring segment interface comprising a single downstream dam.
[0026] FIG. 6 g illustrates a front view of a ring segment interface comprising dual dams.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The major sections of a typical gas turbine engine 10 of FIG. 1 include in series, from front to rear and disposed about a central longitudinal axis 11 , a low-pressure compressor 12 , a high-pressure compressor 14 , a combustor 16 , a high-pressure turbine 18 and a low-pressure turbine 20 . A working fluid 22 is directed rearward through the compressors 12 , 14 and into the combustor 16 , where fuel is injected and the mixture is burned. Hot combustion gases 24 exit the combustor 16 and expand within an annular duct 26 , driving the turbines 18 , 20 . The turbines 18 , 20 , in turn drive coupled compressors 14 , 12 via concentric shafts 28 , 30 , forming a high rotor spool 32 and a low rotor spool 34 respectively. Although a dual spool engine 10 is depicted in the figure, three spool engines 10 are not uncommon. The combustion gases exit the engine 10 as a propulsive thrust 36 , used to power an aircraft or a free turbine. A portion of the working fluid 22 is bled from the compressors 12 , 14 and is directed radially inward of the combustor 16 and axially rearward to the turbines 18 , 20 for use as cooling air 38 .
[0028] In an exemplary low-pressure turbine 20 of FIGS. 2-4 , the combustion gases 24 are directed rearward through an annular duct 40 approximately defined by a radially outer flow path 42 and a radially inner flow path 44 . Disposed circumferentially within the annular duct 40 are alternating stages of rotating blades 50 a - 50 e and stationary vanes 52 a - 52 d . The blades 50 extend radially outward from a rotor disk 54 by roots 56 disposed radially inward of platforms 58 . Each blade 50 further comprises an airfoil 60 , extending radially between the platform 58 and an outer tip shroud 62 . The airfoil 60 has a forward facing leading edge and a rearward facing trailing edge. In some instances, the blades 50 are removable from the disks 54 and in some instances non-removable. The vanes 52 are cantilevered inward from a case 64 by hooks 66 extending radially outward from the outer tip shrouds 62 . Each vane 52 comprises an airfoil 60 that extends radially between an inner shroud 68 and an outer shroud 70 .
[0029] Outer seals 72 restrict leakage of the combustion gases 74 at the outer flow path 42 . The outer seals 72 are disposed at the interface of the rotating blades 50 and the stationary case 64 . The tip shrouds 62 contain outwardly extending runners 74 that radially cooperate with inwardly facing lands 76 affixed to the case 64 by supports 78 . The radial cooperation of the runners 74 and the lands 76 , along with the rotation of the blades 50 , cause a damming effect and thus restricts leakage of the combustion gases 24 from the outer flow path 42 . Overlapping platforms 58 and a constant supply of higher pressure cooling air 38 restrict leakage of the combustion gases 24 at the inner flow path 44 .
[0030] Cooling air 38 , bled from the compressors 12 , 14 is directed to bore cavities 80 . The bore cavities 80 are bounded axially by adjacent disk bores 82 and radially outwardly by an annular coupling 84 . The coupling 84 joins adjacent disks 54 with bolts, rivets, welds, threads, splines, tapers, snap fits, or other means. The coupling 84 may also be integrally formed with each of the adjacent disks 82 (not shown). The cooling air 38 is pumped radially outward, against the couplings 84 , by the rotation of the disks 54 . Apertures 86 in the couplings 84 direct the cooling air 38 into rim cavities 88 . The apertures may be circular holes, slots, or other forms and are typically, evenly distributed cirumferentially about the coupling 84 . The apertures 86 are sized to allow the appropriate cooling air 38 volume to enter the rim cavity 88 .
[0031] The cooling air 38 inside the rim cavity 88 is maintained at a higher pressure than the combustion gases 24 in the annular duct 40 under all engine-operating conditions. The higher pressure cooling air 38 prevents combustion gas 24 ingestion into the rim cavities 88 and provides cooling for the blade 50 to vane 52 interface. A portion of the cooling air 38 is directed axially rearward through a plurality of slots 90 disposed between the blade roots 56 and the disk 54 . This portion of cooling air 38 reduces the temperature of the blade root 56 to disk 54 interface before being directed axially rearward to a downstream rim cavity 88 . Another portion of the cooling air 38 is directed radially outward to cool the blade 50 to vane 52 interface region.
[0032] As specifically illustrated in FIGS. 3 and 4 , seals 92 according to various embodiments of the current invention restrict the leakage of the cooling air 38 at the interfaces of the blades 50 and vanes 52 . The blade platforms 58 form one or more circumferentially segmented rings 94 that radially cooperate with inwardly facing lands 96 affixed to the vanes 52 . Also, one or more integral rings 94 may project radially outward from coupling 84 anywhere along its axial length as specifically illustrated in FIG. 4 . The cooperation of the integral rings 94 and lands 96 form intermediate seals, which partition cavity 88 into two or more smaller cavities 88 . The radially outward projecting ring 94 is not segmented and also radially cooperates with a land 96 affixed to a vane 52 . The proximate radial position of the rings 94 and the lands 96 , along with the rotation of the blades 50 , cause a damming effect and thus restrict leakage of the cooling air 38 from the rim cavity 88 .
[0033] The lands 96 may have a constant radial profile or may be stepped radially to further prevent ingestion of the combustion gases 24 into the rim cavity 88 . A land 96 may be affixed directly to the vane 52 by brazing, welding or other suitable means or may be affixed to a support 97 projecting radially inwardly from the vane 52 . The support 97 may be integrated with the vane 52 or may be affixed by brazing, welding or other suitable means. A land 96 is typically comprised of a honeycomb shaped, sheet metal structure, or any other structure and material known in the sealing art to restrict leakage.
[0034] The rings 94 project axially from a platform 58 of a blade 50 in a leading edge direction, a trailing edge direction, or both directions. An integral ring 94 may also project radially from coupling 84 . With the blades 50 assembled into a disk 54 , individual ring 94 segments axially and radially align, to form a substantially complete ring 94 about central axis 11 . A ring 94 may contain one or more radially extending runners 98 , which are also known as knife-edges. The addition of multiple runners 98 provides a greater cooling air 38 leakage restriction, but the actual number may be dictated by space and/or weight limitations. The width of a runner 98 should be as thin as possible, adjacent to a land 96 , to reduce the velocity of any cooling air 38 flowing therebetween. Since intermittent contact between a runner 98 and a land 96 may occur, a coating, hardface or other wear-resistant treatment is typically applied to the runners 98 . A runner 98 may also be canted at an angle (●) from between about 22.5 degrees to about 68 degrees, preferably 55 degrees, relative to the longitudinal axis of the segmented ring 94 . By canting the runner 98 in the direction opposing the cooling air 38 flow, a damming effect is created, providing for an increased leakage restriction. Canting a runner 98 also reduces the length of the thicker, segmented ring 94 , reducing weight even further. The rings 94 and runners 98 are formed by casting, conventional machining, electrodischarge machining, chemical milling, or any other suitable manufacturing methods.
[0035] As further illustrated by the blade 50 embodiment of FIG. 5 , adjacent ring 94 segments may contain mechanical sealing elements to reduce leakage of cooling air 38 therebetween. With the blades 50 installed, a tongue 100 and a groove 102 cooperate between adjacent ring 94 segments to reduce leakage of the cooling air 38 . It is noted that the tongue 100 may be inclined radially outward to ensure it completely contacts the groove 102 under centrifugal loading. Since an increased radial thickness of the ring 94 segment is only required to accommodate the tongue 100 and groove 102 , one or more pockets 104 are typically located between the tongue 100 and groove 102 to reduce the rotational mass of the blade 50 . The pockets 104 are formed by casting, conventional machining, electrodischarge machining, chemical milling or any other suitable manufacturing methods.
[0036] As illustrated in the ring 94 segment embodiments of FIGS. 6 a - 6 g , adjacent ring 94 segments may contain aerodynamic sealing means to reduce leakage of cooling air 38 therebetween. By directing a volume of cooling air 38 and combustion gases 24 radially inward through the mechanism of reverse inward pumping, the radially outward leakage of cooling air 38 from the rim cavity 88 is opposed, and therefore reduced. In each of the figures, the reference rotation of the blades 50 is in the clockwise direction. If the rotation of the blades 50 is in the counterclockwise direction, the inventive aerodynamic sealing elements are mirrored about a plane extending through the longitudinal axis 11 of the engine 10 . Also, the upstream ring 194 segment is illustrated to the right and the downstream ring 294 segment is illustrated to the left in each of the figures.
[0037] FIG. 6 a illustrates a chamfered edge 106 , reverse pumping element. The chamfered edge 106 is located at the intersection of a tangentially facing surface 108 and a radially outer surface 110 of the upstream ring 194 segment. A volume of cooling air 38 and combustion gases 24 encounters the chamfered edge 106 and is pumped radially inward, between adjacent ring 194 , 294 segments, by the rotation of the blades 50 . The inward pumping opposes the radially outward leakage of cooling air 38 .
[0038] FIG. 6 b illustrates a double chamfered edge 106 , reverse pumping element. A chamfered edge 106 is located at the intersection of a tangentially facing surface 108 and a radially outer surface 110 of the upstream ring 194 segment. Also, a chamfered edge 106 is located at the intersection of a tangentially facing surface 108 and a radially inner surface 112 of the downstream ring 294 segment. A volume of cooling air 38 and combustion gases 24 encounters the chamfered edges 106 and is pumped radially inward, between adjacent ring 194 , 294 segments, by the rotation of the blades 50 . The inward pumping opposes the radially outward leakage of cooling air 38 .
[0039] FIG. 6 c illustrates a single sloped edge 114 , reverse pumping element. A sloped edge 114 is located between a radially outer surface 110 and a radially inner surface 112 of the upstream ring 194 segment. A volume of cooling air 38 and combustion gases 24 encounters the sloped edge 114 and is pumped radially inward, between adjacent ring 194 , 294 segments, by the rotation of the blades 50 . The inward pumping opposes the radially outward leakage of cooling air 38 .
[0040] FIG. 6 d illustrates a dual sloped edge 114 , reverse pumping element. A sloped edge 114 is located between a radially outer surface 110 and a radially inner surface 112 of the upstream ring 194 segment. Also, a sloped edge 114 is located between a radially outer surface 110 and a radially inner surface 112 of the downstream ring 194 segment. A volume of cooling air 38 and combustion gases 24 encounters the sloped edges 114 and is pumped radially inward, between adjacent ring 194 , 294 segments, by the rotation of the blades 50 . The inward pumping opposes the radially outward leakage of cooling air 38 .
[0041] FIG. 6 e illustrates a dual tangentially sloped wing 116 , reverse pumping element. A radially inner sloped wing 116 is located adjacent the tangentially facing surface 108 of the upstream ring 194 segment. Also, a radially outer sloped wing 116 is located adjacent the tangentially facing surface 108 of the downstream ring 294 segment. A volume of cooling air 38 and combustion gases 24 encounters the wings 116 and is pumped radially inward, between adjacent ring 194 , 294 segments, by the rotation of the blades 50 . The inward pumping opposes the radially outward leakage of cooling air 38 .
[0042] FIG. 6 f illustrates a single downstream dam 118 , reverse pumping element. The tangentially facing surface 108 of the downstream ring 294 segment is radially thickened and protrudes radially outward, beyond the tangentially facing surface 108 of the upstream ring 194 segment to form the dam 118 . A volume of cooling air 38 and combustion gases 24 encounters the dam 118 and is pumped radially inward, between adjacent ring 194 , 294 segments, by the rotation of the blades 50 . The inward pumping opposes the radially outward leakage of cooling air 38 .
[0043] FIG. 6 g illustrates a dual dam 118 , reverse pumping feature. The tangentially facing surface 108 of the downstream ring 294 segment is radially thickened and protrudes radially outward, beyond the tangentially facing surface 108 of the upstream ring 194 segment. Also, the tangentially facing surface 108 of the upstream ring 194 segment is radially thickened and protrudes radially inward, beyond the tangentially facing surface 108 of the downstream ring 294 segment. A volume of cooling air 38 and combustion gases 24 encounters the dam and is pumped radially inward, between adjacent ring 194 , 294 segments, by the rotation of the blades 50 . The inward pumping opposes the radially outward leakage of cooling air 38 .
[0044] Although a low-pressure turbine 20 is illustrated throughout the figures for succinctness, it is understood that high-pressure and mid-pressure turbines are similarly constructed and would therefore benefit from the exemplary seals 92 and rim cavity 88 cooling arrangements.
[0045] While the present invention has been described in the context of specific embodiments thereof, other alternatives, modifications and variations will become apparent to those skilled in the art having read the foregoing description. Accordingly, it is intended to embrace those alternatives, modifications and variations as fall within the broad scope of the appended claims.
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Disclosed are various embodiments of a gas turbine blade to vane interface seal for restricting leakage of cooling air and improving the apportioning of the cooling air to the seal. Accordingly, a turbine rotor contains a first and a second stage of radially extending and circumferentially distributed blades. The stages are separated axially from one another by an annular coupling located radially inboard of the blades, forming a chamber therebetween. Interposed between the blade stages is a vane stage. The vane stage contains a land, facing radially inwardly. A ring projects axially from each of the first and second blade stages towards the vane stage. A ring may also project radially from the coupling towards the vane stage. The rings radially cooperate with the land and together form the blade to vane interface seal. The coupling contains an aperture for radially introducing a cooled fluid to the chamber for use in cooling the seal.
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BACKGROUND OF THE INVENTION
This invention relates generally to surveying of boreholes, and more particularly concerns methods and apparatus which enable significant reductions in well survey time.
In the past, the task of position mapping a well or borehole for azimuth in addition to tilt has been excessively complicated, very expensive, and often inaccurate because of the difficulty in accommodating the size and special requirements of the available instrumentation. For example, magnetic compass devices typically require that the drill tubing be fitted with a few tubular sections of non-magnetic material, either initially or when drill bits are changed. The magnetic compass device is inserted within this non-magnetic section and the entire drill stem run into the hole as measurements are made. These non-magnetic sections are much more expensive than standard steel drill stem, and their availability at the drill site must be pre-planned. The devices are very inaccurate where drilling goes through magnetic materials, and are unusable where casing has been installed.
Directional or free gyroscopes are deployed much as the magnetic compass devices and function by attempting to remember a pre-set direction in space as they are run in the hole. Their ability to initially align is limited and difficult, and their capability to remember degrades with time and environmental exposure. Also, their accuracy is reduced as instrument size is reduced, as for example becomes necessary for small well bores. Further, the range of tilt and azimuthal variations over which they can be used is restricted by gimbal freedom which must be limited to prevent gimbal lock and consequent gyro tumbling.
A major advance toward overcoming these problems is described in my U.S. Pat. No. 3,753,296. That invention provides a method and means for overcoming the above complications, problems, and limitations by employing that kind and principal of a gyroscope known as a rate-of-turn gyroscope, or commonly `a rate gyro`, to remotely determine a plane containing the earth's spin axis (azimuth) while inserted in a bore hole or well. The rate gyroscope has a rotor defining a spin axis; and means to support the gyroscope for travel in a bore hole and to rotate about an axis extending in the direction of the hole, the gyroscope characterized as producing an output which varies as a function of azimuth orientation of the gyroscope relative to the earth's spin axis. Such means typically includes a carrier containing the gyroscope and motor, the carrier being sized for travel in the well, as for example within the drill tubing. Also, circuitry is operatively connected with the motor and carrier to produce an output signal indicating azimuthal orientation of the rotating gyroscope relative to the carrier, whereby that signal and the gyroscope output may be processed to determine azimuth orientation of the carrier and any other instrument thereon relative to the earth's spin axis, such instrument for example comprising a well logging device such as a radiometer, inclinometer, etc.
U.S. Pat. No. 4,192,077 improves upon 3,753,296 in that it provides for use of a "rate gyro" in combination with a free gyroscope, with the rate gyro used to periodically calibrate the free gyroscope. While this combination has certain benefits, it does not provide the unusually advantageous modes of operation and results as are afforded by the present invention. Among these are the enablement of very rapid surveying of boreholes; the lack of need for a free gyroscope to be periodically calibrated; and reduction in time required for surveying slanted boreholes, of particular advantage at depths where high temperatures are encountered.
SUMMARY OF THE INVENTION
It is a major object of the invention to provide method and apparatus facilitating rapid surveying of boreholes, as referred to. Typically, the survey method employs first means for measuring angular rate, and second means for sensing tilt, and a rotary drive for the first and second means, the basic steps of the method including:
(a) operating the drive and the first and second means at a first location in the borehole to determine the azimuthal direction of tilt of the borehole at such location,
(b) then traveling the first and second means and the drive lengthwise of the borehole away from that location, and operating the drive and at least one of the first and second means during such traveling to determine changes in borehole alignment during traveling.
As will be seen, the (b) step of the method typically involve maintaining an input axis defined by the second means at a predetermined orientation (such as horizontal) during traveling, the drive being controlled to accomplish this. For example, the second means may include first and second accelerometers, the latter accelerometer having its input axis maintained horizontal during such travel. Accordingly, if the borehole changes its direction of tilt during instrumentation travel, the first accelerometer detects the amount of change; in addition, first means (such as a rate of turn sensor or gyroscope) senses changes in azimuth during the travel between upper and lower positions in the well. Further, the (a) step of the method may be carried out at each of the upper and lower positions prior to and subsequent to such travel, for accurately determining azimuthal direction of tilt of the hole at such locations. These (a) and (b) steps may be carried out in alternation, up or down the hole, to enable rapid surveying, as will be seen.
Additional method steps include adjusting the angularity (cant angle) of the axis of sensitivity of the first accelerometer relative to the longitudinal direction of travel in the borehole, to improve the determination of azimuthal direction of tilt of the hole; and the use of output from one or more of the sensors (angular rate sensor and acceleration sensor or sensors) to compensate the output or outputs from others of such sensors.
Apparatus embodying the invention comprises:
(a) first sensor means for measuring angular rate about one or more axes,
(b) second sensor means for sensing tilt or acceleration along one or more axes,
(c) rotary drive means for rotating and controling said first and second means in the borehole, and
(d) circuit means operatively connected between said second means and rotary drive means for:
(i) allowing the drive to rotate the first and second means at a first location in the borehole to determine the azimuthal direction of tilt of the borehole at said location, and
(ii) causing the drive to maintain an axis defined by said second means at a predetermined orientation relative to horizontal during traveling of the apparatus in the borehole, whereby at least one of the first and second means may be operated during such traveling to determine changes in borehole alignment along the borehole length.
As will appear, the first sensor means may comprise a rate-of-turn gyroscope; and the second sensor means may comprise first and second tilt sensors, such as accelerometers, the second tilt sensor defining the axis which is maintained at predetermined orientation during travel in the borehole. Also, a resolver may be associated with the first and second sensor means. In addition, means may be provided to adjust the cant or angularity of the first tilt sensor; and other circuitry may be provided to compensate signals derived from the output of either sensor in accordance with values of signals derived from the output of the other of the sensors, or vice versa, to produce compensated signals, thereby improving accuracy.
These and other objects and advantages of the invention, as well as the details of illustrative embodiments, will be more fully understood from the following description and drawings, in which:
DRAWING DESCRIPTION
FIG. 1 is an elevation taken in section to show one form of instrumentation employing the invention;
FIG. 1a is a circuit diagram;
FIG. 2 is an elevation showing use of the FIG. 1 instrumentation in multiple modes, in a borehole;
FIG. 3 is a schematic elevation showing a modification of the FIG. 1 instrumentation;
FIG. 4 is a fragmentary elevation showing variable cant mechanism as usable in the FIG. 1 instrumentation;
FIG. 5 is a side view taken on lines 5--5 of FIG. 4;
FIG. 6 is a vertical section showing further details of the FIG. 1 apparatus as used in a borehole;
FIG. 7 is a diagram indicating tilt of the apparatus in a slanted borehole;
FIG. 8 is a wave form diagram;
FIG. 9 is a block diagram showing modified apparatus; and
FIGS. 10a and 10b show a further modified form of apparatus usable in the dual modes shown in FIG. 2.
DETAILED DESCRIPTION
Referring to FIG. 1, a carrier such as elongated housing 10 is movable in a borehole indicated at 11, the hole being cased at 11a. Means such as a cable to travel the carrier lengthwise in the hole is indicated at 12. A motor or other manipulatory drive means 13 is carried by and within the carrier, and its rotary output shaft 14 is shown as connected at 15 to an angular rate sensor means 16. The shaft may be extended at 14a, 14b and 14c for connection to first acceleration sensor means 17, second acceleration sensor means 18, and a resolver 19. The accelerometers 17 and 18 can together be considered as means for sensing tilt. These devices have terminals 16a-19a connected via suitable slip rings with circuitry indicated at 29 carried within the carrier (or at the well surface, if desired).
Circuitry 29 typically may include a feed back arrangement as shown in FIG. 1a, and incorporating a feed back amplifier 21, a switch 22 having arm 22a and contacts 22b and 22c, and switch actuator 23a. When the actuator closes arm 22a with contact 22c, the resolver 19 is connected in feed back relation with the drive motor 13 via leads 24, 25, and 26, and amplifier 21, and the apparatus operates for example as described in U.S. Pat. No. 3,753,296 to determine the azimuthal direction of tilt of the bore hole at a first location in the bore hole. See for example first location indicated at 27 in FIG. 2. Other U.S. Pat. Nos. describing such operation are 4,199,869, 4,192,077 & 4,197,654. During such operation, the motor 13 rotates the sensor 16 and the accelerometers either continuously, or incrementally.
The angular rate sensor 16 may for example take the form of one or more of the following known devices, but is not limited to them:
1. Single degree of freedom rate gyroscope
2. Tuned rotor rate gyroscope
3. Two axis rate gyroscope
4. Nuclear spin rate gyroscope
5. Sonic rate gyroscope
6. Vibrating rate gyroscope
7. Jet stream rate gyroscope
8. Rotating angular accelerometer
9. Integrating angular accelerometer
10. Differential position gyroscopes and platforms
11. Laser gyroscope
12. Combination rate gyroscope and linear accelerometer
Each such device may be characterized as having a "sensitive" axis, which is the axis about which rotation occurs to produce an output which is a measure of rate-of-turn, or angular rate ω. That value may have components ω 1 , ω 2 and ω 3 in a three axis co-ordinate system. The sensitive axis may be generally normal to the axis 20 of instrument travel in the bore hole, or it may be canted at some angle α relative to axis 20 (see canted sensitive axis 16b in FIG. 1).
The acceleration sensor means 17 may for example take the form of one or more of the following known devices; however, the term "acceleration sensor means" is not limited to such devices:
1. one or more single axis accelerometers
2. one or more dual axis accelerometers
3. one or more triple axis accelerometers
Examples of acceleration sensors include the accelerometers disclosed in U.S. Pat. Nos. 3,753,296 and 4,199,869, having the functions disclosed therein. Such sensors may be supported to be orthogonal or canted at some angle α relative to the carrier axis. They may be stationary or carouseled, or may be otherwise manipulated, to enhance accuracy and/or gain an added axis or axes of sensitivity. In this regard the sensor 17 typically has two imput axes of sensitivity. A canted axis of sensitivity is seen at 17b in FIG. 1, and a canted accelerometer 17' (corresponding to accelerometer 17 in FIG. 1) is seen in FIG. 3. The axis of sensitivity is the axis along which acceleration measurement occurs.
The second accelerometer 18 may be like accelerometer 17, excepting that its input axis 23 is typically orthogonal to the input axes of the sensor 16 and of the accelerometer 17. During travel mode, i.e. lifting or lowering of the carrier 10 in the borehole 11, indicated at 27' in FIG. 2, the output of the second accelerometer 18 is connected via lead 30 (in FIG. 1a), contact 22b, switch arm 22a, and servo amplifier 21 to the drive motor 13. The servo system causes the motor to rotate the shaft 14 until the input axis 23 of accelerometer is horizontal (assuming that the borehole has tilt as in FIG. 2). Typically, there are two such axis 23 horizontal positions, but logic circuitry in the servo-system may for example cause rotation until the output of acceleration sensor 18 is positive. Amplifier 21 typically includes signal conditioning circuits 21a, feedback compensation circuits 21b, and power amplifier 21c driving the motor M shown at 13.
If, for example, the borehole is tilted 45° due East at the equator, accelerometer 17 would register +0.707 g or 45° , and the angular rate sensor 16 would register no input resulting from the earth's rate of rotation. If, then, the apparatus is raised (or lowered) in the borehole, while input axis 23 of accelerometer 18 is maintained horizontal, the output from accelerometer 17 would remain constant, assuming the tilt of the borehole remains the same. If, however, the hole tilt changes direction (or its elevation axis changes direction) the accelerometer 17 senses such change, the amount of such change being recorded at circuitry 29, or at the surface. If the hole changes its azimuth direction during such instrument travel, the sensor 16 senses the change, and the sensor output can be integrated as shown by integrator circuit 31 in FIG. 1a (which may be incorporated in circuitry 29, or at the surface) to register the angle of azimuth change. The instrumentation can be traveled at high speed along the tilted borehole while recording such changes in tilt and azimuth, to a second position (see position 27" in FIG. 2). At that position, the instrumentation is again operated as at 27 (mode #1) to accurately determine borehole tilt and azimuth--essentially a re-calibration step. Thus, the apparatus can be traveled hundreds or thousands of feet, operating in mode #2 as described, and between calibration positions at which travel is arrested and the device is operated in mode #1.
The above modes of operation are typically useful in the tilted portion of a borehole; however, normally the main i.e. lower portion of the oil or gas well is tilted to some extent, and requires surveying. Further, this part of the hole is typically at relatively high temperature where it is desirable that the instrumentation be moved quickly to reduce exposure to heat, the invention lending itself to these objectives. In the vertical or near vertical (usually upper) portion of the hole, the instrumentation can revert to mode #1 operation, at selected positions, as for example at 100 or 200 foot intervals. In a near vertical hole, azimuth contributes very little to hole position computation, so that mode #1 positions can be spaced relatively far apart, and thus this portion of the hole can be mapped rapidly, as well.
FIGS. 4 and 5 illustrate technique for adjusting the angularity of the axis of sensitivity of the first accelerometer relative to the lengthwise direction of instrument travel in the borehole. As shown, the accelerometer 317 (corresponding to accelerometer 17) has an axis of sensitivity (input axis) shown at 317b, which is rotatable about an axis 350 which is substantially normal to the direction of travel 351 in the borehole. Shaft extensions 314a and 314i b correspond to extensions 14a and 14b in FIG. 1. The accelerometer 317 is carried by pivots 352 in a frame 353 to which shaft extensions 314aand 314b are connected, as shown. Control means 354 is also carried by the frame to adjust the cant of axis 317b, as for example at locations of mode #1 operation as described above, to improve the determination of azimuthal direction of tilt of the borehole, at such "calibration" locations, and/or at other instrument locations in the hole. The control means 354 may, for example, comprise a jack screw 355 driven by a reversible motor 356 suspended at 356a by the frame. The jack screw extends laterally and interfits a nut 357 attached to the accelerometer case, as for example at its top, offset from axis 350. A servo system 356b for the drive may be employed, so that a chosen angularity of axis 317b relative to direction 351 may be achieved. Support or suspension 356a may be resiliently yieldable to allow the accelerometer to be adjustably tilted, without jamming of the drive or screw.
FIGS. 6-8 show in more detail the apparatus of FIG. 1, and associated surface apparatus. In FIG. 6, well tubing 110 extends downwardly in a well 111, which may or may not be cased. Extending within the tubing is a well mapping instrument or apparatus 112 for determining the direction of tilt, from vertical, of the well or borehole. Such apparatus may readily be traveled up and down in the well, as by lifting and lowering of a cable 113 attached to the top 114 of the instrument. The upper end of the cable is turned at 115 and spooled at 116, where a suitable meter 117 may record the length of cable extending downwardly in the well, for logging purposes.
The apparatus 112 is shown to include a generally vertically elongated tubular housing or carrier 118 of diameter less than that of the tubing bore, so that well fluid in the tubing may readily pass, relatively, the instrument as it is lowered in the tubing. Also, the lower terminal of the housing may be tapered at 119, for assisting downward travel or penetration of the instrument through well liquid in the tubing. The carrier 118 supports first and second angular sensors such as rate gyroscopes G 1 and G 2 , and accelerometers 120 and 121, and drive means 122 to rotate the latter, for travel lengthwise in the well. Bowed springs 170 on the carrier center it in the tubing 110.
The drive means 122 may include an electric motor and speed reducer functioning to rotate a shaft 123 relatively slowly about a common axis 124 which is generally parallel to the length axis of the tubular carrier, i.e. axis 124 is vertical when the instrument is vertical, and axis 124 is tilted at the same angle form vertical as is the instrument when the latter bears sidewardly against the bore of the tubing 110 when such tubing assumes the same tilt angle due to borehole tilt from vertical. Merely as illustrative, for the continuous rotation case, the rate of rotation of shaft 124 may be within the range 0.5 RPM to 5 RPM. The motor and housing may be considered as within the scope of means to support and rotate the gyroscope and accelerometers.
Due to rotation of the shaft 123, and lower extensions 123a, 123b and 123c thereof, the frames 125 and 225 of the gyroscopes and the frames 126 and 226 of the accelerometers are typically all rotated simultaneously about axis 124, within and relative to the sealed housing 118. The signal outputs of the gyroscopes and accelerometers are transmitted via terminals at suitable slip ring structures 125a, 225a, 126a and 226a, and via cables 127 127a, 128 and 128a, to the processing circuitry at 129 within the instrument, such circuitry for example including that described above, and multiplexing means if desired. The multiplexed or non-multiplexed output from such circuitry is transmitted via a lead in cable 113 to a surface recorder, as for example include pens 131-134 of a strip chart recorder 135, whose advancement may be synchronized with the lowering of the instrument in the well. The drivers 131a-134a for recorder pens 131-134 are calibrated to indicate borehole azimuth, degree of tilt and depth, respectively, and another strip chart indicating borehole depth along its length may be employed, if desired. The recorder can be located at the instrument for subsequent retrieval and read-out after the instrument is pulled from the hole.
The angular rate sensor 16 may take the form of gyroscope G 1 or G 2 , or their combination, as described in U.S. Pat. No. 4,199,869. Accelerometers 126 and 226 correspond to 17 and 18 in FIG. 1.
In FIG. 9 the elements 13, 16, 17 and 19 are the same as in FIG. 1; however, the second accelerometer 18 of FIG. 1 is replaced by a gyroscope 190 which serves the same function as the second accelerometer 18, i.e. the gyroscope 190 maintains a gimble axis fixed (as for example horizontal) during instrumentation travel in mode #2, and its output is connected via the servo loop 22b, 22a, and amplifier 21 to the drive motor 13, so that if the hole changes direction in tilt, during such travel, accelerometer 17 will sense the amount of change, for recordation. The gyroscope 190 may be the second axis of a two-axis gyroscope, the other input axis of which is the first gyroscope.
Referring now to angular rate sensor 16 shown in FIG. 10a it may produce one output ω 1 , i.e. one component of angular rate, or it may produce two or three components, as for example the components of ω along three axes. See in this regard U.S. patent application Ser. No. 241,708. Considering one component ω 1 , it may be directly passed via path 423 and switch 424 to input to the compensation circuit means 425. The latter processes ω 1 and produces a corresponding output ω 1 '. In FIG. 10b computer 426 receives intputs ω 1 ',ω 2 ', and ω 3 ' to produce azimuth output ψ. Inputs ω 2 ' and ω 3 ' are derived from compensation circuits indicated at 427 and 428, and which correspond to circuitry 425'.
In similar manner, the acceleration sensor 17 produces an output a 01 which, after conversion at 430 becomes output a 1 . Output a 01 is transmitted via path 431, which includes switch 432, to co-ordinate conversion circuit 430. If no conversion is required, circuit 430 is eliminated or by-passed (by opening switch 430a and closing switch 430b), and a 01 becomes the same as a 1 . The sensor 17 may also produce component outputs a 02 and a 03 , which after conversion become a 2 and a 3 respectively. The sum of the component vectors corresponding to a 01 , a 02 and a 03 equals the acceleration vector, and the sum of the component vectors a 1 , a 2 and a 3 also equals the acceleration vector. The reason for converting to a 1 , a 2 and a 3 is to produce components in the same co-ordinate system as ω 1 , ω 2 and ω 3 , i.e. the ω system. Circuitry 430 is well known, as indicated in U.S. patent application Ser. No. 241,708. A similar co-ordinate conversion may be performed upon ω 1 , as by means 200 connectible in series in path 201, to convert ω 1 (and also ω 2 and ω 3 ) coordinates the same as the coordinates of a 1 , a 2 , and a 3 ; and devices 430 and 200 may be used to convert into another or third coordinate system.
In FIG. 10a, output a 1 is directly passed via path 133 to input to the compensation circuit means 134. The latter processes a 1 , and produces a corresponding output a 1 '. Computer 435 in FIG. 10b receives inputs a 1 ', a 2 ' and a 3 ' to produce tilt output θ. Inputs a 2 ' and a 3 ' are derived from compensation circuits indicated at 436 and 437, and which correspond to circuitry 434.
Further, an acceleration sensor 18 may also be connected to shaft 14 via shaft extension 14b, to be rotated with the sensors 16 and 17, and it typically has its sensitive axis 23 (along which acceleration is measured) normal to the shaft 14 (generally parallel to the borehole).
In accordance with an important aspect of the invention, any of the compensation circuits 425, 427, 428, 434,436 and 437 may be regarded as a compensation means operatively connected with the sensor means (as for example sensors 16 and 17) for compensating signals derived from the output of at least one of the sensor means (one of 16 and 17, for example) in accordance with values of signals derived from other of the sensor means (the other of 16 and 17 for example), to produce compensated signals. Thus, for example the circuit means is connected with the sensor means to adjust angular rate signals derived from the output of the angular rate sensor thereby to compensate for acceleration effects associated with acceleration signals derived from the output of the acceleration sensor means, so as to produce corrected angular rate values. The compensation means may be indicated at 425 to adjust angular rate signals ω 1 derived from the output of the angular rate sensor 16, thereby to compensate for acceleration effects associated with acceleration signals (as at a 1 ) derived from the output of the acceleration sensor means, to produce corrected angular rate values, ω 1 '. This correction removes the influence of gravity from the angular rate value, for example. Also, corrected values ω 1 " and ω 1 "' may be produced, as described in said U.S. patent application Ser. No. 241,708.
Also associated with the apparatus of FIG. 10a is temperature compensating circuit means to compensate signals derived from at least one, or both, of the sensors 16 and 17 in accordance with temperature changes encountered in the borehole. See for example the circuitry 150 associated with sensor 16, and circuitry 151 asscoiated with sensor 17. When switches 152 and 153 are closed, and switch 424 open, the output of sensor 16 passes through circuitry 150 and to compensating circuitry 425 previously disccused. Thus, if the output of sensor 16 is undesirably increased by an amount ωΔ T due to borehole high temperature, the circuitry 150 eliminates ωΔ T from that output. Known circuitry to produce such compensation is described in said U.S. application Ser. No. 241,708.
In addition, time compensating circuit means is shown in association with the sensors 16 and 17 to compensate their outputs in accordance with selected time values. See for example the time compensating circuit 160 associated with sensor 16, and circuitry 161 associated with sensor 17. When switches 162 and 163 are closed, and switches 152, 124 and 153 are open, the output of sensor 16 passes through circuitry 160, and to compensation circuitry 425 discussed above. Thus, for example, if the voltage output of sensor 16 degrades or diminishes in amplitude over a period of time, it may be restored by circuit 160. An example of a known time compensating (gain restorative) circuit is described in said application Ser. No. 241,708. There are other examples of time compensation, including phase shift, etc.
If desired, switches 152 and 163 may be closed and switches 424, 162 and 163 opened, to pass the output of 16 through both compensators 150 and 160 for both temperature and time compensation.
Similar time compensation switches are shown at 436 and 437 in association with sensor 17.
The above discussed compensation means 134 is shown as operatively and selectively connected with the sensors 16 and 17 to adjust acceleration signals a 1 derived from the output of the acceleration sensor 17 to compensate for angular rate effects associated with angular rate signals ω 1 derived from the output of the angular rate sensor 16, thereby to produce corrected accelerationvalues a 1 '. The compensator 434 may be similar to compensator 425.
Each of blocks 427a and 428a respectively in series with compensation circuits 427 and 428 represents temperature and time circuits like 150 and 160 and associated switches. Likewise, each of blocks 436a and 437a respectively in series with compensation circuits 436 and 437 represents circuits like 151, 161, 430 and associated switches. Blocks 427 and 436 have cross over connections corresponding to connections 181 and 184, and blocks 428 and 437 also have such cross-over connections.
Note also in FIG. 10a the switch 180 in the cross-over path 181 extending from the ω 1 input path 182 to compensator 425, to provide ω 1 input to compensator 434; and the switch 183 in the cross-over path 184 extending from the a 1 input path 433 to compensator 434, to provide a 1 input to compensator 425.
Some or all of the switches shown in FIG. 10a may be suitably and selectively controlled from a master control 187, either in the borehole or at the borehole surface. Thus, for example, either or both of the compensators 425 and 434 may be employed to compensate as described, by control of switches 180 and 183; and various ones or combinations of the temperature and time compensators may be employed, or excluded, by selective operation of the switches associated therewith, as described and shown.
The described circuitry connected to the outputs of the sensors 16 and 17 may be located in the borehole (as on the carrier) outside the borehole (as at the well surface) or partly in the hole and partly out.
FIG. 10b shows circuit means, such as a computer 190, connected with one or both of the compensation circuits 425, 427 and 428, to receive corrected angular rate values ω 1 ', ω 2 ' and ω 3 ' and to produce an output which varies as a function of azimuth orientation of the sensor 16. Operation of the computer is as generally described in Ser. No. 241,708. Also, FIG. 10b shows circuit means, such as a computer 191, connected with one or more of the compensation circuits 434, 436 and 437 to receive corrected acceleration values a 1 ', a 2 ; and a 3 ', and produce an output which varies as a function of tilt of the acceleration sensor means. Operation of the computer 191 is as generally described in Ser. No. 241,708, filed Mar. 9, 1981.
The compensation principles as discussed above may be applied not only to a system which includes one angular rate sensor, but also to two or more angular rate sensors, each or either of which may be connected in compensating relation with an accelerometer or tilt detector. Thus, one or more accelerometers may be employed.
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A borehole survey method employs a first sensor for measuring angular rate, and a second sensor or sensors for sensing tilt, and a rotary drive for the first and second sensors, and includes the steps:
(a) operating the drive and the first and second sensors at a first location in the borehole to determine the azimuthal direction of tilt of the borehole at such location,
(b) then traveling the first and second sensors and the drive lengthwise of the borehole away from the location, and operating the drive and at least one of the first and second sensors during such traveling to determine changes in borehole alignment during such traveling.
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CITATION TO PRIOR APPLICATION
[0001] This is a CONTINUATION-IN-PART with respect to U.S. application Ser. No. 10/665,059, from which priority is claimed under 35 U.S.C. § 120.
BACKGROUND OF THE INVENTION
[0002] 1. Field of The Invention
[0003] The present invention generally relates to mattresses. More specifically, the present invention relates to improved mattress, cushion and packaging material encased in a functional membrane that uniquely reduces stress concentrations when supporting a human or other body.
[0004] 2. Background Information
[0005] The human body can tolerate many forces, but one part of the body subjected to continuous forces is the outer covering of skin or “tissue.”
[0006] When one walks, one generally hardens the underside of the feet through intermittent pressure, abrasion and shear exerted by their body mass against the earth's gravity. The underside of the feet, as well as the hands and elbows, are made of special underlying tissue to be able to withstand these forces and grow calluses, whereas the underside of the arm is tender and not designed for such loading.
[0007] Similarly, the tissue over the posterior (back) of the heels, lateral trochanters (hipbones), ischial tuberosities (sit-bones), malleolus (ankles), iliac crest (waist), scapula (shoulder blades), ears and occiput (back of the head) are thinly covered, poorly vascularized and cannot tolerate “loading” as well as the feet and hands.
[0008] The noted bony areas are primarily sharp compared to the feet, except, of course, the head or where underlying bony spurs are established. Thus, when a load is applied to these surfaces, one momentarily retracts from that load in an effort to protect the trauma being applied to the tissue. However, without good sensation at the surface of the tissue to send signals to the brain for counteraction, one cannot respond appropriately and “tissue trauma” results or skin is damaged. When exceedingly high forces are applied, the pressure or shear adjacent to the applied force is sufficient to damage the tissue integrity, which is referred to as a “cut” or “needle stab” and in dire situations, tissue is actually torn apart by explosion, impact, machinery accidents, etc. But, there is another form of tissue damage that is similar to the development of blisters that occurs when tissue has been over-stressed and the outer covering may break. This results in usually minor tissue damage, but can extend itself to a major “sore” ischemic ulcer or “bedsore” if countermeasures are not immediate.
[0009] Exacerbating this situation is the normal aging process and deterioration of normal body functions. Upon aging, tissue is not as viable as younger tissue. Sensory feedback, which carries signals regarding tissue viability information back to our brain, is no longer as rapid and there is the potential of tissue harm due to the unawareness of tissue failure. Especially prone to this situation are those with diabetes, spinal cord injuries, leprosy, overdose, dementia and so on, as well as the elderly, whose tissue no longer has the turgor to counteract minor inflictions on its surface.
[0010] A person who is elderly or has some enervation and is confined to bed for an extended period will have a propensity to develop tissue trauma sores (ischemic ulcers, decubitus ulcers or bedsores). Typically these sores appear over bony prominences where forces arising from the weight of the body are concentrated and the lack of movement leads to tissue destruction. (Those with normal sensation and mobility become uncomfortable and move to a different position, while those under anesthetics can't move). To avoid such sores, some form of tissue pressure/shear interface should be provided to reduce these forces to a value that the tissue can tolerate.
[0011] To better understand why the tissue dies, a simple example is to push a finger hard onto a flat surface. Immediately, pain can be perceived. The tissue is being forced up the side of the finger bone, under the outer tissue, and the tissue is “shearing” away from the bone. Directly at the center of that finger bone is the “peak” pressure with adjacent tissue being applied “average” pressure. Again, the average pressure may thus be low and the peak pressure very high and this is why “average” pressure readings found in various products and interface pressure studies does not give correct tissue interface pressure information for protection of that tissue.
[0012] This peak pressure eliminates nutrient passage to the stressed tissue area and the tissue dies when the load is sustained. This peak pressure phenomena is also related directly to comfort but average pressure is not, as reported in the article “Body Support Testing and Rating” in Hospital Materiel Management Quarterly, Volume 14, number 1, August 1992 by Aspen Publishers wherein sixteen different configurations of mattresses were tested and rated.
[0013] These tissue trauma forces may be adjusted in a number of ways—i) by putting the load where the body can tolerate it, ii) by attempting to control interface forces across the patient body support surface, or iii) by moving the patient periodically before tissue reaches an irreversible death situation.
[0014] There have been many efforts, as evidenced by patents discussed below, to eliminate this problem by a means other than nursing help, which has resulted in a plethora of equipment claiming to reduce the incidence of so-called Pressure Ulcers, or more correctly known as “Ischemic Ulcers,” as they are caused by factors other than just “pressure”.
[0015] The magnitude of this problem can best be described as “horrific.” It is estimated that in 1989 1.7 million hospitalized patients were afflicted with the above scenarios. The average cost for each patient was $40,000 to repair and settlements in the $250,000 range. Additionally, it is estimated that the United States spends $7-$55 billion per year on this preventable problem, while mortality rate for the afflicted patients is between 23 and 37%. About half of all patients over 70 years of age developing these ulcers have a fourfold increase in the rate of death. More expenses are hidden, e.g., when comparing patients with bedsores (Ischemic Ulcers) to those without bedsores, the average length of stay increased by a factor of five.
DESCRIPTION OF PRIOR ART
[0016] In recent years, inventors have approached this problem of tissue breakdown prevention using two basic approaches for body support, fluidic substance or polymeric foam. Each of these methods encompasses many variations that have met with differing degrees of success. Also of note and in most instances, cross-contamination or dust mite prevention has not been considered as part of a performance requirement until after-the-fact.
[0000] 1. Fluidic Support
[0000] Water/Air. Making use of a shaped structure and air bladders was proposed by Weinstein et al. in U.S. Pat. No. 3,456,270 wherein water was the supporting medium and a lifting inflatable bladder interface was used for raising patient for transfer.
[0017] Whitney in U.S. Pat. No. 3,802,004 changed a patient immersion depth through unique bladder arrangements inflated by air, without changing medium volume.
[0018] Hagopian in U.S. Pat. Nos. 5,072,468 and 5,068,935 describes a special bed frame for ease of manufacture and the use of water as the base medium with an air bladder on its upper surface to lower or raise the patient, as in Reswick (later), with the added ability to provide an inflated wedge for postural trunk control of the patient.
[0019] These approaches also were an attempt to reduce “hammocking” over bony prominences that tends to negate the efficacy of the support medium. It should be noted that the modern waterbed is comprised of water, a supporting envelope to “hammock” some one so that they do not sink into the bed and appropriate baffling or channeling for stability of the water.
[0020] Air. There are a number of ways in which air has been compressed, blown or applied to support a patient. Hart in 1926 in U.S. Pat. No. 1,772,310, described a technique of alternating the fluidic support points on the body by controlling the time each support point was to be activated, while limiting interface pressure to an acceptable value. Hart also introduced a method of patient turning in this same patent.
[0021] Whitney, in U.S. Pat. No. 3,148,391 used a modified method of support that was compact and introduced temperature control of interface as well as the alternating method of support.
[0022] Ford in U.S. Pat. No. 4,711,275 opted to inflate and deflate arrays of air cells through independent air compressors to create an alternating pressure support system.
[0023] Krouskop in U.S. Pat. No. 4,989,283 opted to control height of the supporting bladders in his approach to body support by measuring any changes in cell configuration through a microprocessor using its input from internal bladder sensors to control appropriate valving to pressure sources or exhausts to maintain each bladder at some referenced height.
[0024] Others used lateral support tube shaping (Talley of the UK), while others included an air loss to circumvent needle puncturing problems (3M) with appropriate control mechanisms.
[0025] Air, as a fluidic support, has been proposed in many forms for various purposes of body positioning. A surgical table is the subject of Canadian Patent 1035000 by Carrier where individual bladders of air are positioned to keep the bony prominences clear of the table, while providing a fairly stable support as each bladder is independently inflated to a desired pressure. All are then covered by a forgiving cover.
[0026] Air cushion machines are quite effective in supporting a large unforgiving body against a homogenous and somewhat stiff undersurface; however, their use as a patient support medium is impractical. Then again, if enclosed in a container of soft tough and highly flexible material, air is much more suitable for patient support if designed correctly to reduce hammocking.
[0027] Consequently, by using air in tubular or oval containers and arranging appropriately within the bed frame, a mattress of air tubes is a reasonable approach, depending on cross sectional area of bladders and their positioning. Shaping these air tubes and putting holes in them to circumvent accidental needle punctures and with a pump sufficiently large to keep ahead of the leak rate, had its merits.
[0028] Although Armstrong, U.S. Pat. No. 2,998,817, first developed an inflatable massaging and “cooling” system, as time passed, materials were developed that had built in leak rates suitable for beds and, thus, the current Low-Air Loss mattress approach evolved using so-called vapor-permeable materials. Such materials may consist of 80 denier nylon, or thereabouts, backed with a material of choice such as a film of urethane or vinyl.
[0029] Hess, U.S. Pat. No. 4,638,519, demonstrated use of shaped bladders using such materials with appropriate individual bladder control and methods of bladder attachments with air supplies while Goode, U.S. Pat. No. 4,797,962, used the process of controlling these air bladders in groups as a means of modifying support pressure under portions of the body as others have done in the aforementioned. (Some of these approaches have been prone to collapse when the patient is in the sitting position in the bed, and consequently exposing the coccyx and ischial tuberosities [sit bones] to excess pressure and shear due to increased bladder loading by the vertical component of the trunk.)
[0030] Some have attempted to reach suitable body support through the use of foam on top of slats placed on top of air cylinders, as outlined by Wilkinson, in U.S. Pat. No. 5,070,560.
[0031] High Density Fluid. Reswick, in U.S. Pat. No. 3,803,647, used a mixture of Barium sulfate ore and water (or other fluids) as a medium of support with a loose fitting lifting interface sheet as the top member of the unit. This sheet was inflated and allowed access to the patient at a suitable working height for the attendant personnel. The aqueous solution of barites was used as its specific gravity could be much greater than “1,” and thus support a body without immersion problems of water only. This specific gravity, greater than “1”, allowed the patient to lay in the solution and be supported up the body sides to an optimum immersion point. If the specific gravity is too high, excess pressures can be exhibited as area of support is drastically reduced. Keeping the mixture sufficiently fluidic presented a maintenance problem that led to patient disuse.
[0032] Patent '647 also addressed shaping of the container to reduce the contained mixture volume and of a tubular top bladder as a stiffening method of the upper surface of contained fluid for easier patient transfer or performing dressing changes.
[0033] Thompson, U.S. Pat. No. 4,357,722, demonstrates a flexible open mesh approach in a special bed frame to support the patient interfacing medium to change tension of support under various portions of the body.
[0034] Hargest et al., U.S. Pat. Nos. 3,428,973 and 3,866,606, used fluidized beads to create a specific gravity greater than “1”. These beads were micro-balloons approximating 100 microns in diameter and were “fluidized” by an air plenum chamber placed at the base of the beads separated by appropriate filtering and restrained to remain adjacent to the patient by another optional filter. Fluidization depends on the pressure drop across the supporting beads and that of the filtering system. Excess drop reduces fluidization, increases heat loss and can create ballooning of upper cover. It is thus necessary to adjust pump flow to match patient needs and size.
[0035] Lacoste, U.S. Pat. No. 4,481,686, controls bacteria through bead selection.
[0036] Goodwin addresses support of beads in U.S. Pat. Nos. 4,564,965, 4,672,699 and 4,776,050, with sequential diffusion of beads in U.S. Pat. No. 4,637,083.
[0037] Viard in U.S. Pat. No. 5,402,542 demonstrates use of a programmable EPROM and heat exchanger to control bead system component temperatures.
[0038] River sand has also been used in place of beads and periodically “fluidized” with marginal success.
[0039] Yet another approach that may be considered somewhat fluidic is the use of gel and air wherein a semi fluid gel is used in place of the fluidic bead systems in much thinner beds than the units discussed above. Due to the nature of the gel, however, its accommodation of high forces is somewhat limited.
[0000] 2. Use of Polymeric Foam Such as Polyurethane
[0040] Flat Stock. Polyurethane is formed through the mixing of different polymers under controlled conditions. Some manufacturers provide the fabricator with huge blocks of foam, which are then cut into required sizes and sold to various fabricators of furniture, mattresses and so on. Some of this stock is sold as-is, or as a finished item when placed within some acceptable cover consistent with industry requirements. Some foam is rigid and some flexible.
[0041] Flexible foam acts somewhat like a spring. It is well known that the further a spring is compressed the stronger is the resisting force of that spring, and so it is with foam. The unfortunate part of this foam as a support media is that the human body is not flat and hips protrude further than waists. Accordingly, when one is side lying on foam, the hip sees more spring-back (foam fightback) or a higher load than the waist. The hip bone (Trochanter) is poorly vascularized, and thus the tissue at its surface can be robbed of the desired blood to keep the tissue healthy. Thus, the enervated person is unaware of the damage being incurred with this load, the tissue dies, and the result is a sore where the skin integrity is forever damaged without surgical intervention. Other parts of the human body, e.g., the posterior heels, malleolus (ankles), iliac crest (pelvis), coccyx (tailbone), ischial tuberosities (sit bones), scapula (shoulder blades), occiput (back of head), elbows and ears are areas that are also poorly vascularized and prone to breakdown with small loading of tissue in these areas.
[0042] Those with normal sensation and mobility feel this excess tissue load as a discomfort and responsively move away and thereby restoring circulation in that region. It has been clinically noted that a sleeping person will normally move more than twenty times during an eight hour period on a so-called “standard mattress.”
[0043] Thus, flat stock foam, using current technology, is not very desirable for patients at-risk of tissue breakdown or for their comfort. Some materials tend to give way with applied load as in the case of materials used for the Apollo astronaut couches. However, this material, known as “visco-elastic” foam, is expensive, temperature sensitive, heavy, flaky, tends to tear readily, and was not generally used by the bedding industry in the past.
[0044] Flexible polyurethane foam has been the material of choice recently. These materials are available in many densities and Indention Force Deflections (IFD). Densities may range from the soft 1.1 pounds/cubic foot to about 7 pounds/cubic foot and an IFD range of about 14 to 180 is commonly used for bed support purposes. These foams are generally manufactured as a polyether, polyester, high resiliency or other foam, with all exhibiting different characteristics. The polyether materials are generally found in furniture, while the polyester is used in packaging requiring fire resistance, while high resiliency may be found where continual cycling is encountered. Other foams also include rubber and other compounding, which have not found great favor in the bedding/cushioning industry.
[0045] Although combinations of many of these foams is common knowledge in the industry, polyether material is less expensive and it may be found in products where replacement is no problem or where material is not used extensively. Its durability under continual loading has been less than desirable.
[0046] Cut or Shaped Foam Stock. Reducing forces encountered in flat stock of polyurethane was obtained through reduction of a foam support in the bony areas by cutting the foam in a special pattern, known by the name of “surface technology”, as proposed by Rogers (the inventor herein) in U.S. Pat. Nos. 3,885,257, 3,866,252 and 4,042,987. Others also cut foam as disclosed in U.S. Pat. No. 3,828,378 by Flam, U.S. Pat. No. 4,901,387, by Luke and later U.S. Pat. Nos. 5,025,519 and 5,252,278 by Span. Kraft in U.S. Pat. No. 4,679,266 simulated foam support by zones of inner (mattress) springs with varying strengths.
[0047] Murphy in U.S. Pat. No. 4,628,557 and Rogers (inventor herein) in U.S. Pat. Nos. 4,042,987 and 4,903,359 could make a selection of foam removal under affected areas of the patient, and in Rogers' case, overloaded adjacent support members rolled automatically into the vacancy to spread load gradually to adjacent areas.
[0048] Bony areas of the body can be free of all force in foam products through use of material cutouts in mattresses, mattress replacements, body conforming supports or cushions. However, shearing forces at the demarcation edge of support and no support are a harbinger of tissue death, unless that demarcation is gradual and can be overcome by the body's internal blood pressure without creating total occlusion of the blood supply. It is then of paramount concern that proper shaping of the edges of regions where foam is removed is built into any design of a support surface so that loading is transferred gradually to adjacent support areas of the body more amenable to the applied forces (putting the load where the body can tolerate it). Some methods to do this are disclosed in U.S. Pat. Nos. 5,127,119 and 5,048,137 by Rogers (inventor herein). Foam is cut away from bony areas and edge or shear effects are accommodated by cutting foam around the removed foam area to create supporting foam forces “normal” to the body and give a gradual buildup of load over a reasonable area where blood flow is not compromised. One patent discloses technique of load spreading through shaping of the cutout conically or approaching a bell shape and consideration must also be given to packaging of delicate instruments, fruit, etc.
[0049] Convoluted foam, initially used in anechoic chambers, is formed from flat stock put through a convoluting machine, and has been used as a mattress or pad where the patient is supported by a number of peaks and valleys, such as described by Schulper, in U.S. Pat. No. 3,197,357. This machine can produce two products 4″ thick from one five inch piece of foam. Obviously, material is spread equally between the two halves in such a manner as to create a peak of four inches with valleys to offset the adjacent peaks, a type of “mirror” image.
[0050] Peak sizes were varied, as well as depth of valleys, in an attempt to equalize forces without complete relief of affected areas. In some instances, manufacturers cut the peaks off some of these convoluted pads in an attempt to control support load distribution in a more acceptable product, as the peaks were of little support value and foam was wasted. Most of this type material was fabricated from inexpensive foam and has been banned from use in many medical facilities across the U.S. This is because of its inability to eliminate damaging forces on body tissue when the user had expected more protection than the material could provide without extensive forming, cutting or having its performance completely modified as disclosed in the subject patent.
[0051] It should be noted that the so-called “visco foam” designed for NASA and being more aggressively marketed now, can be significantly improved with the present invention as its spring-back can be eliminated on demand by the user. Water beds, on the other hand, must have sufficient strength in their membrane to hold a person out of the water (and thus create pressure points) with the membrane, else the user would sink to the bottom because of most body's greater than 1.0 specific gravity .
[0052] Replacing water with “oil-well” drilling MUD, with a specific gravity of 2, was proposed by Dr. J. Reswick. This would allow a person to actually float, and if a soft interfacing material was used to separate the user from the MUD, pressures were optimal. However, the concept proved to be impracticable to institute for various reasons, one being that the MUD was a severe handling problem during shipping, and weight was another.
SUMMARY OF THE PRIOR ART
[0053] From the foregoing, it is clear that many different approaches have been used in an attempt to reduce discomfort and injury in a bedridden patient. Such discomfort and possible injury is a direct result of the stress concentration created by the non-uniform shape of the human body. An ideal supporting structure would distribute the forces due to the body weight in a way to minimize or eliminate any localized concentrations of stress, particularly shear, such as would occur at a discontinuity in the underlying material. Fluids, gels, air and such may give an overall uniform support. However, as shown in U.S. Air Force studies, even this approach gives discomfort to the seated person as interface pressures exceed the popular interface pressures of 32 mmHg and portend of potential tissue trauma.
[0054] Where bony structure in the body is near the surface and not protected by a reasonable thickness of soft tissue, an effort should be made to greatly reduce or even to eliminate the stress in that region, compensating by slightly higher forces elsewhere, where the body can tolerate it. Total elimination of stress locally is particularly important to promote healing where a bedsore or injury already exists so that the affected site can be readily supplied with a healthy flow of blood. This same rationale applies for all sites of the body where blood flow may be compromised by an inappropriate body support medium, such as would occur at not only the discontinuity of the inner support material within the mattress or cushion say, but also that major consideration always overlooked in the past, the material between the inner material and the actual tissue of the body being supported. This may come in the form of “fire barrier” material or the actual outer covering of the inner material normally ascribed to as the “mattress cover”. If this interface material is unforgiving in the worst case, all of the inner core characteristics can be masked to such an extent as to completely negate the efforts given by surface technology shaping and such. In this case, each component may perform well on its own but lacks the conformance needed to optimally perform in concert with other components and protect tissue as initially intended. However, with correct design of singular items, the correct symmetry can be attained to perform as needed collectively. This requires consideration of not only the immediate support medium but also the major support structure, such as type of chair, spring or stainless steel sheet bed and such.
[0055] Similarly, packaging of complexly-shaped products to be shipped from one location to another has created a special marketplace for special support media, such as “foam-in-place”, air cells and so on. The present invention addresses this need as well because the packaging of people is no different to packaging components or products—its a matter of degree, as all must be protected from the outside environment where their integrity is challenged. Another reason for including this aspect of protection is to conserve use of oil and forest-related products and help keep the economy in check as the proposed interface protection media can be re-used for reshipping over and over again and the proposed mattress and seat cushions keep much of the environment away from the foam and thus extend its life substantially.
[0056] The prior art has not as a rule directly addressed these goals. Although it has been generally recognized that a support structure for the human body needs to provide different stress patterns in different areas, as do delicate instruments, most schemes do not fully achieve it. In fact, some have discontinuities in material and make no apparent attempt to minimize shear stress at those points. Again, similar to the packaging of products such as glassware, arriving at a destination, broken.
SUMMARY OF THE INVENTION
[0057] This invention relates to the support of a person in the prone, supine, side-lying, semi reclined or sitting position without the usual stress concentrations that may lead to tissue trauma, decubitus ulcers, ischemic ulcers, or bed sores, and is extended in its concepts to the shipping needs of delicate instruments (positioning, cushioning and impact protection) and other items of concern. It is also an object of the present invention to provide support for a human body in a manner so that the forces of support have fewer concentration points which are likely to occur at or near bony prominences, nerves or tendons and which, if not accommodated, can lead to serious complications, such as ulcers, nerve damage or strained muscles, tendons and other disabling factors.
[0058] This invention addresses the stress distribution problem by combining several techniques. First, using a basic foam inner material, or other material that gives a similar performance, the invention provides regions where material has been cut in some selected manner, placed adjacent or in concert with dissimilar material, or the same material with differing support characteristics, cut away, omitted, or formed to reduce the magnitude and abruptness of any stress concentrations when supporting a body (collectively or alternatively: “foam force accommodation zones”). This technique is then combined with the process of applying a membrane (“enclosure member”) of appropriate warp and weft to assure appropriate force distribution is applied to the supported surface should cavities be located under the membrane and over the insert material to smooth out the localized variation in stress and concomitantly, if the membrane is able to control the amount of air or fluid surrounding the space between the bladder and interstices of the foam, the fluid pressure may be varied to change the characteristics of the foam itself.
[0059] This latter components or aspect of the invention can be characterized by reviewing U.S. Pat. Nos. 5,127,119 and 5,048,137 by the present inventor and observing that when the described foam structures were loaded by a body, the foam will “fold” over in a normal direction to the tissue of the body to reduce the shearing occurring at the tissue. (By looking at a cross-section of the conical shape as discussed herein, a linearized “back-sloping” across a surface edge has a much more efficient pressure/shear distribution than the so-called “waterfall” cut.)
[0060] Notably, if a bladder were to be placed between the body and supporting foam of the nature just described, the bladder, with air or fluid control ability, can hold the foam (of the linearized cone edge) in its desired place and virtually create a minimal interface differential force, much as is found when floating in water.
[0061] By considering all the requirements for patient care ranging from personal hygiene to “chucks,” to diapers to sheets, to mattress covering to sweat collectors, to fire barriers to support medium, to the underlying support, the present invention has evolved to give the patient protection as well as comfort. “Comfort” has been shown to be directly related to forces exerted on the body by Rogers, as previously mentioned in the “Hospital Materiel Management Quarterly” article, “Body Support Testing and Rating,” dated August 1992.
[0062] Many inventors and developers of products have been diligent in their detailed design of products, as seen from within the confines of a designer's view without the clinical experience seen by the inventor (substantiated by reports from University of Southern California School of Rehabilitation Engineering Center at Rancho Los Amigos Hospital (California) Annual Reports of progress, CV Mosby Orthopedic Atlas, and being Director of the U.S. Army Field Medical Laboratory fabrication and numerous technical articles) to adequately formulate a suitable set of specifications gained from experience in the clinical care of patients as well as in the design of delicate instrument shipment, such as those encountered in a U.S. Army Field Medical Laboratory. With this background, the present inventor hereof expands on the objectives of this invention to include patients' well-being, as well as handling of delicate equipment and as such, emphasizing that a major objective of the invention is to improve on the many available products, followed by details of collective specifications of previous patents, mingled with personal experience and coalesced into new “Definitive” mattresses, upgrading of past patents and designs, cushions and the supporting structures for handling delicate products.
[0063] In view of the foregoing, it is an object of the present invention to provide an improved mattress enclosed in a functional membrane.
[0064] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane that upgrades existing equipment performances to better meet the needs of consumers and patients
[0065] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane that can be used for patient support, tissue protection and comfort whether seated or laying down.
[0066] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane that clears the sacrum, coccyx and ischial tuberosities of pressure and shear when required by raising the supported person sufficiently to clear pressure points on their body.
[0067] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane that also incorporates alarms, if so needed, to indicate when tissue is being overstressed through built-in sensors.
[0068] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane that has nearly zero interface pressure/shear over the potentially affected site.
[0069] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane that extends the life of the contained foam within a support system by isolation from the local environment.
[0070] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane that allows easy storage and shipping with its self-contained pumps able to be vacuum packed without external pumps or the like.
[0071] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane that can cost-efficiently cover existing mattresses/cushions with portions of the present invention for low cost upgrading of equipment and service cost reduction.
[0072] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane that can control time constants and damping ability of foams, springs of all shapes in spring mattresses and seating to meet the goals of the original designs through compression and expansion of fluid medium surrounding portions, or all of the existing equipment.
[0073] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane that can assess tissue loading by measuring pressure and shear under the bony prominences without any additional equipment to the mattress or cushion which, in turn, will allow one to take the corrective action with built-in features of the existing equipment.
[0074] It is another object of the present invention to provide an improved mattress enclosed in a functional membrane that only requires one person to readily move a patient via the built-in transfer sheet.
[0075] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane that also correctly positions patients with self contouring body supports.
[0076] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane with the ability to self vacuum pack the position of patient or when being transported from one location to another.
[0077] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane that gives the user even more fluid-like support through use of judicious control of fluid surrounding this foam mattress or cushion by use of an enclosed cover and suitable operating means to control the internal environment.
[0078] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane that can complete foam return by scaling closure of a twist valve marked for time constants or rates of response.
[0079] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane that includes the option of time constant changes, or the direction of flow to and/or from the mattress at a controlled rate or all by valve control at user option.
[0080] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane that can vacate or inflate the present invention through twist valves in tandem or unitarily.
[0081] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane that allows the user selection of one, three or five valves, joined integrally with the supported member to improve overall performance needs.
[0082] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane that allows the use a remote plug-in attachment integral to the support surface.
[0083] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane that uses an outside source of energy to operate its functions.
[0084] It is another object of the present invention to provide an improved mattress or cushion enclosed in a functional membrane that can be controlled remotely through suitable RF or RF-like coupling.
[0085] It is another object of the present invention to provide an improved mattress, cushion, packaging enclosed in a functional membrane that can also be used as partial reusable packaging around a product that can perform well with varying time constants tied to springs for buffering at required frequency of vibrations expected during transit.
[0086] It is another object of the present invention to provide an improved mattress or seating enclosed in a functional membrane that can provide a seated driver or passenger in a vehicle with a variable time constant support, much as the variable dampers are tied to the chassis of a vehicle to assist in smoothing out the chassis vibrations encountered over various terrains.
[0087] In satisfaction of these and related objectives, the present invention overcomes the stress distribution problem unlike anything available by combining several techniques. A basic foam inner material is specially cut to reduce the magnitude and abruptness of any stress concentrations when supporting a body. A membrane of appropriate warp and weft is applied to the supported surface to smooth out the localized variation in stress while the fluid pressure may be varied to change the characteristics of the foam itself and the under-support structure designed to assist in meeting these ends.
BRIEF DESCRIPTION OF THE DRAWINGS
[0088] FIG. 1 illustrates the concepts of tissue trauma or tissue death.
[0089] FIG. 2 is a detailed description of drawings for design of a cutout.
[0090] FIG. 3 illustrates the function of a simplistic approach to a difficult problem—care of the hospitalized, elderly or bed-ridden patient.
[0091] FIG. 4 illustrates cavity function with loading and vacuum control.
[0092] FIG. 5 illustrates the pressure/shear transducer.
[0093] FIG. 6 illustrates three versions of the invention for general use with mattresses, cushions and shipping fragile goods with a reusable cover or “shipper.”
[0094] FIG. 7 illustrates a detailed operation of the self-contained pump action.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0095] Referring to FIG. 1 , the concepts of tissue trauma or tissue death is illustrated. Foam compression has a varying, and often times subjective result to people as an identical compression or cushioning feels “hard” to some and is acceptable to others. Mattresses or cushion are generally accepted by “feel,” which relates to peak pressures as illustrated in FIG. 1 .
[0096] Part (a) illustrates a slab of foam ( 1 ). Part (b) shows a body ( 2 ) loading foam ( 1 ) to a height of ( 3 ). Part (c) shows a heavier body placed upon the same foam which compresses to where equilibrium has been reached. However, in part (d), with a heavier, load there is only a thickness ( 5 ), depicting a possibility of “bottoming-out”. This term may be a misnomer, as the foam may not have bottomed out as it could have been compressed a small amount more before all elasticity of the foam has disappeared and only the physical cell mass is supporting the load ( 2 ). Part (e) illustrates a bony body ( 6 ) being placed upon a similar foam block ( 1 ) and the resulting forces are ( 7 ) where the bone ( 9 ) is penetrating the tissue and causing shear forces ( 8 ) up the side of the bone. This force can be shown to be the directly related to the peak pressure ( 12 ), while the additional shear load at the tissue surface ( 11 ) and the surface tension ( 10 ) also contribute as shown in the next part. Part (f) depicts the breakdown of tissue at the surface ( 13 ) but the majority of damage is at the bone demonstrated by ( 14 ).
[0097] These are the forces that restrict blood flow and are the start of the insidious ischemic ulceration previously discussed. One of the primary objectives of the present invention is to prevent these causes of tissue failure.
[0098] Referring to FIG. 2 , which is a detailed description of drawings for design of a cutout. In FIG. 1 , the effect of sharp edges or difference between support and no support results in high shear forces to a body. In FIG. 2 , the body is placed over a shaped cutout which can be a cone in cross section or a straight edge into the drawing. When the edges ( 3 ) of the foam ( 1 ) and a cutout ( 2 ) are loaded by a body, the edges roll inward as at ( 4 ). This gives more surface area of support so the load at ( 4 ) is spread over a greater area than if the walls of the cutout were straight (greater area for load, the less pressure at the site of support), or even cut inward and the forces tend to be normal to the cutout at ( 4 ). This, in turn, reduces shear at the bone and the perpendicular or peak pressure loading ( 5 ) is also reduced creating a safer environment of force control and also resultant comfort.
[0099] FIG. 3 illustrates function of a simplistic approach to a difficult problem—care of the hospitalized, elderly or bed-ridden patient. The shaped cone of the inventor's prior patent has led to the use of the sloping backward method of edge control of shear forces on the body adjacent to the coccyx/Trochanter areas of support in a mattress, cushion and sensitive areas of body support.
[0100] A person's trunk section 1 is shown placed on the support 27 . 2 is the leg section and it also is placed on the support 27 , which may consist of strong corrugated cardboard for low costing that can consist of two adjacent panels which are bifurcated longitudinally to allow rolling of the supported mattress or cushion or in the case of the mattress, allow “gatching” of the bed (and supported mattress) while giving the back support, clearing the coccyx and ischial tuberosities of the patient and allowing positioning of the legs independently. 3 is the foot pillow attached by hinge 28 to the main cover of Dartex like material also used over 2 as in 1 . 4 is the outer edge material as is 15 with a cavity in between and below, to support the use of the collector 24 fitting within the sloping cavity between the two names sections. 5 is the rolled or folded transfer sheet attached to the cover 7 and the leg covering. This sheet is folded back onto itself for the patient to be rolled upon and when in place, sheet is pulled along with the patient for transfer to wheelchair etc. 6 is a sensor shown in following figure. This sensor can be built into the cover or be separate item. 7 is outer fluid proof material that is vapor permeable (thus the need for the sweat collector introduced through the double Ziploc type fastener) that allows moisture to enter the inside foam if not protected. Material is RF welded on all edges to assure fluid proof integrity. 8 is the self-inflating pillow attached by hinging to the cover material. The pillow covering will also be similar to the main cover except more flexible. The pillow will be filled with particulate material of choice so that it can also be vacuum controlled, fluid inflated or time restrained compression to meet patient/ physician needs. 9 is the hinge attachment to the cover. 10 is the valving discussed under the self-inflating description in following. 11 is the pillow deflated and positioned over end of bedding. 12 is the vent control section of the pillow described in the following also. 13 is the inflated pillow. 14 is already covered. 15 is the end filler of the cavity between the head and leg portion of the support system. 16 illustrates the back-sloping edge of the cutout running laterally across the mattress for pressure/shear relief of the Trochanter- coccyx-sacral area of the body fitting over cavity 30 . 17 are valves for controlling the positioning and function of the rotated foot piece 21 hinged at 28 and now used for knee resting shown dotted. 18 is the pillow-leg portion in the knee support position. 19 are valves as in previous sections to control the time constant, vacuum forming or inflating ability of the various portions of the Definitive mattress. 20 shows the same unit pushed up in place and held there by the hinge 28 and particulate material fluid vacated to form unit to feet if needed. 21 is foot pillow position for normal foot control as needed. 22 notes the valve positioning. In smaller units one set of valves will be quite adequate although all will perform well when appropriately designed to match production needs. 23 is hinge point in base unit if it is hard material and will not flex on its own. 24 is collector of waste material that can be removed from under patient when appropriate. 25 is a self inflating pillow for positioning collector or it can have added feature of filling the vacant space 30 if collector not used. 26 is pneumatic sensor for measuring peak pressure/shear in a novel inexpensive way described later. 27 is the composite baseboard previously mentioned. With patient in place on the Definitive mattress the buttock portion of the body will be free of support due to the cavity 30 in which the collector is placed. 28 is hinged portion of pillow 3 . 29 is another Ziploc for placement of stiffener to assure the vacuum aspect pulls down under the patient rather than allow vacuum to also raise bottom of cavity unless this aspect is used to raise collector 24 and pull down covers over modules 1 and 2 when jointly connected through pillow 25 or over baseboard 27 . See following figures for this detail of action. 30 is the cavity over which the buttock portion of a person is placed and in which area the effluent is caught by collector 24 . It becomes obvious that the catch area of this cavity is also the bony area of the body more prone to tissue death if overstressed.
[0101] The mattress can be pneumatically controlled by valves at 22 to any degree needed by patient. More vacuum and the more the edges at 26 will fold into the cavity giving more relief or used to reduce back pain in some.
[0102] The head can be elevated rotated and controlled with softness dictated by inflation level of unit. The knees can be elevated through use of the rotating foot/leg unit and molded to the body shape require while unit is pumped on the side. If the unit is to be stored or shipped, it can be folded back on itself, both sections vacuumed by their self-contained units and unit moved.
[0103] FIG. 4 —Cavity function with loading and vacuum control. As previously illustrated, the back cut top edges of the foam cavity are initially in position 1 when unloaded and cover 4 spans the gap. When a load W is placed on the cover and cavity the foam rolls down to position 2 with the cover also being forced down into the cavity. However, when a vacuum is applied to space 7 and the surrounding foam, the foam and cover 4 is now pulled down into position 5 creating a gap 6 under the loaded site. This is where it is feasible to have zero interface pressure under a bony site, such as a trochanter and the shear forces are now spread over the gently curved area of the foam without the foam spring force in place. Thus, this creates a pseudo fluidic type of support at the tissue interface.
[0104] FIG. 5 —Pressure / shear transducer. The unit illustrated is an integral part of the Definitive mattress where indicated for patients with potentially compromised tissue. As a stand-alone unit, it consists of two layers of highly flexible fluid-proofed material with little or none surface “stiction”. In its preferred embodiment, the unit is RF welded in the form shown with the outer envelope 1 and the internal divisions 2 creating a maze type of path to be placed under a suspected site of concern on a patient's body.
[0105] Air is introduced in preferably “burst” manner or step function. When air is noted coming out of the unit the amount of air applied at the inlet for this to happen gives the interface forces under which the unit is being subjected.
[0106] Calibration of the unit requires demarcation between pressure and shear by using standard weights to close off one part of the maze. It is obvious to those skilled in the art of air flow to see that if the unit is highly flexible it will see not only the pressure involved but also the shear occurring at the site of monitoring. This is unattainable with standard sensors with discrete elements tied together as the measurements in this instance are clouded by sensor placement relative to each other, flexibility of carrier and potential cross-talk between sensors.
[0107] The sensor of the present invention is unique because of its minimal expense as an individual sensor, but also because of its suitability to be included in the covering of product without affecting product performance. The air supply, switching and monitoring gauges are omitted as they are common to those involved in instrumentation methods.
[0108] The transducer can be part of the cover design as its interference with system function is minimal and its usefulness far outweighs any loss of motion to the covering. Monitoring can be by RF link to a station or to attendant or by a simplistic visual indicator that is hand held or part of the bed. In the preferred embodiment, automatic sequencing of air bursts can be self-contained in a hand held or remotely located unit in a number of ways commonly known to those who design such devices.
[0109] FIG. 6 —“Fits-all” covers. FIG. 6 illustrates three versions of the invention for general use with mattresses, cushions and shipping fragile goods with a reusable cover or “shipper.” Illustration A is for covering existing mattresses to make them more functional and without having to replace existing mattresses because the cover is ripped, torn or unusable or the mattress itself can have upgraded performance in preventing tissue trauma or improving comfort of the user.
[0110] Liners of foam can be placed inside or be added while inserting mattress. 1 depicts the foot section as discussed in foregoing. With its hinge to cover 5 if needed for particular application of foot drop, cavity filling a foot handling as in the Definitive unit of FIG. 3 or knee elevation. 2 is Ziploc for mattress insertion. Fitting a mattress into a cover can be problematic. However, the subject invention cover herein being discussed is not necessarily a standard cover, as it can be oversized and surplus (minimum) tucked under assembled item. 3 is pillow with its hinge to 5 and 4 are the controls with functions as outlined in previous disclosures herein. The unit is highly flexible and shipping and handling are satisfactory as all air can be vacated by using outside pressure on package and closing the metering valve. “B” is similar to “A” with the control remote as discussed previously. “C” is the cushion and packaging module sized as needed with Ziploc probably on underside for the seat cushion.
[0111] It should be noted that the Ziploc type structure must be fluid proof under pressure differential or it will not be suitable for vacuum of any extent before its feature is negated.
[0112] For cushion use the unit should be sized appropriately as tucking excess on underside may be suitable for a mattress but problematic for commercial or office use. When the unit is made in factory with sizes established the completed item may be welded in place for function and appearance. Ziploc length and positioning is critical for easy assembly or additional filler will be provided as an extra for appearance.
[0113] Pumping elements needed can be by specification. If no pumping-up is needed, then one function can be omitted and only three valves used or at minimum two. Packaging units are fabricated much like a Ziploc itself or one of the items marketed for storage of clothing. However, this unit has a self contained pump and vent as well as added air if necessary for additional impact protection.
[0114] Cushions can be assembled to be controlled by the same process as the mattress described. The user can deflate/inflate by compressing any part of the cushion with valving appropriate to need activated as discussed in the following explanation of pump operation. A sensor can be included when bottoming is about to occur if a cutout is used. The client then replaces the cushion after emergency inflation. A timer function can also be included with a pneumatic option to assure time of sitting has expired.
[0115] As for positioning and support products, as previously mentioned, all the separate units now in use can be made more effective in function, extend their life and reduce costs by including appropriate valving and sloping of support surfaces at areas of concern to include consideration of design with all or part of the invention as needed to include those to be considered as a minimum head, body, arm, leg and foot positioners (with safer support), operating room table pads, gurney pads, wheelchair inserts, wheelchair cushions and pillows.
[0116] FIG. 7 —detailed operation of the self-contained pump action. The top figure for the self-contained pump concept illustrates a typical concept for the self pumping of fluid in, out and metered. # 1 is outer fluid-impermeable bladder or cover for enclosed mattress/cushion/other # 4 . # 2 is self-inflating inner bladder adjacent # 4 . # 3 is second self-inflating bladder adjacent # 4 . # 4 is main mattress that could be plain foam, textured foam, convoluted foam, batting, sliced/diced foam, surface technology applied to foam surface performance, contoured shapes, irregular shapes of varying densities (spring-back) and demarcations, springs (flat, coiled, conical and such) other fluidic components in various shapes for demarcation control. # 5 is metering twist valve (or other able to adjustably meter flow) for altering # 4 response time and spring constant by modifying flow through cavity # 12 and surrounding areas and interstices of # 4 . # 6 is twist valve (or other to be able to finitely control fluid flow) is for metering and controlling flow out through its related one-way valve # 8 , its self contained foam cavity surrounding # 2 with its enclosing fluid impermeable membrane with fluid entering one way valve # 10 for control of egress of fluid # 12 from around and through # 4 and exiting at one way valve # 8 and metering twist valve # 6 . This action evacuates fluid from within enclosure # 1 and mattress/cushion # 4 by compressing combined unit at position # 12 above # 2 & # 3 with # 5 and # 7 closed. This allows the attendant or user to adjust amount of fluid that is vacated around # 4 to such an extent that fight-back of # 4 is removed or actually overcome to extent of compressing # 4 in its entirety. # 7 is a metering twist valve (or other able to adjustably meter flow) allowing air to enter its associated one-way valve # 9 through foam # 3 and exiting through one way valve # 11 to cavity # 12 with # 5 & # 6 closed. This allows the fluid to enter by the amount needed by user to give a combined inner control plus its surrounding fluid to reach a level of comfort or height needed for various reasons.
[0117] In summary, close valve numbers 6 & 7 and use Valve # 1 to change inner component # 4 to respond as rapidly or as slowly as needed by user. Close # 5 & # 7 and open # 6 to expel contained fluid # 12 to compress around # 4 and where # 4 has been contoured or cut in some manner to give a varying force support topography, the weaker sections will collapse first so that absolute clearance of a supported body, be they seated or laying down, can be obtained through pumping the foam located in an unused portion of the support surface such as the corner of a mattress or cushion (Note the unit may be mounted sideways for cushion or other action if top compression is not suitable.) Closing #'s 5 & 6 and opening # 7 allows fluid to enter the enclosed structure and pumped in a similar manner as when evacuating, will allow fluid to enter at a rate and amount suitable to the user who may wish to have the fluidic feel to their support or allow person to raise themselves to a different working level for comfort or function.
[0118] The lower figure of FIG. 7 illustrates one method of remotely controlling the function described above to be removed from the actual support surface. The following describes one method of direct physical linking to the surface to be controlled but it can be readily understood that such functions can be duplicated through an RF type of interconnect to self contained units mounted suitably around, or in, a surface requiring control as described herein. It is also another method wherein Hospital air vacuum and pressure sources could be connected directly with associated circuitry to remotely control bed/mattress/wheelchair surface support functions. The unit # 9 can contain its own pumping section, as described in previous figures where valves # 1 , 2 , 3 , 4 and 5 replace # 5 , 6 , 7 , 8 , and 9 with valves 10 and 11 selectively placed in portable unit or in the unit under control, or where vacancy # 12 occurs. # 6 & # 7 are self priming pumps as previously described with tubing such as # 8 collectively operating through # 10 on to quick disconnect # 11 attached to the body under control.
[0119] 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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The present invention is an improved mattress or cushion enclosed in a functional membrane that relates to the controlling of flexible, rigid or visco-elastic foam, springs, air, fluids, particulates, combinations thereof and foam density variations to meet varying force support needs, as well as other support means that have employed surface technology to modify the basic support characteristics and the interface created therefrom with a supported body in a manner intended to support the body optimally. One potential non-health-related result of the implementation of the present invention is to save national need for petroleum-based products, forestry and expenses attributed to shipping with complicated interface support methods normally incurred as a shipping expense without a reusable feature.
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FIELD OF THE INVENTION
The present invention relates generally to a spinning box at a spinning station of an open-end spinning machine and, more particularly, to a spinning box having a spinning chamber to which a spinning vacuum is applied and in which a spinning rotor turns at high speed (rpm), and having a cover enclosing the rotor at a front side and supporting means for feeding fibers from a sliver to the rotor and a yarn withdrawal tube for drawing spun yarn out of the rotor. The present invention has particular application to the provision of an opening in the spinning box cover for air supply and to a closure therefor which can be actuated during the preparation and operation of the piecing process by means of a service unit performing the piecing process.
BACKGROUND OF THE INVENTION
If the yarn is broken at a spinning station of an open-end rotor spinning machine, or when spinning is to commence at a spinning station, a trailing yarn end is brought back through the yam draw-off tube to the rotor in the respective spinning station, so that it can be combined therein with the fibers fed into the rotor. The spinning process starts with continuous feeding of fibers and drawing off the yarn. The insertion of the yarn into the rotor, as well as the feeding of the fibers, must be exactly matched to each other, so that the area of the pieced section does not differ in appearance or quality from the remaining yarn in an impermissible manner.
A piecing process requires particular care when feeding the fibers. If a yarn breaks, the sliver feed is immediately stopped. As a rule, the yarn is pulled out of the spinning chamber and therefore out of the rotor by means of the high winding speed. It is customary to clean the rotor prior to each piecing process before the yarn is returned into the spinning chamber. This measure is for the preventative purpose of increasing the quality of the yam and is intended to remove dirt which has collected in the rotor, as well as fibers which would hamper the piecing process. However, during this process the sliver being fed remains inserted in the opening device, and the opening roller continues to turn with the spinning vacuum being continuously applied to the spinning chamber. Thus, it cannot be ruled out that, after a cleaning process has been performed and while the stopped rotor awaits the piecing process, fibers are being transported in the direction toward the rotor and collect at the lowest point in the fiber collection trough of the rotor. These uncontrolled fibers flying around in the spinning chamber can form flocks in the yarn when being deposited on the rotor and can therefore trigger yarn faults. For this reason it is important that no stray fibers can get caught in the rotor prior to the piecing process. In order to be able to perform piecing and yarn formation without interfering fibers, it is known from German Patent Publication DE 44 45 740 A1 to generate an air flow in the spinning chamber by opening a flap, and to maintain this air flow until the speed (rpm) of the rotor has reached a value in which the centrifugal force of the fibers causes a deposition of the fibers in the rotor trough, which can no longer be affected by the airflow.
It is also known from German Published, Non-Examined Patent Application DE-OS 28 18 794 to influence the vacuum in the spinning chamber during the piecing process by opening a flap at an air supply opening of the spinning chamber, in order that, prior to feeding in fibers for piecing, the rotor is freed from fibers which have already been deposited therein, and so that the feeding speed of the fibers fed to the piecing device can be matched to the rotor rpm. Fibers and dirt, which adhere to the rim of the opening or have been caught when the flap was closed, can be aspirated from the vicinity through an opening unblocked by a flap. The deposition of dirt is made easier in particular by fibers carrying gummy or sticky substances. If the flap is prevented from closing completely, secondary airflows can occur in the spinning chamber, which have a negative effect on the feeding of the fibers to the rotor and thus on the spinning process.
It is further known from the earlier filed, but later published German Patent Publication DE 196 24 537 A1 to blow compressed air centrally into the rotor cup for the purpose of blowing out fibers interfering with the spinning process through an exhaust nozzle for the yarn located opposite the rotor. A valve which blocks a compressed air feed line is provided to this end in the cover over the spinning chamber, sometimes referred to as a hood. The valve consists of a sphere which is pressed against a sealing face by means of a spring acting counter to the spinning vacuum. The sphere is lifted off the sealing face by the effect of the compressed air flowing into the rotor cup, and the compressed air flows through the exhaust nozzle into the rotor. If fibers and dust on the sealing face prevent the complete seating of the sphere, secondary air can flow through the valve during the spinning process. If fibers and dust cling to the spring and in this way reduce its resiliency, a controlled air supply is no longer possible.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide an improved means for optimally controlling the air supply within the spinning box of an open-end spinning, in particular for cleaning the rotor when preparing and performing a yarn piecing process. A more particular object of the present invention is to control the air supply via a closable opening in the spinning box and to prevent the admission of secondary air during spinning.
The present invention is basically adapted for a spinning station of an open-end spinning machine wherein a spinning box comprises a spinning chamber, means for applying a spinning vacuum within the chamber, a rotor disposed rotatably within the chamber, and a cover enclosing the spinning chamber. The cover has means for feeding fibers to the rotor, means for withdrawing spun yarn out of the rotor, an opening for supplying air into the chamber, and, in accordance with the present invention, a slide member for opening and closing the air supplying opening during a yarn piecing operation by means of a service unit for performing the piecing operation. Such service unit preferably includes a manipulator having a profiled element movable relative to the spinning station and the slide member includes an actuating element disposed in the path of movement of the profiled element so that the opening and closing disposition of the slide member can be changed as a function of the movement of the profiled element.
The deposition of dirt at the opening, which hampers the functional ability of the closure and allows secondary air to be admitted into the rotor, is effectively prevented by closing the opening by means of a slide member for the controlled supply of air to the spinning chamber of the spinning box in accordance with the present invention. In particular, the closing movement of a slide member over the rim of the opening constituting the sealing face has a cleaning effect, because dirt possibly deposited on the sealing face is stripped off, and in this way the desired function of the slide member for tightly sealing the opening is assured.
The slide member can be actuated by a service unit which also performs the piecing process. For example, the actuation of the slide member can take place by means of a manipulator, which is placed at the spinning station in order to feed the sliver to the spinning station during the piecing process. The slide member has an actuating element, which can be arranged in the movement path of a profiled surface of the manipulator, so that the opening position of the slide member is a function of the placement movement of the manipulator. But the manipulator can also have an actuator, which can be triggered independently of the movement of the manipulator and can be brought into operative connection with the actuating element of the slide member. It is also possible to actuate the slide member by means of a blower nozzle, which can be placed at the opening for preparing the piecing process. In this case the blower nozzle has a profile which, for opening the slide member, acts on the actuating element thereof.
A slide member offers the advantage over known closure elements of being able to be placed into any selected opening position. It is possible by means of this to selectively adjust the uncovered cross section of the opening and therefore to change the intensity of the airflow continuously and to adapt it to the respective prevailing requirements, for example as a function of the rotor diameter and the yarn parameters.
The cleaning function of the slide member is aided by providing a front edge of the slide member with a profile which cleans the rim of the opening in the course of a closing process. For example, viewed in the direction of closing movement of the profile, the profile can terminate in a wedge-like point like a scraper. In order to protect the rim of the opening constituting the sealing face from damage and to better match the profile of the slide member, the front edge of the cleaning profile of the slide member can be made of an elastic material, for example a plastic or hard rubber material or the like. Because of possible wear it is furthermore advantageous to fasten the cleaning profile of the slide member exchangeably at its front edge. Fastening can be accomplished by clamping or screwing, for example.
To aid the closing movement of the slide member after it has been activated, it is advantageous if the slide member is connected with an automatically acting restoring device for returning to its closing position. The restoring device can additionally contribute to stabilizing the position of the slide member in the course of selectively varying the opening cross section for controlling the airflow.
The sealing effect of the slide member against the admission of secondary air during spinning is considerably increased if the slide member is covered with a diaphragm on its surface facing the opening. When the slide member is closed, the diaphragm is pulled by suction against the opening to be held in contact with its edge under the effect of the spinning vacuum prevailing at the opening. In this way the opening is advantageously completely sealed against any admission of air.
According to a further aspect of the invention, the opening on the spinning box can be designed to receive a compressed air nozzle, which can be advanced when the slide member has released the opening. Particularly effective cleaning takes place because of the increased pressure and the higher flow speed of compressed air in comparison to suction air created by the spinning vacuum. Cleaning of the rotor by means of compressed air centrally blown into the rotor is described, for example, in German Patent Publication DE 196 24 537 A1.
Additional features, objects and advantages of the present invention will be explained in more detail hereinbelow with reference to exemplary embodiments illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view, partially in cross-section, of one spinning station of a multi-station open-end spinning machine in accordance with a preferred embodiment of the present invention, depicted with a service unit positioned at the front of the station to place a manipulator with a compressed air nozzle against the spinning box for sliver draw-in as well as for actuating the slide member of the present invention,
FIG. 2 is an enlarged cross-section of a portion of the spinning station of FIG. 1 in greater detail, showing the compressed air nozzle placed against the opening completely unblocked by the slide member,
FIG. 3 is another cross-sectional view similar to FIG. 2, showing the opening with the slide member in the closed position, and
FIG. 4 is a partial top view of the opening and closed slide member of FIG. 2,
FIG. 5 is a longitudinal cross-sectional view of the slide member,
FIG. 6 is another side elevational view, partially in cross-section, similar to FIG. 1, of one spinning station of a multi-station open-end spinning machine with a service unit positioned at the front of the station to place a manipulator with a compressed air nozzle against the spinning box, depicting a second preferred embodiment of the present invention wherein the compressed air nozzle can be placed against the spinning station independently of the manipulator, and
FIG. 7 is another side elevational view, partially in cross-section, similar to FIGS. 1 and 6, of one spinning station of a multi-station open-end spinning machine with a service unit positioned at the front of the station, wherein the compressed air nozzle has a profile for actuating the slide member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the accompanying drawings and initially to FIG. 1, a portion of a spinning station of an open-end rotor spinning machine is illustrated and indicated generally at 1. A travelling service unit 2 is positioned in front of the spinning station 1, of which only the features necessary for aiding in understanding the present invention are represented. The spinning station 1 has a spinning box 3 defining a spinning chamber 4 in which a rotor 5 is rotatably supported. The spinning chamber 4 is connected to a vacuum source, not represented here, for maintaining a spinning vacuum within the rotor 5. The rotor 5 is mounted on a drive shaft 6 which is supported in a housing 7 of the spinning box 3 in a disk bearing comprised of spaced disk pairs which define therebetween a wedge-like notch or gap for receiving the shaft 6 as is known from the prior art. One disk 8 of the disk bearing in which the shaft 6 of the rotor 5 is seated can be seen. The spinning chamber 4 is closed by means of a cover, in the form of a hood 9, in which a yarn withdrawal tube 10 is supported to extend from a yarn draw-off nozzle 11 located opposite the rotor 5, to a remote outlet opening 12 in the hood 9. The hood 9 also contains a yarn guide conduit 13, through which individualized fibers combed from a sliver (not shown) by an opening roller 15 in an opening device 14, are transported to the rotor 5. Feeding of the sliver to the opening roller 15 is performed by means of a delivery roller (not shown) having an axial extension 16 which projects from the housing of the opening device 14. The delivery roller is actuated by the service unit 2 during the process of piecing a yarn within the rotor 5 for controlling the feeding of the sliver.
The hood 9 additionally contains a tube 17 which, in the instant exemplary embodiment, terminates within the cup-like interior 5a of the rotor 5 in the spinning chamber 4. The tube 17 is used for supplying aspirated air or compressed air into the rotor 5 particularly for cleaning the rotor cup 5a. In accordance with the exemplary embodiment in German Patent Publication DE 196 24 537 A1, the tube 17 can also terminate in the yarn withdrawal tube 10 behind the yarn draw-off nozzle 11. An opening 18 at the opposite end of the tube 17 is disposed in an adapter 19 configured for receiving a compressed air nozzle 25, which can be advanced from the service unit 2. The adapter is set into a wall 20 of the hood 19 and, in accordance with the invention, is openable and closable by means of a slide member 21.
The opening and closing movements of the slide member 21 are actuated by the service unit 2. The service unit 2, not shown in detail, is movably seated on the frame of the spinning machine, as generally known within the art, for movement along the spinning stations 1 and, upon a yarn break or bobbin change, is operative to perform a yarn piecing operation. The service unit 2 is equipped with a manipulator 22 for this purpose. The manipulator 22, for example, has a drive 23 for the delivery roller, which can be coupled with the extension 16 thereof for feeding sliver during the piecing process.
The manipulator 22 is furthermore equipped to actuate the slide member 21, thereby to unblock the opening 18. In the instant exemplary embodiment, the manipulator 22 has an actuator 24 with a profiled element 51, which engages an actuating element 49 of the slide member 21. Upon opening of the slide member 21, air flows through the opening 18 into the tube 17 and thus into the rotor 5 and the spinning chamber 4. Prior to each yarn piecing operation, the rotor 5 and the spinning chamber 4 are purged of stray fibers in this manner. This manner of cleaning is known, for example, from German Patent Publication DE-OS 28 18 794. Cleaning of the rotor 5 can additionally be aided by blowing of compressed air into the spinning chamber. For this purpose, the manipulator 22 can be equipped with a compressed air nozzle 25, which is disposed to be placed against the opening 18 when unblocked by opening of the slide member 21. The nozzle 25 is connected with a compressed air source indicated only schematically by the symbol 26.
The manipulator 22 is pivotably mounted on the service unit 2. Two essentially parallel rocker arms 27 and 28 of equal length are seated at respective ends in hinges 29, 30 on the service unit 2 and support the manipulator 22 in hinges 31 and 32 on at opposite ends of the rocker arms 27, 28. The rocker arm 27 can be pivoted around the hinge 29 by means of a drive 33, as indicated schematically by the arrow 34. In this manner, it is possible to retract the manipulator 22 when the service unit 2 is moving, and to extend it for placement against a spinning station after the service unit has been positioned in front of a spinning station 1. Such movement takes place in an arc about a relatively large radius, as indicated by the arrow 35. The movements of the service unit 2, the movements of the manipulator 22 and the drive 23 for the delivery roller are controlled by a control device 36 in the service unit 2.
FIG. 2 shows in a more detailed cross-section the slide member 21 completely opened to unblock the opening 18, with the compressed air nozzle 25 placed against the adapter 19 in the wall 20 of the hood 9 to extend into the opening 18. The adapter 19 is configured in a funnel-shape formed compatibly with a cone-shaped mouth 37 of the compressed air nozzle 25 for mated receipt thereof. As previously indicated, the tube 17 for supplying air to the rotor 5 is connected with the adapter 19. The annular rim 38 of the opening 18 serves as a detent for the mouth 37 of the compressed air nozzle 25, as well as a sealing face on which the slide member 21 rests when closed. The compressed air nozzle 25 consists of a tube 39, which tapers in the aforementioned cone-shape at the mouth 37. The nozzle tube 39 is displaceably seated telescopically in a further tube 40 against a biasing spring 41 therein. By means of this manner of spring-loaded telescopical mounting of the tube 39, it is possible to overcome path tolerances when advancing the manipulator 22, as indicated by the arrow 42. An annular seal ring 43 formed of an elastic material, for example rubber, is disposed about the end of the tube 39 adjacent the conical mouth 37 to engage against the sealing rim 38 of the adapter 19 in order to prevent the undesired exit of air at the opening 18. After the compressed air nozzle 25 has been placed against the adapter 19, a valve (not shown) is opened and, as indicated by the arrow 44, compressed air flows from the compressed air source 26 (FIG. 1) through the tube 39 into the tube 17.
The slide member 21 is configured to match the profile of the sealing rim 38 of the opening 18, and is curved into the form of a shield. A triangular piece 46 of sheet metal is pivoted at its apex on a shaft 47 arranged below the adapter 19 in the wall 20 of the hood 9 and the triangular piece 46 is fastened at the opposite side thereof on one of the narrow sides 45 of the slide member 21 to serve as a pivot lever for the slide member 21. The slide member 21 is normally kept in a closed position by a spring 48, which is fixed at one end to the hood 9 and at the other end to the pivot lever 46. An actuating element 49 is additionally arranged on the narrow side 45 of the slide member 21. In the instant exemplary embodiment, the actuating element 49 is a pin extending into the path of movement 50 of the profiled element 51 arranged on the forwardly projecting end of the slide actuator 24 of the manipulator 22. During the advancing movement of the manipulator 22, this profiled element 51 abuts against the actuating element 49 of the slide member 21 and pushes it in the open position illustrated in FIG. 2. In the process, the slide member 21 is pivoted in the direction of the arrow 52 around its pivot shaft 47, wherein the actuating element 49 slides along the actuating profile 51.
For cleaning the annular sealing face 38 formed around the opening 18 by the rim of the adapter 19, the slide member 21 has a tapered angular profile 54 on its leading edge, by means of which dirt, fibers stuck together by gummy or sticky residue, and dust, which have possibly been deposited on the sealing face 38, can be stripped off in the course of each closing movement of the slide member 21 in order to clean the sealing face 38.
In order to achieve a particularly good sealing of the opening 18 when the slide member 21 is closed, a diaphragm 55 is stretched across the side of the slide member 21 facing the opening 18. With the slide member 21 closed, the diaphragm 55 is pulled by the suction of the spinning vacuum prevailing at the opening 18 and is thereby held against the sealing face 38. In this way the opening 18 is effectively sealed during the spinning process, so that a possible admission of secondary air is prevented.
FIG. 3 shows the slide member 21 in the closed position in a lateral view, corresponding to FIGS. 1 and 2. FIG. 4 is a top view of the closed slide member 21. By means of the spring 48 and via the sheet metal piece 46 attached to the narrow side 45 of the slide member 21, the slide member is maintained in the closed position in front of the opening 18.
FIG. 5 shows the slide member 21 in detail. Since the angular edge profile 54 and the diaphragm 55 are wear elements, it is advantageous if these elements are exchangeably fastened on the slide member 21. To this end, the diaphragm 55 is placed around the front edge 53 of the slide member 21 and is clamped by the edge profile 54, which is fastened by screws 56 on the front edge 53. For example, the profile 54 can be made of plastic having a wedge-like tapering edge 57 for scraping off the dirt from the sealing face 38, and having a detent 58 for exactly fitted placement on the slide member 21. The diaphragm furthermore is extended around the lower edge 59 of the slide member 21 and, on its side facing away from the opening 18, is clamped by means of a retainer strip 60 fastened with screws thereat.
A variant of the arrangement of the manipulator, the actuator for the slide member and the compressed air nozzle is represented in FIG. 6. In contrast to the exemplary embodiment according to FIG. 1, the compressed air nozzle 25 can be advanced independently of the manipulator 122 by means of the drive of the draw-in roller. The characteristics agreeing with FIG. 1 are identified by the same reference numerals.
As in the exemplary embodiment in accordance with FIG. 1, the manipulator 122 is pivotably seated on two rocker arms 127 and 128 of the same length, with the rocker arm 127 seated in a hinge 129 in the service unit 2 supporting the manipulator 122 by a hinge 131 and the rocker arm 128 seated in a hinge 130 in the service unit 2 supporting the manipulator 122 in a hinge 132. A drive 133 arranged at the hinge 130 actuates pivoting of the rocker arm 128, as symbolized by the arrow 134, and in this manner allows the retraction of the manipulator 122 during the movement of the service unit 2 along the machine, and the extension of the manipulator 122 when the manipulator 122 has been positioned at a spinning station 1. The manipulator 122 supports the drive 23 for the draw-in roller and the actuator 124 for the slide member 21. However, in contrast to the exemplary embodiment in accordance with FIG. 1, the actuator 124 is not rigidly mounted on the manipulator 122 but instead is formed by the piston of a pneumatic cylinder 62. This pneumatic cylinder 62 is triggered by the control device 36 and therefore can engage the actuating element 49 of the slide member 21 with its profiled element 151, independently of the position of the manipulator 122.
The compressed air nozzle 25 is pivotably supported independently of the manipulator 122 on two rocker arms 63 and 64 of equal length on hinges 65, 66, respectively. The rocker arms 63 and 64 in turn are pivoted by hinges 67, 68, respectively, in the service unit 2. Thus, the compressed air nozzle 25 can be pivoted outwardly and inwardly, as indicated by the arrow 70, by means of a drive 69, to be placed against the opening 18 for supplying compressed air to the spinning chamber 4.
The ability for separate advancement of the compressed air nozzle 25 and the manipulator 122 represented in this exemplary embodiment has the advantage that, following cleaning of the rotor 5 and the spinning chamber 4, the compressed air nozzle 25 can be retracted into the position shown in FIG. 6, and that subsequently, for example at the time of feeding in the fibers by means of the delivery roller actuated by the drive 23, a controlled air supply through the tube 17 into the spinning chamber 4 and to the rotor 5 can be accomplished by a controlled movement of the actuator 124 to selectively adjust the position of the slide member 21 in respect to the opening 18. Such movement of the actuator 124 is controlled by the control device 36 by means of air supplied to the pneumatic cylinder 62. In the instant exemplary embodiment, the opening 18 is unblocked by the retracted compressed air nozzle 25 and is blocked about halfway by the slide member 21.
The exemplary embodiment in accordance with FIG. 7 differs from the exemplary embodiments in accordance with FIGS. 1 and 6 in that the compressed air nozzle 25 itself carries a profiled element 251 for actuating the slide member 21. This profiled element 251 is constituted by the end of an actuator 224 which is advanced into operative connection with the actuating element 49 of the slide member 21. If the actuator 224 is rigidly arranged on the compressed air nozzle 25, the opening position of the slide member 21 depends on the advancing movement of the compressed air nozzle 25. In the exemplary embodiment of FIG. 7, as in the exemplary embodiment of FIG. 6, the actuator 224 is the piston of a compressed air cylinder 262 whereby the slide member 21 can be actuated when the compressed air nozzle 25 has withdrawn from the opening 18. The compressed air cylinder 262 can be triggered by means of the control device 36 in such a way that the slide member 21 can be placed into predeterminable opening positions by the actuator 224.
It is also conceivable, but not shown, that no compressed air nozzle 25 is provided. Cleaning of the rotor and the spinning box then takes place exclusively by unblocking of the opening 18 by the slide member 21. In such a case the unblocking of the opening 18 is performed by a controlled movement of the actuator 124 by means of its own drive and without it being necessary to move the manipulator 122 for this purpose.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of a broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for the purpose of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements.
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So that stray fibers do not become attached to the rotor during a yam piecing process in the spinning box of a rotor spinning machine, the rotor may be cleaned by an air flow generated by drawing air into the rotor by the prevailing spinning vacuum or by blowing compressed air into the rotor through a closable opening in the rotor chamber. To avoid the danger that soiling of the closure of the opening will permit aspiration of secondary air and impair control of the air supply, the closure is formed as a slide member with a leading edge configured for cleaning the opening during closing movement.
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RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/432,694, filed on Dec. 11, 2002.
[0002] The entire teachings of the above applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0003] [0003]FIG. 1 is a schematic diagram of a five-stage Clos switching network 10 .
[0004] In the pictured embodiment, there are 144 space inputs, one to each time switch slice 12 of stage 1. Each space input has 48 timeslots, illustrated as separate parallel inputs to the time switch slices 12 , for a total of 6,912 input timeslots. Similarly, there are 6,912 output timeslots.
[0005] Stages 1, 3 and 5 are timeslot interchange stages. Each of these stages has 144 time switch slices 12 , each of which has 48 inputs and 48 outputs. Stages 2 and 4 are space switch stages. Each has 48 space switch slices 14 and each space switch slice 14 has 144 inputs and 144 outputs.
[0006] In stage 1, the 48 time slots for each of the 144 inputs are rearranged, and perhaps duplicated, and forwarded to appropriate ones of the space switches in stage 2. Specifically, data placed in timeslot [0] at each time switch slice 12 is forwarded to switch 14 [0] in stage 2. All timeslots [1] are forwarded to switch 14 [1], and so on.
[0007] In stage 2, space switch slice 14 [0] directs each of the 144 [0] timeslots to an appropriate one of 144 time switch slices in stage 3, space switch slice 14 [1] directs all of the [1] timeslots, and so on.
[0008] Subsequent stages perform similarly. For simplicity, only representative interconnects between switch stages are shown.
[0009] Stages 1 and 2 operate together as a concentrator. Stage 3 performs copy distribution. Stage 3, 4 and 5 function collectively as a rearrangeably non-blocking unicast Clos network. A unicast hardware scheduler arranges all connection calls from input timeslots to output timeslots.
SUMMARY OF THE INVENTION
[0010] A fast hardware scheduler embodying the present invention can be used in conjunction with the grooming switch of FIG. 1.
[0011] As described in U.S. Ser. No. 10/114,398, “Non-Blocking Grooming Switch,” filed on Apr. 1, 2002 and incorporated herein by reference, this five-stage Clos network can be rearrangeably non-blocking for arbitrary fanout.
[0012] One embodiment of the present invention hardware scheduler can be implemented, for example, in a 144×144 five-stage grooming switch to support rearrangeably non-blocking for arbitrary fanout at STS-1 granularity, i.e., 6912×6912.
[0013] An embodiment of the present invention hardware scheduler includes various data structures. In particular, RRFIFO, xRAM and yRAM data structures are implemented to reduce overall scheduling time. The hardware scheduler accumulates all rearrangeable requests, for example, into a buffer before serving the requests. This buffer may be, for example, a first-in, first-out buffer, and is referred to hereafter as the RRFIFO, although one skilled in the art would recognize that the buffer need not be restricted to first-in, first-out. The hardware scheduler then serves the buffered requests together in the pipeline, at a designated time, such as when the buffer is full. The xRAM and yRAM data structures allow the hardware scheduler to process two looping steps within one clock period.
[0014] Accordingly, a switching method for a grooming switch having at least three switching stages comprising first, middle and last switch stages, for example, stages 3, 4 and 5 respectively of the Clos network of FIG. 1, includes accumulating a list of connection requests that cannot be granted given currently scheduled connection assignments. Each request designates an input of the first switch stage and an output of the last switch stage which are to be connected. At a designated time, for each request in the list, two data structures are dynamically built.
[0015] The first data structure (xRAM) records, for each output of a first switch slice of the middle stage, a configured input of the first switch slice that is currently assigned to said output. That is, the xRAM structure records which input is currently assigned to each output.
[0016] The second data structure (yRAM) records, for each of the same outputs (i.e., for each output of the first switch slice of the middle stage), the output of a second switch slice of the middle stage that is connected to an input of the second switch slice corresponding to the configured input of the first switch slice.
[0017] In other words, for some middle stage slice output, the xRAM gives the input (of the same stage slice) that is currently scheduled to be connected to that output. For the same output, the yRAM gives another output on another slice (of the middle stage) that is currently scheduled to be connected to a like-numbered input on the respective slice. These xRAM and yRAM structures thus provide a fast lookup, enabling fast switching of scheduled connections during the looping algorithm. Finally, connections are assigned, as scheduled, to satisfy the stored unassigned requests, by reassigning existing connection assignments using the xRAM and yRAM data structures.
[0018] The designated time may be, for example, when the list holds a predetermined number of requests, or when all requests have been examined.
[0019] The list itself may be maintained in, for example, a first-in, first-out (FIFO) buffer.
[0020] At least one embodiment of the present invention includes multiple sets of xRAM/yRAM pairs. A scheduling engine can then schedule one connection using a first set of xRAM/yRAM, while a second set of xRAM/yRAM is being dynamically built to schedule a second connection.
[0021] Preferably, hardware maintains the list, dynamically builds the xRAM and yRAM data structures, and performs all scheduling functions.
[0022] Embodiments of the present invention may support dual frame alignment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
[0024] [0024]FIG. 1 is a schematic diagram of a five-stage Clos switching network.
[0025] [0025]FIG. 2 is a block diagram of an embodiment of the hardware scheduler of the present invention, illustrating several data structures used by the hardware scheduler.
[0026] [0026]FIG. 3 is a schematic diagram illustrating the OCT, the ICT and the OCCT in a 144×144 grooming switch.
[0027] [0027]FIG. 4 illustrates the structure of a preferred IFSV.
[0028] [0028]FIG. 5 is a schematic diagram illustrating the structures of one pair of xRAM and yRAM.
[0029] [0029]FIG. 6 is a flowchart illustrating operation of an embodiment of the hardware scheduler of the present invention at a top level.
[0030] [0030]FIG. 7 is a flowchart of the chip-scheduling algorithm of FIG. 6.
[0031] [0031]FIGS. 8A and 8B are block diagrams illustrating two cases which occur in the present invention.
[0032] [0032]FIG. 9 is a flowchart of the unicast looping algorithm executed in FIG. 7.
[0033] FIGS. 10 A- 10 J are schematic diagrams illustrating the execution of the looping algorithm of FIG. 9.
[0034] [0034]FIG. 11 is a timing diagram that illustrates alternating use of multiple sets of RRFIFO/xRAM/yRAM structures.
DETAILED DESCRIPTION OF THE INVENTION
[0035] A description of preferred embodiments of the invention follows.
[0036] [0036]FIG. 2 is a block diagram of an embodiment of the present invention hardware scheduler, illustrating several data structures used by the hardware scheduler.
[0037] The hardware scheduler 40 includes a scheduling engine 45 that schedules connections within the switch 10 (FIG. 1), using various data structures. Each of these data structures is described in more detail below.
Output Connection Table (OCT) 33
[0038] The OCT 33 records, for each of the 6,912 output timeslots (FIG. 1), which input timeslot has requested to connect to that output timeslot. In one embodiment of the present invention, the OCT 33 is implemented as a single-port 6,912×15 static RAM (SRAM). Alternatively, the OCT 33 could be implemented, for example, as two single-port 3,456×15 SRAMs.
[0039] Thirteen address lines encode the absolute output timeslot number (0-6,911). In one embodiment, data stored in the OCT 33 contains information as described in Table 1:
TABLE 1 data value range definition bit[14] 0˜1 Frame Alignment A(“0”) or B(“1”) bit[13:6] 0-143 input port number 144-255 reserved bit[5:0] 0-47 connected input timeslot 59 AISP 60-63 Unequipped 0-3 Other Reserved
[0040] After a reset or master disconnection, bit[ 14 ] of each OCT entry is set to the value defined by the Frame Alignment A/B registers and bit[ 13 : 0 ] is set to the unequipped format. Note that AISP and Unequipped 0-3 are special SONET data formats.
Input Connection Table (ICT) 49
[0041] The ICT 49 is preferably 6,922×15 bits. The first 6,912 entries record, for each of the 6,912 input timeslots (FIG. 1), which output timeslot has been requested to connect to that input timeslot. An unconnected input timeslot is denoted by a value of all ones, e.g., 255 (=0×FF). If multiple fanouts have been requested for an input timeslot, then the ICT 49 records only one of the requested output timeslots.
[0042] In the first 6,912 entries, thirteen address lines encode the absolute input timeslot number (0-6,911).
[0043] Although the switch has 6,912 input timeslots and 6,912 output timeslots, in an actual application, not all 6,912 output timeslots may be connected to input timeslots. For example, only half of the output timeslots may be used, while the other half is reserved for future expansion. Thus, some output timeslots do not connect to any input timeslots. The SONET standard nevertheless requires those unconnected output timeslots to transmit data streams in unequipped formats. An output timeslot transmits a data stream in AISP format if the input timeslot to which it is connected is broken. Therefore, chains must be built for those special output timeslots. For this reason, the last ten entries of the ICT 49 are reserved for unequipped or AISP timeslots. Table 2 illustrates ICT entry assignment, while Table 3 illustrates the ICT data definition.
TABLE 2 entry assignment 0˜6911 S1.I(0)˜S1.I(6911) 6912˜6915 unequipped0-3 in the Frame Alignment domain A 6916˜6919 unequipped0-3 in the Frame Alignment domain B 6920 AISP in the Frame Alignment domain A 6921 AISP in the Frame Alignment domain B
[0044] [0044] TABLE 3 data value range definition bit[14] 0˜1 Frame Alignment A(“0”) or B(“1”) bit[13:6] 0˜143 output port number 144˜255 reserved bit[5:0] 0˜47 connected output timeslot 48˜63 reserved
[0045] Before whole-chip re-configuration, the hardware scheduler resets each ICT entry to all ones.
Output Connection Chain Table (OCCT) 51
[0046] The Output Connection Chain Table (OCCT) 51 , preferably 6,912×14 bits, is used to accommodate multicast connections. For each of 6,912 output timeslots, the OCCT 51 records another output timeslot to which connection to the same input timeslot has been requested. The OCCT 51 is thus organized as a one-way linked chain. That is, all output timeslots requesting to connect to the same input timeslot are linked together. Except for the ending node, each output timeslot in a chain has a link to the next output timeslot.
[0047] The starting node of each such chain is pointed to by the ICT 49 . The ending node is denoted, in the OCCT 51 , by a special value, e.g., all ones.
[0048] Before whole-chip re-configuration, all entries of the OCCT 51 are reset to all ones.
[0049] [0049]FIG. 3 is a schematic diagram illustrating the OCT 33 , the ICT 49 and the OCCT 51 in a 144×144 grooming switch. Using the nomenclature SnS[m].I/O(j) (abbreviated from SnSm.SnI/Oj as used in FIG. 3) to designate input/output j of stage n, slice m, the configuration shown in this example has the following multicasting connections:
[0050] S 1 S[ 0 ].I( 1 )→S 5 S[ 143 ].O( 2 ), S 5 [ 1 ].O( 1 ), S 5 [ 143 ].O( 0 ), S 5 [ 1 ].O( 47 ) (shaded) S 1 S[ 0 ].I( 2 )→S 5 S[ 143 ].O( 1 ), S 5 [ 1 ].O( 2 ) S 1 S[ 1 ].I( 0 )→S 5 S[ 1 ].O( 0 ) S 1 S[ 1 ].I( 47 )→S 5 S[ 142 ].O( 47 ) S 1 S[ 143 ].I( 2 )→S 5 S[ 0 ].O( 0 )
[0051] For example, entry 63 A in the ICT 49 , indicates that, as requested, the input time slot at stage 1 slice 0 input 1 , S 1 S[ 0 ].I( 1 ), should be connected to stage 5 slice 143 output number 2 . Entry 63 B in the OCCT 51 indicates that the same input, i.e., S 1 S[ 0 ].I( 1 ), is to be connected to stage 5 slice 1 output 1 . The same input should also be connected to stage 5 slice 143 output 0 and stage 5 slice 1 output 47 , as indicated by entries 63 C and 63 D respectively within the OCCT 51 . Finally, entry 63 E in the OCCT 51 , corresponding to the last output in the chain, stage 5 slice 1 output 47 , is all ones, indicating the end of the multicast chain.
[0052] Stage-4 Input Free Slot Vector (IFSV) 43 and Output Free Slot Vector (OFSV) 41
[0053] The IFSV 43 and OFSV 41 are each 144×48-bit. Each may be implemented, for example, as a dual-port SRAM with 48-bit data and eight address lines.
[0054] [0054]FIG. 4 illustrates the structure of the IFSV 43 in a preferred embodiment. In the IFSV 43 , each 48-bit row corresponds with a stage 3 switch slice.
[0055] For example, row 1 (address 1 ) of the IFSV 43 , shown expanded at 72 , is associated with slice 1 of stage 3 (S 3 S[ 1 ]). Each bit in the row 72 indicates the status of a particular output of stage 3 (i.e., whether it is free or assigned). It follows then that each bit also indicates whether the stage 4 switch slice connected to that stage 3 output is free or assigned (busy).
[0056] For example, in the example switch configuration at 74 , stage 3 slice 1 (S 3 S[ 1 ] outputs 0 and 47 (i.e., S 3 S[ 1 ].O( 0 ) and S 3 S[ 1 ].O( 47 ) respectively) have been assigned (i.e., they are busy), so that bit[ 0 ] and bit[ 47 ] in the expanded IFSV row 72 each have the value “1”, while stage 3 slice 1 output 1 (S 3 S[ 1 ].O( 1 )) is not assigned, so that bit[ 1 ] in the same row 72 has the value “0”.
[0057] The OFSV 41 (FIG. 2) has a similar data structure. In the OFSV 41 , the 48-bit data indicate, for each stage 5 switch slice, which stage 4 switch slices are free and which are busy. The 8-bit address is an encoded stage 3/stage 5 switch slice number ( 0 to 143 ).
[0058] Preferably, the IFSV 43 and OFSV 41 are each memory-mapped and can be accessed directly when hardware scheduling is off.
[0059] S 1 PRAM/S 2 PRAM/S 3 PRAM/S 4 PRAM/S 5 PRAM
[0060] The SnPRAMs 57 indicate the assigned through-connections for each stage of the grooming switch. The switch configuration is complete once all of the connection assignments have been written into the SnPRAMs. Preferably, there are 144 of each of the S 1 PRAM, S 2 PRAM, S 3 PRAM, S 4 PRAM and S 5 PRAM.
[0061] Each S 1 PRAM 57 A records, for each of the 48 outputs of a stage-1 switch slice, which stage-1 input (0-47) is connected to that output.
[0062] Each S 2 PRAM 57 B records, for each of the 48 inputs of a stage-3 switch slice, which stage-2 input (0-143) is connected to that stage-3 input.
[0063] Each S 3 PRAM 57 C records, for each of the 48 outputs of a stage-3 switch slice, which stage-3 input (0-47) is connected to that output.
[0064] Each S 4 PRAM 57 E records, for each of the 48 inputs of a stage-5 switch slice, which stage-4 input (0-143) is connected to that stage-5 input.
[0065] Each S 5 PRAM 57 D records, for each of the 48 inputs of a stage-5 switch slice, which stage-5 output (0-47) is connected to that stage-5 input.
[0066] Because, in a preferred embodiment, an SPRAM address encodes an absolute output timeslot number (0-6,911) and the linker data is defined as separate port and timeslot number, an address translator is implemented to convert linker to absolute address. The translator is implemented as a substructure:
Absolute Address[ 13 : 0 ]=Data[ 13 : 0 ]−{Data[ 13 : 6 ],0000}
[0067] Rearrangeable Request FIFO (RRFIFO) 47
[0068] The RRFIFO 47 is a 16-entry×28-bit FIFO RAM. It accumulates requests that cannot be serviced without rearranging the switch configuration for performance enhancement. The RRFIFO 47 has a single read/write port, operating, for example, at 311 MHz. The RAM has flip-flops on both inputs and outputs. Back-to-back read cycles are supported.
[0069] Table 4 describes the ports of the RRFIFO 47 .
TABLE 4 Port name Description CLK read/write clock DI(27:0] write data input ADR[3:0] read/write address WE write enable DOUT[27:0] read data output ME memory enable. When it is 0, RAM is power down, data output r_DATA[31:0] is all 1's.
[0070] Stage 4 Switch Connection RAM (xRAM) 55
[0071] The xRAM 55 is a 144×8 bit structure. It records, for each of the 144 outputs of some slice x of stage 4, i.e., S 4 S[x], which input is connected to that output. An unconnected output may be denoted by, for example, all ones, (e.g., 255). Here, “x” represents a first switch slice (slice x) of stage 4, while “y” represents a second switch slice (slice y) of stage 4.
[0072] The xRAM 55 is implemented as a 144×1 byte SRAM with a one read/write (r/w) address port and one write address port. The read/write address is organized as the encoded output number (0-143).
[0073] The algorithm guarantees that a simultaneous read/write to the same byte location cannot occur.
[0074] Sorted Stage 4 Switch Connection RAM (yRAM) 53
[0075] The yRAM 53 is a 144×8 bit. It records, for each of the 144 outputs of the first stage 4 switch slice, S 4 S[x], which output (0-143) of a second stage 4 slice, S 4 S[y], is connected to the same input number to which that output of S 4 S[x] is connected. An unconnected output may be denoted by a value of 255.
[0076] Like the xRAM 55 , the yRAM 53 is implemented as a 144×1 byte SRAM with one r/w address port and one write address port. Each address is the encoded S 4 S[x] output number (0-143). The algorithm guarantees that a simultaneous read from or write to the same byte location cannot occur.
[0077] The xRAM 55 and yRAM 53 are dynamic structures. They are loaded based on the contents of S 4 PRAM 57 E, when the looping algorithm is executed to reconfigure the switch in order to service a request.
[0078] In one embodiment, the hardware scheduler has two xRAMs ( 55 A, 55 B) and two yRAMs ( 53 A, 53 B), allowing one set of xRAM/yRAM to schedule a connection while the other set is loading data from S 4 PRAM 57 E.
[0079] [0079]FIG. 5 is a schematic diagram illustrating the structures of one pair of xRAM 55 and yRAM 53 . In the example shown, entry 80 of the xRAM 55 at address 00 indicates that output S 4 S[x].O( 0 ) is connected to input S 4 S[x].I( 1 ). This connection is illustrated as line 81 , in stage 4 switch slice x (S 4 S[x]) 18 A. Similarly, each entry in the xRAM 55 indicates, for S 4 S[x], which output is indicated to which input. Unconnected outputs in this case have the value 255, i.e., all ones.
[0080] The yRAM 53 , on the other hand, indicates which outputs on another stage 4 switch slice (S 4 S[y]) are available for the connected input. For example, entry 83 in the yRAM 53 indicates that both S 4 S[x].O( 0 ) and S 4 S[y].O( 73 ) are both connected to a common input number (and thus a common stage 3 slice). By referencing the xRAM 55 , it can be seen that S 4 S[x].O( 0 ) is connected to S 4 S[x].I( 1 ). Thus, by implication, S 4 S[y].O( 73 ) is connected to S 4 S[y].I( 1 ). (This connection is shown as line 84 at 18 B.)
[0081] Thus the xRAM 55 and yRAM 53 together quickly provide alternate paths through stage 4 for routing.
[0082] Functional Description
[0083] [0083]FIG. 6 is a flowchart 90 illustrating operation of an embodiment of the hardware scheduler of the present invention at a top level.
[0084] At step 91 , the scheduler receives requests and stores them into the OCT 33 (FIG. 2), until, at step 92 , an End Of Request (EOR) is detected. Once an EOR is detected, the scheduler builds a link list in the ICT 49 and OCCT 51 (step 93 ). Finally, at step 94 , the hardware scheduler reads the link chains one by one and schedules them by writing them into the SnPRAMs 57 .
[0085] Building the link list in ICT/OCCT
[0086] The following pseudo code describes building the ICT/OCCT linked list.
// build a link list from OCT into ICT/OCCT // initialize the ICT // ip = input port; its = input time slot // op = output port; ots = output time slot Initialize every entry in the ICT to all ones (including Unequipped AISP entries) // build the list for (op =0, op<= 143, op = op +1) begin For (ots =0, ots<= 47, ots = ots +1) begin ip.its[13:0] = OCT[op.ots][13:0]; frame_domain = OCT[op.ots][14]; if (ip.its = = unequipped or ip.its = = AIS-P) ip.its[5:0] = unequipped/AISP address; c_bptr[13:0] = ICT[ip.its][13:0]; OCCT[op.ots] = c_bptr; ICT[ip.its][13:0] = op.ots; ICT[ip.its][14] = frame_domain; end end
[0087] Chip Scheduling
[0088] After building the linked list, the hardware scheduler reads the sorted connection data from the ICT 49 and OCCT 51 , and makes the connection by writing to the SPRAMs 57 . As discussed previously, stages 1 and 2 function as a concentrator, and stage 3 performs copy distribution. Stage 3, 4 and 5 function as a rearrangeably non-blocking unicast Clos network. The present invention unicast hardware scheduler arranges all connection calls from stage 3 to stage 5.
[0089] [0089]FIG. 7 is a flowchart 100 of the chip-scheduling algorithm, corresponding to block 94 of FIG. 6, of an embodiment of the present invention.
[0090] First, at step 102 an entry from the ICT 49 is read. If there are no more entries, as determined at step 104 , then the loop algorithm is executed at step 106 for every entry in the RRFIFO 47 , after which the chip scheduling algorithm 100 terminates. The loop algorithm is described in more detail further below.
[0091] If, on the other hand, the end of the ICT is not detected at step 104 , then step 108 determines whether the end of a chain in the ICT has been detected. If so, then the next entry from the ICT is read, again at step 102 . If, on the other hand, the end of the chain is not detected, then at step 110 , connections are made on the appropriate S 1 PRAM 57 A and S 2 PRAM 57 B according to some concentrator algorithm. Thus, for this entry, the input time slot has been routed through stages 1 and 2 to a particular input of a particular stage 3 slice.
[0092] At step 112 , the input and output free slot vectors, 43 and 41 respectively, are searched to determine whether a common stage 4 slice exists for the requested connection's stage 3 input and stage 5 output. If such a common stage 4 connection is available, as determined at step 114 , then at step 116 that connection is made by writing to the S 3 PRAM 57 C, S 4 PRAM 57 E and S 5 PRAM 57 D, and the IFSV 43 and OSFV 41 are updated accordingly (step 117 ).
[0093] If, on the other hand, no common stage 4 connection is available, then the request is written to the RRFIFO at step 118 . At step 120 a determination is made as to whether the RRFIFO is full. If it is full, then at step 122 the loop algorithm is executed for every entry in the RRFIFO.
[0094] After the loop algorithm completes, in step 122 , or if the RRFIFO was not full at step 120 , then the next fanout of the chain from the OCCT 51 is read at step 124 . If at step 126 the end of a chain is detected, then execution returns to step 102 and the next entry is read from the ICT 49 . If, on the other hand, an end of chain is not detected, then at step 128 a determination is made as to whether a new fanout is needed on the S 2 PRAM. If so, the connection is made on the S 2 PRAM at step 130 . In either case however, execution proceeds to step 112 as previously described.
[0095] The following pseudo code describes the scheduling function. Where appropriate, step numbers corresponding to the flowchart 100 of FIG. 7 are listed.
[0096] In one embodiment, the hardware scheduler supports dual frame alignment so that the grooming switch can be partitioned into two independent grooming switches. To support two distinct frame alignment domains, two sets of stage-2/stage-3 counters are used in the algorithm below, one set for each domain. The counter of the frame alignment domain A counts from top to bottom. The counter of the frame alignment domain B counts from bottom to top. The Unequipped/AISP output timeslot (OTS) is scheduled as a regular connection.
// 5 stages connection s3o_counter_a = 0; s3s_a = 0; s2s_a = 0; s3o_counter_b = 0; s3s_b = 143; s2s_b = 47; For (ip =0, ip<= 144, ip = ip +1) begin For (its =0, its<= 47, its = its +1) begin if (ip = = 1 44 and its = = 10) // step 104 begin loop_algrithm(every valid entry in RRFIFO); // step 106 exit; end if (ICT[ip.its] != all 1's) begin // make connection read frame_domain from ICT[ip][14]; read fanout (op.ots) from ICT[ip][13:0]; if (frame_domain = = 0) begin // Frame Domain A s3o_counter = s3o_counter_a; s2s = s2s_a; s3s = s3s_a; s2s_a = (s2s_a + 1) % 48; end else begin // Frame Domain B s3o_counter = s3o_counter_b; s2s = s2s_b; s3s = s3s b; s2s_b = (s2s_b − 1) % 48; end if (ip != 144) begin // step 110 write “its” to S1PRAM_ip[s2s]; write “ip” to S2PRAM_s3s[s2s]; s3i = s2s; write frame_domain to s2s/s3s; end else begin s3i = Unequipped/AISP code; write frame_domain to s3s; end while (not the end of the chain) begin search for common free slot com_s4s; // step 112 if (com_s4s = = null) // step 114 // no common Stage-4 switch (Fig. 8B) write (s3s.s3i, op.ots) into RRFIFO; // step 118 else begin // common Stage-4 switch (Fig. 8A) // step 116 write s3i to S3PRAM_s3s[com_s4s]; write s3s to S4PRAM_op[com s4s]; write ots to S5PRAM_op[com s4s]; update IFSV & OFS V; // step 117 end if (frame_domain = = 0) begin // Frame Domain A s3o_counter_a = (s3o_counter_a + 1) % 48; if (s3o_counter_a = = 0) s3s_a = s3s_a + 1; s3o_counter = s3o_counter_a; s3s = s3s_a; end else begin // Frame Domain B s3o_counter_b = (s3o_counter_b + 1) % 48; if (s3o_counter_b = = 0) s3s_b = s3s_b − 1; s3o_counter = s3o_counter_b; s3s = s3s_b; end if (RRFIFIO full) //step 120 loop_algrithm(every entry of RRFIFO); // step 122 read the next fanout (op.ots) from OCCT; // step 124 if (not the end of the chain) // step 126 begin if (s3o_counter = = 0 and ip != 144) // step 128 begin write “ip” to S2PRAM_s3s[s2s] // step 130 write frame_domain to s2s/s3s; end else if (s3o_counter = = 0 and ip = = 144) write frame_domain to s3s; end end end end end
[0097] [0097]FIGS. 8A and 8B are block diagrams illustrating the two cases as described in the above pseudocode.
[0098] In case 1 (FIG. 8A), a common stage-4 switch 18 A exists for the requesting input and output 140 , 141 respectively. Therefore, the connection can be made immediately.
[0099] In case 2 (FIG. 8B), the connection cannot be made immediately in either of two switch- 4 slices 18 A, 18 B, because a connection 144 has already exists between stage 4 slice 18 A and stage 5 slice op, and another connection 143 already exists between stage 3 slice s 3 s and stage 4 switch slice 18 B.
[0100] Unicast looping algorithm on stages 3, 4 and 5
[0101] The looping algorithm makes a connection from a stage 3 input S 3 S[s 3 s].I(s 3 i) to a stage 5 output S 5 S[s 5 s].O(s 5 o), where ‘s 3 s’ is the stage 3 slice number, ‘s 3 i’ is the stage3 input number of that stage 3 switch, ‘s 5 s’ is the stage 5 slice number, and ‘s 5 o’ is the output number of that stage 5 slice.
[0102] [0102]FIG. 9 is a flowchart 200 of the unicast looping algorithm executed at both steps 106 and 122 of FIG. 7. This algorithm is executed for each rearrangeable request previously stored in the RRFIFO 47 (FIG. 2). FIG. 9 is described in conjunction with FIGS. 10 A- 10 J.
[0103] At step 202 , the input and output free slot vectors 43 , 41 are searched for a common stage 4 switch slice for the requesting request. If a common stage 4 switch is available (determined at step 204 ), then at step 206 the connection is made on the appropriate S 3 , S 4 and S 5 PRAMS, respectively 57 C, 57 E and 57 D. Finally, at step 208 , the IFSV 43 and OFSV 41 are updated and the algorithm exits.
[0104] If, on the other hand, step 204 determines a common stage-4 switch is not available, then the xRAM 55 and yRAM 53 are loaded from the S 4 PRAM 57 E at step 210 . FIG. 10A illustrates an exemplary configuration as might be loaded from the S 4 PRAM. The dashed lines 401 show that the requested connection cannot be granted with the current configuration. Initial connections 403 are made at step 212 on the S 3 , S 4 and S 5 PRAMS, resulting in the configuration shown in FIG. 10B.
[0105] At step 214 , using a fast look-up of the data contained in the xRAM and yRAM, connections are swapped ( 405 ) within the S 4 PRAM and S 5 PRAM, resulting in the configuration of FIG. 1C.
[0106] In step 216 a determination is made as to whether the yRAM entry is all ones, i.e., is Connection A in FIG. 10D already committed? If it is uncommitted, that is, the yRAM entry is all ones, then at step 217 , the connection is made in the S 3 PRAM, resulting in the configuration shown in FIG. 10E. Next, step 208 is executed and the IFSV 43 and OFSV 41 are updated and the algorithm exits.
[0107] If, on the other hand, step 216 determines that Connection A is already committed, then at step 218 , additional connections are made and swapped, resulting in the configurations of FIGS. 10F and 10G respectively.
[0108] Next, in step 220 a determination is made as to whether the xRAM entry for next_s 5 s is all ones, i.e., is Connection B in FIG. 10H already committed? If it is uncommitted, that is, the xRAM entry is all ones, then at step 221 , the final connection is made in the S 4 PRAM and S 5 PRAM, resulting in the configuration shown in FIG. 101. Then, as before, the IFSV and OSFV are updated in step 208 .
[0109] Of, on the other hand, step 220 determines that Connection B is already committed, then at step 222 the algorithm prepares to read the next pair of values from the xRAM and yRAM. Use of these values will result in the configuration of FIG. 10J.
[0110] The following pseudo code describes the looping function:
//makes a connection from Stage-3(s3s.s3i) to Stage5(s5s.s5o) read IFSV[s3s]; read OFSV[s5s]; if ((IFSV[s3s]) & OFSV[s5s]) != 48’b0) begin // common Stage-4 switch get the first free common Stage-4 switch number ‘s4s’; write ‘s3i’ to S3PRAM_s3s[s4s]; write ‘s3s’ to S4PRAM_s5s[s4s]; write ‘s5o’ to S5PRAM_s5s[s4s]; end else begin // no common Stage-4 switch get the first free Stage-4 switch number ‘x’ for s3s; get the first free Stage-4 switch number ‘y’ for s5s; load xRAM; load yRAM; write ‘s3i’ to S3PRAM_s3s[x]; write ‘s3s’ to S4PRAM_s5s[y]; write ‘s5o’ to S5PRAM_s5s[y]; current_s3s = s3s; current_s5s = s5s; while ( ) // looping begin next_s3s = xRAM[current_s5s]; next_s5s = yRAM[current_s5s]; swap S4PRAM_current_s5s[x] and S4PRAM_current_s5s[y]; swap S5PRAM_current_s5s[x] and S5PRAM_current_s5s[y]; if (yRAM[current_s5s] = = all 1's) begin S3PRAM_next_s3s[y] = S3PRAM_next_s3s[x]; S3PRAM_next_s3s[x] = all 1's; exit the loop; end else begin swap S3PRAM_next_s3s[x] and S3PRAM_next_s3s[y]; if (xRAM[next_s5s] = all 1's) begin S4PRAM_next_s5s[x] = S4PRAM_next_s5s[y]; S4PRAM_next_s5s[y] = all 1's; S5PRAM_next_s5s[x] = S5PRAM_next_s5s[y]; S5PRAM_next_s5s[y] = all 1's; exit the loop; end end current_s3s = next_s3s; current_s5s = next_s5s; end end update IFSV & OFSV;
[0111] In the hardware scheduler, all rearrangeable connections are stored temporarily in the RRFIFO 47 . When the RRFIFO 47 is full, or the end of the ICT 49 is reached, the scheduler makes those rearrangeable connections using a pipeline (discussed below with reference to FIG. 11). A search is performed for a common Stage-4 switch which might have become available after the rearrangement in previous requests, in which case the connection is simply made.
[0112] [0112]FIG. 11 is a timing diagram 300 that illustrates this alternating use of multiple sets of xRAM/yRAM structures. Graph 301 pertains to a first set, while graph 303 pertains to a second set. For example, at 305 , a first set of xRAM and yRAM is loaded from SnPRAM. At 307 , the loaded xRAM and yRAM are used by a first RRFIFO entry for performing the looping algorithm. Meanwhile, at the same time, at 309 , a second set of xRAM and yRAM is loaded from SnPRAM, for subsequent use with the second RRFIFO entry (at 311 ). Thus, at every step, it is possible to be loading xRAM and yRAM for one RRFIFO entry, while executing the looping algorithm with another RRFIFO entry, effectively halving the execution time.
[0113] While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
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A hardware scheduler for a grooming switch with at least three switching stages accumulates a list of connection requests that cannot be granted given currently granted connection assignments. At a designated time, two data structures are dynamically built: an xRAM which records, for each output of a switch slice, which input is currently assigned to that output; and a yRAM which records, for each of the same outputs, the output of a second switch slice that is connected to a corresponding input of the second switch slice. Connections are assigned to satisfy the stored unassigned requests, by reassigning existing connection assignments using the xRAM and yRAM data structures.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a tufting machine used for carpet manufacture.
2. Description of the Related Art
Tufting machines are distinguished over other carpet making methods in that loops of yarn which constitute the pile of the carpet are inserted in a backing medium or cloth, which may be fibrous or woven according to the carpet application. The loops are held in place by the retentive pressure of the backing cloth having been expanded locally through the insertion of the yarn. A subsequent operation covers the rear face of the yarn and backing cloth with a retaining adhesive. The adhesive also holds a further layer of backing material, usually hessian.
The yarn is inserted into the backing material by a multiplicity of needles which perform a reciprocating motion. The needles have eyes at the lower extremities through which yarn is both fed and captured. Generally, the needles are connected to one or more transverse bars known as needle bars so that all needles may be reciprocated together into and out of the backing material. In certain specialized tufting machines, the needles are carried by needle holders that may be selectively latched to a reciprocating latch bar so that the needles are capable of individual selection and only those needles selected are subject to the reciprocation, whilst those not selected are not reciprocated. The reciprocating action usually is delivered through a series of pistons or push rods couple by various conventional means to a rotating main-shaft driven by electric motor or similar means. The coupling mechanism is of a crank-shaft type so that the extent of the needle motion is the throw of the crank. Other more complex arrangements are also known which endow features to enable the motion envelope of the needle to be controlled and easily set to any desired range.
The loops of yarn may be of varying heights on the face side of the carpet in order to provide a patterning effect. There are several techniques for causing this effect, such as changing the tension of yarn from low to high from one insertion of a yarn loop to the next (high pile to low pile). Yarn tension may be set by modulating the speed of the yarn feed mechanism controlling the length of yarn delivered for each loop (stitch). A simple form of yarn feed mechanism uses a pair of rollers with a high friction surface between which the yarn is pinched. Variations in the speed of the rollers allows control of the length of yarn delivered for each tuft of carpet pile. There are many more complex mechanisms for exerting control over the yarn delivery. Some of these deliver control over individual strands of yarn, some over subsets of all the strands.
Additional patterning features include the use of cut pile as opposed to pile formed from loops. The cut pile effect is achieved usually during the tufting process by catching the loops formed by the insertion of yarn through the backing cloth on a suitably formed hook on the face (lower) side of the carpet. A knife shears the yarn on one side of the hook after several further loops have been inserted in the backing material. The knife is articulated to move in synchronism with the insertion of yarn. The hooks involved in the loop capture during yarn insertion are also arranged to move into position in synchronism with the yarn insertion process.
The foregoing is a non-exhaustive illustration of some of the features of tufting machines and the mechanisms for controlling carpet patterning. Further features of tufting machines include the ability to introduce a plurality of colors. Tufts of different colored yarns can be made to form attractive carpet patterns such as can be achieved in woven carpets in which any chosen color may be inserted in any location in the carpet by correct design of the patterning commands. One way in which this is done is by burying one colored yarn by giving it a very low pile height in an area of higher pile height of different color by the well known process of backrobbing yarn from the previous stitch to reduce the pile height of that previous stitch. When the buried color is required, the pile height is set high whilst that of the other color in that area is set lower. This results in patches of different colors but has a number of disadvantages in the wastage of yarn which cannot be seen and in the straight line arrangement of the colored yarn. Means for altering the lateral position of the yarns have consequently been developed to overcome some of these limitations.
There are normally up to two needle bars on a machine although more may be fitted. These are reciprocated by the main-shaft rotation and crank means in the vertical direction. An additional degree of freedom of motion is afforded to the needle bars by a mechanism which allows side to side motion, that is across the width of the tufting machine laterally. Yarns may thus be moved from one needle position to others. This provides greater flexibility to produce a required pattern, as needles containing a particular color can be shifted laterally to a position where that particular color is required in the pattern.
Mechanisms for moving the needle bars include cam driven systems, hydraulic actuators, pneumatic actuators, and electric servo controlled motors with a rotational to linear conversion device. This latter mechanism is typified by WO 97/15708 and EP 867,553. In these cases, the rotational to linear conversion devices include screw thread and nut arrangements (including those with acme threads and other thread profiles; ball screws; inverted roller screws and similar equivalent devices). These mechanisms provide the necessary motional requirements from a functional view but also limit the speed capability of the tufting machine. This limitation may arise due to the speed, rate of acceleration and slackness or free play in the mechanisms connecting the servo motor with the sliding needle bar; other relate to the amount of force required to provide the acceleration, inertia effects and control loop stability.
Further, with these systems, the sliding needle bar drive system, servo motors, or equivalent hydraulic or pneumatic actuators have been mounted on the external and faces of the tufting machine. This has required the provision of holes in the end plates or housing to allow the servo motor output shaft to feed into the sliding needle bar assembly. The servo motor output shaft has been coupled to a ball screw or equivalent device (such as an inverted roller screw or screw and nut assembly). The motion sensor for the servo motor has usually been coupled directly to its rotating shaft so that lost motion in any coupling mechanism between the servo and the sliding needle bar has remained uncompensated.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a tufting machine comprising a housing, a needle bar which is reciprocable within the housing and on which a plurality of needles are mounted for reciprocation towards and away from a web of backing material, and at least one linear motor for moving the needle bar in a lateral direction across the width of the web, each linear motor having first and second parts which may be selectively coupled to one another by electromagnetic forces. In a preferred embodiment, the first part fixed with respect to the housing, and the second part is electromagnetically coupled with respect to the first part and fixed with respect to the needle bar, and a power source supplies electric power to one of the motor parts to drive the first and second parts relatively to one another in the lateral direction.
As a part of the linear motor is connected with respect to the needle bar, no linkage or other intervening mechanism is required to drive the needle bar laterally. The mechanism is therefore simple and cannot introduce any lost motion.
The tufting machine may have a single needle bar. However, preferably, it comprises at least one further needle bar, which is selectively driven by a linear motor for moving the further needle bar in a lateral direction across the width of the web.
The linear motor could be of the kind comprising a tubular arrangement of magnets surrounded by an annular arrangement of coils. However, in this case, a further mechanism would be required to permit reciprocation and a bearing would be required to mount the coil assembly with respect to the housing. Therefore, preferably, the or each first part fixed with respect to the housing, and the second part is electromagnetically coupled with respect to the first part and fixed with respect to the needle bar, and a power source supplies electric power to one of the motor parts to drive the first and second parts relatively to one another in the lateral direction.
As a part of the linear motor is connected with respect to the needle bar, no linkage or other intervening mechanism is required to drive the needle bar laterally. The mechanism is therefore simple and cannot introduce any lost motion.
The tufting machine may have a single needle bar. However, preferably, it comprises at least one further needle bar, which is selectively driven by a linear motor for moving the further needle bar in a lateral direction across the width of the web.
The linear motor could be of the kind comprising a tubular arrangement of magnets surrounded by an annular arrangement of coils. However, in this case, a further mechanism would be required to permit reciprocation and a bearing would be required to mount the coil assembly with respect to the housing. Therefore, preferably, the or each linear motor allows relative movement of the first and second parts in the direction of reciprocation of needle in addition to the lateral movement provided.
Preferably, one of the first and second parts is a U-shape channel extending in the lateral direction, and the other of the first and second parts is within the U-shape channel. This represents a particularly efficient way of electromagnetically coupling the first and second parts, as there is a relatively large surface area between the two parts.
Preferably the or each linear motor has a plurality of coils on the first or second part which are electrically coupled to the power source, and a plurality of corresponding magnets on the other of the first and second part, wherein the coils and magnets form the electromagnetic coupling between the two parts.
From an electromotive point of view, it does not matter whether the coils are provided on the first or the second part of the motor. However, it is preferable for the coils to be mounted on the first part of the linear motor, as this does not move during operation, thereby making for simpler electrical connections to the coil.
A particularly advantageous construction is for the coils to be provided on the first part of the linear motor which is the U-shape channel. Coils are disposed on both legs of the channel which ensures that the attractive forces between the coils and the magnets are balanced out. In this case, heat produced in the coils may now be removed by conduction through the coil mounting structure and the housing of the tufting machine, or by convection with fins provided on the outer surface of the U-shaped channel. The number of magnets is reduced where the magnets are fixed to the central web or second part of the linear motor, and is approximately half of the number required where the magnets are provided on the legs or first part of the U-shape channel. The magnet assembly is connected to the needle bar and is significantly reduced in weight as compared to a U-shape structure connected to the needle bar. This consequential reduction in the mass and inertia of the needle bar assembly allows the required motion to be completed in shorter times for the same electromotive input forces.
Preferably, there is an air gap between the first and second motor parts, so that no motor bearing is required between the two parts. There are attractive forces between the coil part of the linear motor and the permanent magnets. These are balanced in the motor construction used. Furthermore, the mechanical construction of the supporting assembly in the sliding needle bar ensures that the two parts of the motor are positioned so that they do not touch. Additional non-loaded bearings such as are made of plastic may be used between the first and second part of the motor to ensure that the air gaps are maintained with approximately the same spacing, without the need for close tolerances to be maintained elsewhere in the sliding needle bar assembly. This also means that the needles can reciprocate without requiring a mechanical coupling between motor parts to allow for this.
The tufting machine also preferably comprises a control system for controlling the motion of the or each linear motor, the control system comprising a sensor for detecting the position of at least one motor on the or each needle bar, a signal generator for generating a signal relating to the angular position of the reciprocating mechanism, and a processor provided with data relating to the pattern for the carpet to be tufted and having means to generate signals to drive the or each motor to locations determined from the sensor and signal generator readings and the data relating to the pattern.
BRIEF DESCRIPTION OF THE DRAWINGS
An example of a tufting machine constructed in accordance with the present invention will now be described with reference to the accompanying drawings in which:
FIG. 1 is a front view showing the general arrangement of the tufting machine,
FIG. 2 is a section along line II—II in FIG. 1;
FIG. 3 is a perspective view showing two needle bars and their respective linear motors;
FIG. 4 is a perspective view showing the detail of one linear motor;
FIG. 5 is a cross-section through the two linear motors as illustrated in FIG. 3; and
FIG. 6 is a cross-section similar to FIG. 5 showing an alternative arrangement of linear motor.
DESCRIPTION OF PREFERRED EMBODIMENTS
In most respects, the machine is a conventional tufting machine, so that a detailed description of the tufting operation will not be included here. The machine has a top housing 1 housing the yarn feed mechanism 2 , and three reciprocating pistons 3 for reciprocating needles 4 . A bottom housing 5 is mounted on legs 6 (neither of which are shown in FIG. 1) as is the bed plate 7 and is provided with a series of rollers 8 for feeding the backing medium through the machine. As the backing medium is fed through the machine, the needles 4 are vertically reciprocated by the reciprocating pistons 3 and cooperate with a plurality of hooks or loopers beneath the backing material to produce a tufted carpet in the conventional manner as is well known in the art.
The apparatus shown in FIGS. 3 and 5 comprises a pair of needle bars 9 , each of which have needles 4 connected along their length. Three plates 10 are reciprocally vertically movable by means of a respective push rod 11 driven by a respective reciprocating motion piston 3 . As shown in FIG. 3, the plates 10 are connected by four laterally extending guide bars 12 which are rigidly fixed to the plates 10 . Each needle bar 9 is associated with its own pair of laterally spaced linear motors 13 as shown in FIG. 1 . The detail of one such linear motor for each needle bar 9 is shown in FIGS. 3 and 5. In FIG. 5, the linear motor for one needle bar 9 is on one side of the center line Y—Y, while the other linear motor is on the other. Each linear motor comprises a sliding part 14 and a static part 15 . Each sliding part 14 comprises a magnet support 14 A mounted to a respective needle bar 9 and a mounting part comprising a pair of flanges 14 B which are slidable along two of the guide bars 12 on linear bearings 12 A so as to move the needle bar 9 laterally.
The construction of the linear motor is shown in greater detail in FIG. 4 . The sliding part 14 has a generally U-shape channel extending laterally. The sliding part 14 is made from aluminum, and has a series of magnets 16 fitted to the inside of the U-shape channel in such a way as to provide an alternating magnetic field along the length of the channel. The magnets are arranged as shown in FIG. 4 with their poles alternating both along the channel, and across the channel. The poles shown in FIG. 4 are those which face towards the center of the channel. The outer sides of the magnets have the opposite magnetic sense to those parts facing the inner side of the U-shape channel as shown. In normal construction, there is an air gap or other non-magnetic part positioned between each magnet in order to provide separation between said magnets.
The fixed part 15 is provided with a plurality of coils 15 A fixed to the housing by a bracket 15 B. These coils 15 A are elongate in the vertical direction and are not of approximately the same pitch as the magnets or the motor would lock in position and not move. Special arrangements are made in respect of the coil arrangement to prevent the cogging effect of identical pitch as shown in U.S. Pat. No. 5,642,013.
Referring to FIG. 3, it should be noted that all of the parts illustrated in this figure, with the exception of the fixed parts 15 will reciprocate vertically with the needles 4 . Reciprocating vertical motion is thus provided to the needles 4 from the reciprocating pistons 3 , via push rods 11 , plates 10 , guide bars 12 , sliding parts 14 and needle bars 9 . The effect of this will be to cause the moving part 14 to reciprocate vertically with respect to the fixed part 15 . An air gap (not shown in FIG. 5) between the two parts ensures that this motion can be accommodated without requiring any bearings between the two.
The application of electrical power to the coils 15 A will cause a corresponding lateral movement of the sliding part 14 along guide bars 12 , causing the attached needle bar 9 and needles 4 to be moved laterally.
As the sliding part 14 is moved downwardly during reciprocation, the electromotive force will be diminished, as the coils 15 A on the fixed part 15 will be partially or completely moved out of the magnetic way provided in the U-shape channel. Lateral movement of the needles bar will normally be made when the needles are out of the backing and at approximately 25 to 30° of top dead center (TDC) and thus the U-channel and coil assembly are nearly fully engaged. In this condition the motor exerts nearly or exactly its maximum force capability and provides the greatest lateral acceleration.
The linear motor is servo-driven and hence requires the means to commutate the coils to provide a reaction force. For this purpose, there is a Hall-effect (magnetic) sensor (not shown) or equivalent embedded in the coil assembly which provides feedback of the location of the coil assembly in relation to the magnetic field formed in the U-shape channel.
A further requirement of the servo controlled motor is that there be means to measure the location of the motor relatively to the rest of the machine. This takes the form of positional sensors, which may be optical or magnetic, external to the motor assembly. The measuring system must be insensitive to the vertical reciprocating motion of the needles, while providing precise transverse location data. In order to achieve this, the Hall-effect sensor used for commutation may also be used to provide location data. As an alternative to a separate location measurement sensor, the Hall-effect sensor or equivalent used for commutation may also be used to provide location data for the position feedback function.
When in the raised position, with the coil assembly fully inserted into the U-shape channel, the needle bar is subject to rapid movement using the linear motor. This changes the position of the needle bar, if required by the pattern commands, usually by an integer number of gauge jumps (that is an integer number times the distance between each needle). Some patterns require needle bar shifts by other non-integer distances as disclosed in U.S. Pat. No. 4,501,212 as will be recognized by those skilled in the art of tufted carpet design. In such cases, it is normal for the motion of the sliding needle bar to occur whilst the needles are still engaged in the backing cloth. In this case only a fraction of the full force available from the motor is necessary and is available in this configuration. For motions of the needle bar requiring an integer number of gauge jumps, the needles are in a withdrawn state from the backing web and the motor parts are more or less fully engaged. The motive force available in this raised condition is at a maximum. The motive force available from the motor is at a maximum in this raised condition. The motion of the linear motor is controlled by a servo amplifier and position control system offering the features of velocity and acceleration feed-forward. These last two characteristics ensure that the motion of the needle bar 9 has little position over shoot. This optimum combination of these control settings minimizes the overall duration of the needle bar motion. The tightly coupled nature of the structure ensures that the position measurement of the servo control system accurately reflects that of the sliding needle bar with no lost motion or slack as in previous machines.
An alternative arrangement of linear motor is shown in FIG. 6 . In many respects, this example is similar that shown in the other figures and the same reference numerals have been used, where appropriate, to designate the same components.
The difference between this example and that previously described is essentially that the part with the coils which is fixed to the housing 1 is now the U-shape channel while the magnets are within this U-shape channel.
More particularly, the fixed part 115 of the linear motor has a plurality of coils 115 A fixed to the inside of a downwardly opening U-shape channel 115 B which is fixed at its top end to housing 1 . The sliding part 114 comprising a mounting part 114 A arranged to slide on two of the guide bars 12 and to which a needle bar 9 is mounted. A set of magnets 114 B project upwardly from the mounting part 114 A into the U-shape channel 115 B between the coil assemblies 115 A. An air gap (not shown in FIG. 6) is provided between the magnets and coils. The set of magnets 114 B has the same alternating configuration as that shown in FIG. 4, and cooperates with the coils 115 A which are correspondingly arranged in order to drive the needle bar 9 laterally.
Other forms of linear motors may be used in the tufting machine without departing from the invention. For example, besides the U-shaped channel arrangement, there is a known open form of linear motor in which the magnets form one part and the energized coils form the other part. Also, there is known an enclosed form of motor in which the magnets are arranged inside a thin walled tube an inner part) and the energizing coils are arranged in another tubular form (the outer part) with the magnet assembly sliding in the circumferentially arranged outer coils.
The ‘open’ form of linear motor experiences considerable attractive force between the permanent magnets and the coil structure in operation. Bearings are required to resist these otherwise unusable forces.
In all of these arrangements, the motors use permanent magnets and coils to generate the electromotive forces, although it would be possible to have the permanent magnet system replaced by electrical excitation (as in a DC excited dynamo). Unfortunately, the steady state fields produced by coils subject to electrical excitation are significantly smaller than those available from rare earth magnets (due to coil heating effects. Improvements in cooling the coils may be contemplated using alternative thermal conductivity mechanisms such as heat pipes. The heating effects may be avoided using superconductivity effects). Consequently, such motors are relatively inefficient and thus not currently practical.
Some forms of linear motor may preferably be mounted on the body of the tufting machine away from the tufting area and coupled to the sliding needle bars using a translated motion mechanism by which the linear motions from the motor are transmitted to the sliding needle bar and the sliding needle bar can be substantially reciprocated without affecting the translated linear motion. This arrangement is similar to rotational ‘servo-controlled’ motors and rotation-to-linear conversion mechanism (ball screw, lead screw, etc.).
Some simple translated motion devices exhibit coupling between the desired horizontal motion required in the sliding needle bar of the tufting machine and the reciprocation of the needle assembly. This coupling can be removed by either open or closed loop techniques with the linear motor arrangement. An example of simple coupling mechanism is a bar coupled at one end to the linear motor moving part and at the other end to the sliding needle bar assembly. Rotational bearing are necessary to allow the bar to move in the direction of reciprocation. In the open loop compensation method, the linear motor is excited with a correction motion profile linked to the motion of the needle bar assembly so as to compensate for the variations in the resolved length of the bar in the horizontal plane (perpendicular to the direction of reciprocation). In the closed loop compensation arrangement, the sliding needle bar location sensor (mounted on the needle bar in the first part and on the machine housing in the second part) provides error signals to the motion control system which operates to reduce the errors to a small quantity. Such a closed loop control system may be aided by the additional input of approximate corrections such as would be used in the open loop compensation arrangement.
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.
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A tufting machine has a reciprocating needle bar which may be shifted laterally by a drive which includes at least one linear motor. Each linear motor has two major elements which may be coupled together electromagnetically. One of the elements is connected to a fixed portion of the tufting machine and another of the elements is connected to the needle bar. When electrical power is supplied to the motor, the element connected to the needle bar moves relatively to the other thereby moving the needle bar.
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PRIORITY CLAIM
[0001] This application is a continuation of, and claims the benefit and priority of, U.S. patent application Ser. No. 14/013,797, filed on Aug. 29, 2013, which is a continuation of U.S. patent application Ser. No. 11/467,247, filed on Aug. 25, 2006 (now U.S. Pat. No. 8,545,235). The entire contents of such applications are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to the field of CATV filters, and more particularly to a torque transmitting outer sleeve for a CATV filter.
BACKGROUND
[0003] In typical CATV applications, a filter circuit or network is provided to pass signals having frequencies within one or more specified bandwidths, sometimes with a desired amount of signal attenuation, while blocking signals of other frequencies. It is convenient, but not necessary, to mount the electrical components such as capacitors, inductors, and resistors on one or more printed circuit boards in essentially conventional fashion. The circuit board carrying the filter circuit components is mounted within a suitable protective housing. Physical rigidity is required to maintain stable electrical response. Connection headers at each end provide for connecting the filter to a coaxial cable connector and to an equipment port. The entire assembly is commonly referred to as a filter or trap.
[0004] It is customary in the CATV industry for system technicians to use special wrenches for the installation and removal of traps. These special wrenches are of the pin spanner type where the driving pins of the wrench are accepted by two shallow holes bored into the end face of one header, sometimes referred to as engagement holes. This has been effective, but requires a degree of manufacturing difficulty and material usage which increases the cost of the trap housing components.
[0005] U.S. Pat. No. 5,150,087 (Yoshie et al.); U.S. Pat. No. 5,432,488 (Kotani et al.); U.S. Pat. No. 5,662,494 (Zennamo, Jr. et al.); U.S. Pat. No. 6,273,766 (Zennamo, Jr. et al.); U.S. Pat. No. 6,636,129 (Zennamo, Jr. et al.); U.S. Pat. No. 6,829,813 (Zennamo, Jr. et al.); and U.S. Pat. No. 6,888,423 (Tresness et al.) all show traps with the two engagement holes drilled into the end face of one of the headers.
SUMMARY
[0006] Briefly stated, a housing for a CATV filter includes an outer sleeve which can be made of stainless steel. A filter assembly and two headers are contained within the outer sleeve. Two engagement holes for a special pin spanner-type wrench are formed in a face of the outer sleeve instead of in a header. The engagement holes are preferably “drifted” holes, which in effect means that rims are created during the forming of holes which add to the strength of the holes.
[0007] According to an embodiment, an outer sleeve for a CATV filter has a first and second end. The second end includes a face that defines a connector hole. The connector hole is configured to receive a cable connector and the connector hole is located on a first axis. The face also defines at least one engagement hole located on a different axis.
[0008] According to another embodiment, a method for making an outer sleeve for a CATV filter includes forming a first hole located on a first axis in a face. The face is located on an end of the outer sleeve and the first hole is configured to receive a cable connector. The method also includes forming at least one engagement hole in the face. The at least one engagement hole located on a different axis.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 shows a cutaway perspective view of a filter with a housing according to an embodiment of the present invention.
[0010] FIG. 2 shows a perspective view of the housing of the embodiment of FIG. 1 with two engagement holes shown.
[0011] FIG. 3 shows a front elevation view of the embodiment of FIG. 1 .
[0012] FIG. 4 shows a cross-sectional view taken across line 4 - 4 of FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] Referring to FIGS. 1-4 , a CATV filter 10 includes a circuit board 28 connected to an inner frame 26 . At one end of filter 10 , an insulator 34 is adjacent to one end of circuit board 28 and is held in place partly by a header 22 , while at another end of filter 10 , an insulator 36 is adjacent to another end of circuit board 28 and is held in place partly by a header 24 . An outer sleeve, also known as a housing, 16 fits over inner frame 26 and headers 22 , 24 holding the assembly together. A portion of header 22 is shaped to connect to an equipment port (not shown), while a portion of header 24 is shaped to connect to a coaxial cable (not shown) via a coaxial cable connector (not shown), and in particular, includes a threaded connector 38 .
[0014] Outer sleeve 16 includes a central hole 32 in a face 30 to accommodate threaded connector 38 . Outer sleeve 16 also includes two engagement holes 12 , 14 to accommodate the driving pins (not shown) of the special pin spanner-type wrench (not shown) which is used in the industry to screw filters and traps onto equipment ports. Outer sleeve 16 is preferably of stainless steel, which is comparable to brass in terms of durability. When fabricating outer sleeve 16 of stainless steel, the part is deep drawn, which means that it starts out as steel sheet and is successively stamped into ever deeper and narrower “soup cans” until the final diameter and length are reached. The bottom end is closed, while the top end is still attached all the way around the rim to the parent sheet.
[0015] Engagement holes 12 , 14 are then formed in face 30 by punching two small holes in the bottom of the partially formed outer sleeve, after which a larger diameter tapered pin is forced through the holes, pushing the edge inward and stretching the diameter of each engagement hole 12 , 14 to its final diameter. Central hole 32 is then punched out, after which the part is sheared off the parent sheet and the edge is compacted in an operation known as a “pinch trim” which tapers edge 18 while eliminating the sharp edge left from the shearing. The taper of edge 18 is preferably approximately 15 degrees to aid in fitting outer sleeve 16 over inner frame 26 and headers 22 , 24 .
[0016] Engagement holes 12 , 14 are “drifted” holes, meaning that they have curled-in edges 40 , 42 , respectively, as a result of how they were made. Simply die-punching engagement holes 12 , 14 would not add curled edges 40 , 42 to engagement holes 12 , 14 . The strength of the “drifted” edge of the holes, combined with the durability of the stainless steel base metal, makes engagement holes 12 , 14 comparable in performance to drilled holes in brass. Curled edges 40 , 42 add effective thickness to engagement holes 12 , 14 which is greater than the thickness of the sheet metal itself, thus providing structural rigidity to withstand the up to 90 in-lb of torque expected when abused, with minimal deformation of engagement holes 12 , 14 . Non-drifted holes actually tear under those conditions, whereas the drifted holes merely become slightly egg-shaped. In addition, the prior art method of drilling engagement holes in one header is costlier than the present method of forming engagement holes 12 , 14 in outer sleeve 16 .
[0017] With no engagement holes in the header, machining or casting or metal injection molding without secondary machining operations becomes possible. The material thickness of the header may also be reduced, also saving costs.
[0018] While the present invention has been described with reference to a particular preferred embodiment and the accompanying drawings, it will be understood by those skilled in the art that the invention is not limited to the preferred embodiment and that various modifications and the like could be made thereto without departing from the scope of the invention as defined in the following claims.
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An outer sleeve for a CATV filter has, in one embodiment, a first end and a second end. The second end has a face with one or more engagement holes.
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TECHNICAL FIELD
This invention relates to a portable reading light and more particularly to a portable clip-on reading light which has a telescoping arm and improved illumination.
BACKGROUND
Portable clip-on reading lights are known. For example, a book light such as that disclosed in U.S. Pat. No. 4,432,042 has a base, an integral clamp from which a vertical lamp bearing arm is mounted to one end with the other end supported by the base. These devices typically comprise a body having means to clip on to a surface, such as a book cover, and include an arm that may be flexible or foldable for aligning a light for illuminating, for example, a page of a book.
Generally, such lights are popular but they do suffer from several drawbacks. Typically, illumination is provided by an incandescent bulb which itself has a limited life and such bulbs are often sensitive to shock during handling and are also difficult to replace. The sensitivity to shock promotes early bulb failure. In addition, power consumption is rather high which may result in reduced battery life and therefore frequent battery replacement. Often, the bulb is somewhat underpowered and therefore the amount of illumination may dim significantly over time leading to possible eye strain. Lastly, while folding and bending arms are useful, these do require additional space and any effort to reduce the size or bulkiness of the portable reading light promotes its portability and convenience for the user.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a clip-on reading light with increased bulb life.
It is a further object to provide a clip-on reading light which has increased battery life.
It is yet another object to provide a clip-on reading light with improved illumination.
It is yet another object to provide a clip-on reading light that is compact and light weight.
These and other objects of the present invention are achieved by a portable reading light having a housing, a power source disposed in the housing, a telescoping arm having an articulatable light source at the outer end thereof, the arm being mounted on a base, slidable within the housing for storing the telescoping arm therein. The light source comprises at least one light emitting diode (LED). Preferably, a magnifying lens is located adjacent the LED for directing and focusing the light emitted therefrom. The housing has means for clipping onto the surface of an object. Preferably, the light source comprises a plurality of light emitting diodes, most preferably three LEDs, which are set at specific angles relative to each other and disposed adjacent one or more magnifying lens which focus and direct the light for improved illumination.
Utilizing the present invention, a compact portable reading light is provided with an articulatable light that not only illuminates a page but which is rugged, and is low power consuming yet provides particularly bright white light without substantial dimming, for promoting long term reading with limited eye strain. Incorporating the telescoping arm within the housing also provides a compact device since the arm is stored within the housing when not in use.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a is a side view of the portable reading light of the present invention with the telescopic arm extended; FIG. 1 b is a perspective view showing the portable reading light from an alternate angle.
FIG. 2 is a top perspective view of the portable reading light with the arm collapsed and stored in the housing.
FIG. 3 is a cross-sectional view of the portable reading light with the arm collapsed within the housing.
FIG. 4 is a cross-sectional view of the portable reading light with the arm extended outside of the housing.
FIG. 5 a is an enlarged cross-sectional view of the arm pivot; FIG. 5 b is a cross-sectional view with the arm coaxial with the housing; FIG. 5 c is a view with the block collapsed within the housing.
FIG. 6 is a cross-sectional view of the arm in the extended position.
FIG. 7 is a top view of the lamp support assembly of the present invention, FIG. 7 a is a view taken along line A-A thereof, FIG. 7 b is a view taken along line B-B thereof, FIG. 7 c is a view taken along line C-C thereof, FIG. 7 d is a view taken along line D-D thereof and FIG. 7 e is a view taken along line D-D thereof and FIG. 7 e is a view taken along line E-E thereof.
FIGS. 8 a - c are views showing how each LED illuminates a specific page portion, relative to its angle in the lamp support.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 a , a portable reading light 1 has a housing 2 having a clip 3 on a side 4 thereof. The clip pivots on a hinge 5 and is biased by a spring 6 . The light has a slidable base 7 with a pivot 8 supporting a telescoping arm 9 which has three sections, 9 A, 9 B and 9 C. An outer pivot 10 is located at an outer end of the arm section 9 c and has a light support 11 rotatably mounted thereto, within which are disposed three light emitting diodes 12 . In FIG. 1 a , the portable reading light is shown extended for use. FIG. 1 b shows the extended light at an alternate angle, the light emitting diodes 12 and disposed behind individual magnifying lenses 12 a which focus the light to improve lighting on the surface illuminated as will be described further below. Using directed light significantly improves readability over the use of LEDs alone.
Referring to FIG. 2 , the portable reading light 1 has the arm 9 stored within the housing 2 , and the light support 11 received within a socket 13 at a forward end 14 of the housing. Thus, the portable reading light is shown in a compact form for storage. A sliding switch 15 is provided on a side 16 of the housing for ease in actuating the light. In this position, the portable reading light can function as a flashlight.
Referring to FIG. 3 , the reading light housing 2 is shown in cross-section. A power source 17 is located within the housing 2 for powering the light. While various configurations are possible, in this embodiment, 3 AAA size battery receiving slots 18 are provided and interconnected by conductors 19 to the switch 15 . The switch is slidable, having on and off positions. A flexible pair of conductors, shown as a single wire 20 , pass from the switch to and through the arm 9 which includes a wire storage chamber 21 therein. The wire storage chamber is sized for receiving a sufficient length of wire as would be needed for connecting to the light source when the telescoping arm is in the extended position. When the telescoping arm is collapsed, the wire bunches or coils within the chamber. Sufficient wire must be provided to reach the bulbs in the lamp support when in the extended position.
Referring to FIG. 4 , the arm 9 is fully out of the housing 2 . The slide block 7 is positioned adjacent to the lamp support receiving socket 13 at the forward end of the housing. The slide block is an assembly of three components including a first base 14 having a section slidable within a second base 15 slidable within a third base 16 . The bases collapse together when set for storage but extend when in use to add stability to the extended arm. The first base 14 has slots 17 on each side 18 . The slots 17 are received in corresponding slots 19 in the second base 15 . Similarly, within the third base 16 , the pivot portion 8 has slots 20 for receiving the second base but only when the arm is coaxially aligned, so that the arm is locked in this position when the second base is received within the third base. Each of the first and second bases have a responsive projection 21 and 22 that ride on rails 23 disposed on opposite sides of an arm receiving chamber 24 within the housing. A stop 25 is provided at the forward end of the rails to stop the forward movement of the base, so that it does not exit the housing. Each of the second and first bases have downwardly projecting prongs 26 that are received in a pair of grooves 27 within the housing. The grooves provide stability for the arm as well. The third base similarly has prongs 28 that slide within the slots of the second base.
In operation, these bases slide into each other to form a compact slidable block when the arm is stored within the housing, but have an extended form when the arm is pulled out of the housing.
Referring to FIG. 5 a - b , the pivot 8 is shown in cross section, with the bases fully extended. The pivot itself has detents 30 that receive stops 31 for providing a ratchet type pivoting, that is, the pivot moves in increments. This prevents slippage of the light from the optimum angle set by the user. The pivot has a circular support 32 with a flat side 33 for locking the pivot in the coaxial position for storage. A cylinder portion 34 extends through the second and third bases for additionally locking the pivot for storage.
Two projections 35 are received within detents 36 disposed in supporting the opposed side walls 37 within the housing so as to semi-permanently lock the slide block in position when the lamp is in the received position.
Referring to FIG. 5 b , the pivot 8 for the arm 9 is engaged to the base, having a plurality of slots 30 that act as stops for receiving a pair of projections 31 extending from a rotating portion of the pivot. These slots receive the projections therein so as to semi-permanently lock the arm in different angular positions to allow the user to set the arm at particular angles for reading and thereby prevent the arm from pivoting inadvertently. The projections and slots lock in a sufficient amount to prevent rotation of the arm, yet allow the locking to be overcome by manual pressure when the arm is manipulated for storage.
Referring to FIG. 6 , the arm is extended, with the bulbs 12 in the lamp support connected to the power supply in the housing. Similar slots and projections are used to lock the lamp support in the socket in the housing and to lock the base in the forward most position.
The light emitting diodes alone do not provide satisfactory lighting for reading as the light emitted from the diode has a directivity angle. The angle either focuses the light in a bright circular spot or scatters the light for greater illumination coverage but with a loss of light intensity, as either the light is uneven, or too diffused for successful use as a reading light.
Referring to FIGS. 7-7 e , the present invention overcomes these deficiencies by incorporating a magnifying lens 32 adjacent to an LED 33 which captures the light emitted and changes the directivity angle and converts it preferably to a closely rectangular shape, increasing the efficiency for illuminating a specific area of a reading page. The lens spreads the light which would otherwise be too concentrated on a focal point, while avoiding over diffusion of the light to too large of an area. If not filtered by the lens, the light is also too white which results in too much reflection back to the reader, which is annoying and may strain and tire the eyes.
As seen in FIG. 7 , a lamp support 34 has three light emitting diodes 33 a, b and c each of which is set at a specific angle. As shown in FIGS. 7 a , 7 b and 7 c , these are 35, 28.5 and 22 degrees, respectively though other angles could also be used. As shown in FIGS. 8 a , 8 b and 8 c , placing the LED's at these angles, and illuminating through the associated lenses 32 a, b and c , provides illumination of a full page, each LED illuminating a particular portion of the page.
One or more magnifying lenses can be used with one or more single or multiple LED configurations. However, one LED may be insufficient to provide even light distribution on a page, and about three LED's are preferred in one embodiment, the magnifying lens may be adjusted so that the light overlaps from each LED on or about the same rectangular space, providing an additive effect. This may be useful for longer extension embodiments.
Alternatively, and preferably, each LED can be focused on different portions of a page, so as to cover more area, for example, one covers the top of a page, a second covers a middle of a page and a third covers a bottom of a page. The direction and area covered are a function of the magnifying/focusing lens design. This works quite well with the telescoping arm, as adjusting the distance of the light source from the page allows a user to adjust the area covered, as well as intensity.
The circuitry for powering the LED's preferably includes means to enhance LED life. In one embodiment, each LED 33 a, b and c has a resistor 35 a, b and c which prevents overloading the LED's with too much voltage or current. In addition, each LED has an associated heatsink 36 a, b and c which are integrated into a simple heatsink to draw heat away from the LED's and prevent damage from overheating. Preferably, a single heat sink 36 is used for all the LED's.
While preferred embodiment of the present invention have been shown and described it will be understood by those skilled in the art that various changes or modification could be made without varying from the scope.
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A portable reading light has a telescoping arm that is slidable within a housing, the arm having a light source at the end thereof which has one or more light emitting diodes which provide bright light, low power consumption and durability. The light emitting diodes preferably are located in an articulatable light support and disposed adjacent to a focusing lens to better direct and shape the light onto a surface. The arm is mounted to a base assembly slidable within the housing and being telescopically expandable for stabilizing the arm when set for use.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation in part of U.S. patent application Ser. No. 14/482,277, filed on Sep. 10, 2014, now U.S. Pat. No. 9,091,107, which is continuation in part of U.S. patent application Ser. No. 14/284,511 filed on May 22, 2014, now U.S. Pat. No. 9,015,996, which is a continuation of U.S. patent application Ser. No. 14/011,041 filed on Aug. 27, 2013, now U.S. Pat. No. 8,769,871, which is a continuation of U.S. patent application Ser. No. 13/547,172 filed on Jul. 12, 2012, now U.S. Pat. No. 8,539,716, which is a continuation of U.S. patent application Ser. No. 12/652,241 filed on Jan. 5, 2010, now U.S. Pat. No. 8,245,446. U.S. patent application Ser. No. 12/652,241 claims the benefit of U.S. Provisional Application No. 61/219,435 filed on Jun. 23, 2009. This application is also related to U.S. patent application Ser. No. 14/663,780 filed on Mar. 20, 2015 which is a continuation of U.S. patent application Ser. No. 14/284,511 filed on May 22, 2014, now U.S. Pat. No. 9,015,996 mentioned above.
BACKGROUND OF THE INVENTION
The invention relates to doors for large buildings such as airplane hangers, farm equipment storage buildings, marine storage buildings and heavy equipment storage buildings. Such buildings can have doors that pivot up to an open position to allow the stored equipment to be moved into or out of the building. For door openings wider than approximately 15′ to 25′ conventional sectional overhead doors are typically not used because of the span and the problem of preventing door panel sections from sagging in the middle as the door is opened. A single panel door can be provided with a truss to support the door to preclude sagging of the door in the open position.
BRIEF SUMMARY OF THE INVENTION
The invention relates to a tilt-up door system for a building having an opening including a pair of vertically juxtaposed members that can define a vertical track. The vertical members can each have a first cam extending generally laterally from the vertical track at an upper portion. The first cams can have a first steep inclined segment, a second inclined segment and a third segment. A door sized to span the opening can be pivotally coupled to the vertical members with at least one roller disposed within each of the vertical tracks, and a cam follower extending laterally from an upper portion of the door in register with each of the first cams. When the door is placed in alignment with the opening in a closed, lowered position with the rollers disposed within the vertical tracks and the cam followers located adjacent to the first cams and an upwardly-directed motive force acts upon the door, the cam followers come into abutment with the first steep inclined segments of the first cams which moves the door generally vertically, then into abutment with the second inclined segments of the first cams which rotates the upper portion of the door inwardly, and then into abutment with the third segments of the first cams to bring the door into an opened, raised position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a tilt-up door installed on an aircraft hanger building.
FIG. 2 is a perspective view of the tilt-up door shown in FIG. 1 partially opened.
FIG. 3 is a perspective view of the tilt-up door shown in FIG. 1 fully opened.
FIG. 3A is a perspective view of the tilt-up door shown in FIG. 3 showing an alternate door stop arrangement.
FIG. 4 is a view of the tilt-up door shown in FIG. 1 with the door fully open showing the door support and a hydraulic actuator operating mechanism.
FIG. 4A is a view of the tilt-up door shown in FIG. 1 with the door fully open showing the door support and an alternate hydraulic actuator operating mechanism.
FIG. 4B is a partial schematic cutaway drawing of a hydraulic pump assembly that can be used with the alternate hydraulic actuator of FIG. 4A .
FIG. 4C is a partial schematic drawing of the lower portion of the alternate hydraulic actuator of FIG. 4A .
FIG. 4D is a partial view looking at one side the lower portion of the alternate hydraulic actuator of FIG. 4A .
FIG. 4E is a partial view looking at the opposite side of the lower portion of the alternate hydraulic actuator of FIG. 4A .
FIG. 5 is a partial view looking up showing a carriage in the U-shaped channel pivotally connected to the door frame.
FIG. 6 is a partial view looking down showing the carriage in the U-shaped channel pivotally connected to the door frame.
FIG. 7 is a partial view looking down showing the top of the carriage in the U-shaped channel pivotally connected to the door frame.
FIG. 8 is a top view of a carriage.
FIG. 8A is a side view of a carriage.
FIG. 8B is a top view of an alternate carriage.
FIG. 8C is a side view of the alternate carriage of FIG. 8B .
FIG. 8D is a partial top view of an alternate carriage.
FIG. 8E is a partial top view of an alternate carriage.
FIG. 9 is a partial view looking up showing a cam follower pivotally mounted to the tilt-up door with the cam follower engaging the cam surface.
FIG. 10 is a partial view showing the track and cam surface with the cam follower engaging the cam surface with the tilt-up door in the closed position.
FIG. 10A is a partial view showing an alternate track and cam surface with the cam follower engaging the cam surface with the tilt-up door in the closed position.
FIG. 10B is a partial view showing an alternate track and cam with the cam follower engaging the cam with the tilt-up door in the closed position.
FIG. 11 is a partial view showing the cam follower engaging the cam surface with the tilt-up door in the open position.
FIG. 12 is a schematic view illustrating an alternate U-shaped channel and track arrangement.
FIG. 12A is a schematic view illustrating a track and cam arrangement including the alternate cam illustrated in FIG. 10B .
FIG. 13 is an exploded view of FIG. 5 illustrating the U-shaped channel, carriage, pivot shaft and door frame pivot shaft tube.
FIG. 14 is a schematic drawing of a hydraulic circuit that can be used with a tilt-up door.
FIG. 14A is a schematic drawing of an alternate hydraulic circuit that can be used with a tilt-up door.
FIG. 14B is a schematic drawing of the alternate hydraulic circuit of FIG. 14A with the hydraulic cylinders activated to raise a tilt-up door.
FIG. 14C is a schematic drawing of the alternate hydraulic circuit of FIG. 14A with the check valves activated to allow a tilt-up door to close.
FIG. 15 is a partial schematic front view looking into the door opening of a building having a tilt-up door with the door removed showing an alternate U-shaped channel arrangement that can be used with the alternate carriage illustrated in FIGS. 8B-8E .
FIG. 16 is a partial schematic top view showing an alternate actuator that can be used with the U-shaped channel arrangement of FIG. 15 .
FIG. 16A is a partial schematic top view illustrating the alternate actuator that can be used with U-shaped channel arrangement illustrated in FIG. 15 .
FIG. 17A is a partial schematic front view looking into the door opening of a building having a tilt-up door with the door removed showing an alternate U-shaped channel arrangement that can be used with an alternate carriage as illustrated in FIGS. 8B-8E .
FIG. 17B is a partial schematic top view showing the alternate U-shaped channel arrangement of FIG. 17A .
FIG. 18 is a partial schematic side view looking at the edge of a door opening of a building having a tilt-up door with the door removed showing an alternate U-shaped channel arrangement that can be used with an alternate carriage as illustrated in FIGS. 8B-8E .
FIG. 19A is a partial schematic front view of an alternate U-shaped channel looking into the door opening of a building having a tilt-up door with the door removed showing an alternate linear actuating mechanism that can be used with an alternate carriage as illustrated in FIGS. 8B-8E .
FIG. 19B is a partial schematic side view of the alternate U-shaped channel of FIG. 19A showing the alternate carriage.
FIG. 19C is a partial schematic side view of the alternate U-shaped channel and alternate linear actuating mechanism of FIG. 19A showing the alternate linear actuating mechanism.
FIG. 19D is a partial schematic view of the pulley block for use with the alternate linear actuating mechanism of FIG. 19A removed from the U-shaped channel.
DESCRIPTION OF THE INVENTION
Tilt-up doors can be used on storage buildings that can include, but are not limited to, aircraft hangers, farm equipment storage buildings, marine storage buildings and heavy equipment storage buildings requiring doors that are too wide for sectional overhead doors used on residential and commercial buildings. Typically sectional overhead doors can used for door openings up to 15′ to 25′ wide without requiring extra support for the door sections to prevent the door sections from sagging when the door is in the open position. Tilt-up doors are well known for storage buildings requiring door openings wider than 20′ to 25′ wide. The tilt-up door can include an improved door lift arrangement.
Turning to FIGS. 1 to 3 , a tilt-up door 10 can be seen pivotally mounted on a building 20 having a door opening 19 and a roof 21 . The tilt-up door 10 can have a passage door 15 to permit individuals to enter the building 20 without opening tilt-up door 10 . Tilt-up door 10 can include a truss 12 that can be mounted on the outside 11 of tilt-up door 10 above passage door 15 . Tilt-up door 10 can have a frame 16 that can include horizontal members 17 and vertical members 18 that can be square or rectangular box members that can be fastened together into a frame 16 as is well known in the art. Truss 12 can be sized to provide the desired support for tilt-up door 10 to prevent sagging in the open position shown in FIG. 3 and to support the door for loads such as can be presented by rain, snow and wind conditions. Truss 12 can be attached to tilt-up door 10 with suitable mounting brackets 14 that can be attached to vertical members 18 of door frame 16 and can receive mounting bolts, not shown, to connect truss 12 to tilt-up door 10 . Truss 12 can be mounted on tilt-up door 10 in a position where truss 12 will not interfere with building 20 when the tilt-up door 10 is in the open position as shown in FIG. 3 . An advantage of mounting truss 12 generally in the vertical center portion of the door is that truss 12 is spaced above the floor and surface in front of building 20 and above a passage door 15 when a passage door is desired. In addition, truss 12 can be located near the pivot point for tilt-up door 10 as described below. Tilt-up door 10 can have door panels 13 attached to horizontal members 17 and additional vertical members 18 for frame 16 . As desired door panels 13 can be selected to match panels used to enclose building 20 . Door panels 13 can be typical door panels and can be insulated panels if desired as are well known. Truss 12 can be mounted to tilt-up door 10 after door panels 13 are attached to frame 16 to avoid inserting door panels 13 between truss 12 and frame 16 .
Tilt-up door 10 will be illustrated in combination with a steel frame aircraft hanger building although, as mentioned above, a tilt-up door 10 can be installed on other types of storage buildings including, but not limited to, wood frame pole barns, masonry buildings and open web truss buildings as desired. Building 20 can have a plurality of I-beams or columns 22 that can collectively form the framework 28 for building 20 and support roof 21 . In the event the building framework 28 does not include I-beams a U-shaped channel that can be similar to U-shaped channel 32 can be employed adjacent the door opening. Building 20 can have walls 25 as desired to enclose building 20 . Roof trusses 23 , see FIG. 10 , can be provided to support roof 21 as are well known. While I-beam trusses are shown in the drawings other roof support systems can be used as desired.
As mentioned above, a tilt-up door 10 can be pivotally mounted to building 20 . Turning to FIG. 4 , an I-beam 22 forming part of the building framework 28 at one side of door opening 19 can be seen. While the tilt-up door 10 will be described employing an I-beam 22 those skilled in the will appreciate that other support columns can be used and can be provided with a U-shaped channel in lieu of an I-beam 22 . A similar I-beam 22 or U-shaped channel can be provided on the other side of door opening 19 and the following description applies to an I-beam 22 and the pivotal mounting structure for tilt-up door 10 on both sides of door opening 19 . I-beam 22 can be attached to floor 24 with a plurality of mounting bolts 26 , or other suitable well known fasteners, and can be connected to the building framework 28 at the top of I-beam 22 , not visible, as is well know. I-beam 22 can include a web 30 and a pair of flanges 31 that can form generally U-shaped channel 32 . When a tilt-up door 10 is used with building structures that do not include I-beams, as discussed above, a U-shaped channel, not shown, can be mounted to the building support structure on each side of door opening 19 to provide a channel that can be similar to channel 32 shown in FIG. 4 .
In one embodiment the actuator 39 for the tilt-up door 10 can be single acting hydraulic cylinders 40 that can be mounted in channel 32 on each side of door opening 19 to a support plate 42 that can be supported by web 30 and flanges 31 . A double acting hydraulic cylinder can be used instead of a single acting hydraulic cylinder. When I-beam 22 is a steel beam, support plate 42 can be welded to web 30 and flanges 31 . The hydraulic cylinders 40 can be secured in channels 32 with a bracket or clamp 44 that can be attached to I-beam 22 spaced from support plate 42 to secure hydraulic cylinder 40 in place. In FIG. 4 tilt-up door 10 is in the open position and piston 41 of hydraulic cylinder 40 is extended. The distal end 45 of piston 41 can be connected to a carriage or push block 60 that can be pivotally connected to door frame 16 as will be described below.
Turning to FIGS. 5, 8 and 13 , one embodiment of a pivotal mounting arrangement for pivotally mounting tilt-up door 10 to the building 20 will be described. As noted above, the mounting structure of tilt-up door 10 can be the same on both sides of the tilt-up door 10 and door opening 19 . Accordingly, while the tilt-up door 10 pivotal mounting arrangement on one side of tilt-up door 10 will be described in detail those skilled in the art should understand the following description applies to both sides of tilt-up door 10 and door opening 19 in building 20 . In FIG. 5 carriage 60 can be seen in channel 32 with tilt-up door 10 in the partially open position. Referring to FIGS. 5, 8, and 13 , carriage 60 can be formed by connecting plates 62 and 64 in spaced relationship with end plates 66 and 68 . A horizontally extending pivot shaft journal 70 can be attached to carriage 60 by plates 62 and 64 . Plates 62 and 64 can have an opening to receive pivot shaft journal 70 and pivot shaft journal 70 can be welded to plates 62 and 64 and end plates 66 and 68 can be welded to plates 62 and 64 to form carriage 60 . Reinforcing plates 72 can be welded to pivot shaft journal 70 and end plates 66 and 68 to further support pivot shaft journal 70 relative to plates 62 and 64 . Pivot shaft journal 70 can be a hollow cylinder to receive pivot shaft 71 , see FIG. 13 , to pivotally connect tilt-up door 10 to carriage 60 . For example, pivot shaft 71 can be a 1″ diameter solid rod. Those skilled in the art will understand that the diameter of pivot shaft 71 and the pivot shaft journal 70 can be smaller or larger depending on the size and weight of the tilt-up door 10 . Likewise those skilled in the art will understand that carriage 60 can be formed in other ways to support a pivot shaft journal if desired. In addition, pivot shaft 71 can have a threaded hole 85 adjacent one end to facilitate removal of pivot shaft 71 if desired following installation. The end of pivot shaft journal 70 at plate 62 can have a plug, not shown, welded in pivot shaft journal 70 to close the end of pivot shaft journal 70 at the outer surface 63 of plate 62 .
Vertical members 18 on both sides of door frame 16 can have a horizontally extending pivot shaft tube 78 that can be connected to vertical member 18 to rotatably support pivot shaft 71 , see FIG. 13 , to pivotally connect door 10 to carriage 60 . Pivot shaft tube 78 can be welded in an opening in vertical member 18 at a desired location that can be generally in the vertical center portion of tilt-up door 10 . The vertical position of pivot shaft tube 78 can be determined by the vertical height of door 10 and whether tilt-up door 10 includes a passage door 15 as illustrated in FIG. 1 . When a passage door 15 is included in tilt-up door 10 pivot shaft tube 78 can be located above the top of passage door 15 in order to allow truss 12 to be located generally adjacent the pivot point of tilt-up door 10 . Typically pivot shaft tube 78 can be located at least one quarter of the vertical height above the bottom edge 37 of the tilt-up door 10 and less than three quarters of the vertical height above the bottom edge of the tilt-up door 10 . The location of pivot shaft tube 78 , and accordingly the pivot point of tilt-up door 10 can be determined by the overall height of tilt-up door 10 , whether a passage door 15 will be included and how much of tilt-up door 10 should extend from the face of the building 20 when the tilt-up door is in the open position which can determine the location of truss 12 . It can be advantageous to locate the pivot point of tilt-up door 10 generally in the vertical center portion of the door, but, as noted above, the pivot point can be located as desired in the vertical center portion of the tilt-up door 10 to accommodate a passage door 15 and to allow vertical location of truss 12 generally adjacent to the pivot shaft tube 78 . In the embodiment illustrated in FIGS. 1-3 the pivot shaft tube 78 can be located approximately ⅔ of the distance up from the bottom 37 of tilt-up door 10 to the top of tilt-up door 10 .
Pivot shaft tube 78 can have a shaft tube closure 80 that can be mounted to a mounting ring 79 attached to the end of pivot shaft tube 78 . Shaft tube closure 80 can be mounted to mounting ring 79 using suitable fasteners 83 . Shaft tube closure 80 can have an adjusting bolt nut 81 attached to the external surface of shaft tube closure 80 . An adjusting bolt 82 can be threaded into adjusting bolt nut 81 to bear against the end of pivot shaft 71 in shaft tube 78 to position door frame 16 relative to carriage 60 and accordingly I-beams 22 and building 20 . By adjusting the adjusting bolts 82 on the opposite sides of tilt-up door 10 the tilt-up door 10 can be positioned side to side as desired in door opening 19 by adjusting the adjusting bolts 82 . Adjusting bolts 82 can have a square or hex head 82 ′ or can have a recessed socket to receive a tool to facilitate rotation of the respective adjusting bolts 82 on the opposite sides of tilt-up door 10 to position the tilt-up door 10 as desired. A lock nut 84 can be secured to each adjusting bolt 82 after the tilt-up door 10 is satisfactorily positioned in door opening 19 to lock adjusting bolts 82 in position. In order to adjust, or re-adjust, the side to side position of tilt-up door 10 in door opening 19 lock nuts 84 can be loosened and adjusting bolts 82 rotated to position the tilt-up door 10 in door opening 19 as desired and then lock nuts 84 can be retightened to secure the adjusting bolts 82 in the desired position. To remove pivot shaft 71 , tilt-up door 10 can be partially opened to provide access to shaft tube cover 80 and tilt-up door 10 can be supported at the bottom edge 37 to remove weight from pivot shaft 71 . Shaft tube cover 80 can be removed and a shaft puller can be threaded into threaded hole 85 to pull pivot shaft 71 from the pivot shaft tube 78 . Pivot shaft 71 can be replaced and adjusted and the shaft tube cover can be replaced to complete any service of the pivot shaft and/or tilt-up door. Pivot shaft 71 can allow pivot shaft tube 78 to rotate relative to pivot shaft journal 70 as tilt-up door 10 is moved from the closed to the open position or from an open position to the closed position. Grease fittings 73 can be provided for pivot shaft journal 70 and pivot shaft tube 78 as shown on FIGS. 5, 8 and 13 . Applicant has found that sleeve or other bearings are not required for pivot shaft 71 in pivot shaft journal 70 or pivot shaft tube 78 since the amount of relative rotation of pivot shaft 71 in pivot shaft journal 70 and pivot shaft tube 78 is relatively small in a door opening or closing cycle. If desired, suitable sleeve bearings could be used in addition to or instead of grease fittings to facilitate rotation of pivot shaft tube 78 relative to pivot shaft journal 70 on pivot shaft 71 as the tilt-up door 10 is opened and closed.
Carriage 60 end plate 68 can have a piston connector 74 attached to the outer surface 69 of end plate 68 . Piston connector 74 can be arranged to receive the distal end 45 of piston 41 and a connector bolt 77 , see FIGS. 8 and 8A . Distal end 45 can have a connector hole 46 bored transversely through the distal end 45 . Connector 74 can have a connector bolt hole 75 on one side of connector 74 and tapped threads 76 on the opposite side of connector 74 to receive connector bolt 77 to secure carriage 60 to distal end 45 of piston 41 . In the embodiment disclosed in FIGS. 4-8A a threaded connector bolt 77 is shown to secure carriage 60 to piston 41 . Those skilled in the art will understand that other known fasteners such as a pin or a set screw or other fastener can be used to secure carriage 60 to the distal end 45 of piston 41 as desired.
Referring to FIGS. 5, 6 and 7 , carriage 60 can have a plurality of wheels that can facilitate movement of carriage 60 in channel 32 as tilt-up door 10 is opened and closed. Carriage 60 can have an exterior side 60 ′, namely the side of carriage 60 that faces the outside of building 20 when carriage 60 is positioned in channel 32 , and an interior side 60 ″ that faces the interior of building 20 . As tilt-up door 10 is opened by operating an actuator 39 such as hydraulic cylinder 40 , carriage 60 is pushed upward in channel 32 by piston 41 pushing door frame 16 and, accordingly, tilt-up door 10 upward. Carriage 60 can have a pair of bearing wheels 86 rotatably mounted between plates 62 and 64 on bearing wheel shafts 87 . As carriage 60 is pushed upward by hydraulic cylinder 40 , carriage 60 is forced toward the exterior of building 20 due to the load of tilt-up door 10 . Bearing wheels 86 can be steel bearings that can withstand the load of tilt-up door 10 thereby facilitating the movement of carriage 60 in channel 32 . While steel bearing wheels can be used as illustrated in the embodiment of FIGS. 4-8 , those skilled in the art will understand that other wheels designed to support the anticipated load of a tilt-up door 10 can be used. Carriage 60 can also have a pair of idler wheels 88 rotatably mounted between plates 62 and 64 on the interior side 60 ″ of carriage 60 on idler wheel shafts 89 . Bearing wheel shafts 87 and idler wheel shafts 89 can be attached to carriage 60 utilizing cotter keys 92 as shown in FIGS. 5 and 6 or other well know shaft retainers as desired. Idler wheels 88 can be urethane wheels since, normally, idler wheels 88 are not in contact with flange 31 on the inside of building 20 . Idler wheels 88 can help assure that carriage 60 remains generally centered in channel 32 during opening or closing of tilt-up door 10 . Carriage 60 can also have a low friction pad 90 positioned on the outer surface 63 of plate 62 to facilitate movement of carriage 60 along web 30 in channel 32 as tilt-up door 10 is opened and closed. Low friction pad 90 can be a well known plastic resin material such as nylon or Delrin®. Those skilled in the art will understand that other low friction materials can be used for low friction pad 90 . A low friction pad such as low friction pad 90 can be attached to plate 62 with a plurality of countersunk flat head machine screws 91 that can be threaded into tapped holes in plate 62 . Those skilled in the art will understand that the number of screws required to secure low friction pad 90 to plate 62 depends on the size of low friction pad 90 . Typically 4 to 6 screws 91 can be used to secure low friction pad 90 to plate 62 .
In addition to the pivotal mounting of tilt-up door 10 to building 20 described above, the tilt-up door mounting arrangement can include a track 50 that can be attached to I-beam 22 adjacent the top end of I-beam 22 on each side of door opening 19 . Referring to FIGS. 1 and 9-11 , the first end 48 of track 50 can be connected to I-beam 22 and roof truss 23 adjacent the top of I-beam 22 . Track 50 can be a C-section steel beam having a bottom flange 51 and a top flange 52 in addition to a mounting flange 53 to facilitate attachment of track 50 to I-beam 22 . Top flange 52 can be attached to roof truss 23 to connect track 50 to the building structure. While the building 20 illustrated in the drawings includes roof trusses 23 , those skilled in the art will understand that other building trusses can be used to secure track 50 in place at the top of I-beam 22 . In addition, as described below in connection with FIG. 12 , a tilt-up door 10 can be used in combination with buildings that to not have trusses or other supports positioned above track 50 . The length of track 50 can be determined based on the overall height of tilt-up door 10 and the pivot point that determine how far tilt-up door 10 will extend into building 20 when tilt-up door 10 is in the open position as shown in FIG. 3 . Those with ordinary skill in the art will understand that track 50 can be a beam having a configuration other than a C-section as desired.
Track 50 can include a cam surface 55 . Door frame 16 can have a horizontally extending cam follower 95 positioned adjacent to top edge 36 of tilt-up door 10 . Cam follower 95 can include a mounting bracket 96 that can be connected to vertical member 18 of door frame 16 adjacent to the top horizontal member 17 . Mounting bracket 96 can be welded to vertical member 18 and can be arranged to support flange bearings 98 on opposite faces 97 of mounting bracket 96 . Flange bearings 98 can be secured to mounting bracket 96 with fasteners 99 and can include grease fittings 73 . Cam follower 95 can further include a cam follower shaft 102 that can be rotatably supported by flange bearings 98 on opposite sides of mounting bracket 96 and shaft 102 can extend outwardly from door frame 16 to rotatably support cam follower wheel 104 . Cam follower wheel 104 can be an enlarged end of shaft 102 and can have a relatively hard urethane surface formed on the enlarged end of shaft 102 . As can be seen best in FIG. 11 cam follower wheel 104 can engage cam surface 55 as tilt-up door 10 moves from the closed position, shown in FIG. 10 , to the open position shown in FIG. 11 . When the pivot point of tilt-up door 10 is above the vertical center of tilt-up door 10 , cam follower wheel 104 can be biased into contact with cam surface 55 by the unbalanced weight of tilt-up door 10 with respect to the pivot point about pivot shaft 71 . Accordingly, as an actuator 39 such as hydraulic cylinders 40 are operated, carriages 60 are forced upward by pistons 41 thus pushing tilt-up door 10 upward as pivot shaft tubes 78 attached to door frame 16 are forced upward. As door frame 16 moves upward the top edge 36 of tilt-up door 10 rotates inward as cam follower wheels 104 roll along cam surfaces 55 . As tilt-up door 10 moves upward, tilt-up door 10 rotates approximately 90° as shown in FIGS. 2 and 3 . Thus, tilt-up door 10 has a moving pivot point, pivot shaft 71 in pivot shaft tubes 78 , moving along a substantially straight line (carriages 60 and pivot shaft journals 70 move in substantially vertical channels 32 ), about which tilt-up door 10 rotates as it is moved upward. Cams 55 can be arranged to rotate tilt-up door 10 from the vertical position in FIG. 1 to a generally horizontal position as shown in FIG. 3 as hydraulic cylinders 40 lift tilt-up door 10 from the closed position in FIG. 1 to the open position in FIG. 3 .
Referring to FIG. 10 , as tilt-up door 10 approaches the closed position cam surface 55 becomes substantially vertical adjacent the first end 48 of track 50 so that tilt-up door 10 initially moves generally vertically for the first few inches from closed position as tilt-up door 10 opens and moves generally vertically over the last few inches to the closed position as tilt-up door 10 closes. An advantage of generally vertical movement from and to the closed position is that material lying against the outside surface of tilt-up door 10 such as snow or ice does not need to be moved by the door opening mechanism as tilt-up door 10 initially rises vertically. An additional advantage of vertical movement at the beginning of an opening cycle and the end of a closing cycle is that a mechanical latch arrangement can be employed to secure the bottom edge 37 of tilt-up door 10 in the closed position. One mechanical latch arrangement can be seen in FIGS. 2 and 3 and can include hooks 34 that can be attached to vertical members 18 on the outside edges of door frame 16 spaced above the bottom edge 37 extending inward from door frame 16 . Tabs 35 can be attached to I-beams 22 on opposite sides of door opening 19 extending into door opening 19 and positioned to be engaged by hooks 34 as tilt-up door 10 moves to the closed position shown in FIG. 1 . Hooks 34 and tabs 35 can be dimensioned and positioned so that hooks 34 engage/disengage tabs 35 as tilt-up door 10 moves generally vertically to the closed position/from the closed positioned as described above. In addition, tabs 35 can prevent over swing of tilt-up door 10 past the closed position during closing and provide a secure stop for tilt-up door 10 in the event of wind pressure and the like. Referring to FIG. 3A , extended tabs 35 ′ can be provided to extend along I-beam 22 from adjacent the floor 24 to a position adjacent the top of hydraulic cylinder 40 to provide an extended door stop and to provide an improved door seal. An improved door seal arrangement can be desirable for applications in climates where climate control of the interior of building 20 may be desired. Extended tabs 35 ′ can have a slot 38 to allow hook 34 to engage tab 35 ′ as described above.
Referring again to FIGS. 10 and 11 , track 50 can include additional cam surfaces that can restrain cam follower wheel 104 as tilt-up door 10 approaches the open position adjacent the second end 49 of track 50 , FIG. 11 , and the closed position adjacent the first end 48 of track 50 , FIG. 10 . A closed cam follower surface 56 can be provided on track 50 beneath cam surface 55 that can prevent cam follower wheel from moving out of contact with cam surface 55 allowing tilt-up door 10 to lift and rotate cam follower wheel 104 out of contact with cam surface 55 such as might occur in a high wind condition before tilt-up door 10 is open enough to provide sufficient cantilever load to hold cam follower wheel 104 in contact with cam surface 55 . An open cam follower surface 57 can be provided to engage cam follower wheel 104 as tilt-up door 10 approaches the open position adjacent the second end 49 of track 50 , FIGS. 3 and 11 . By engaging cam follower wheel 104 , open cam surface 57 can help prevent tilt-up door 10 from bouncing up and down when substantially open as might otherwise occur in high wind conditions. Alternately as illustrated in FIG. 10A , track 50 can have secondary cam surface 58 positioned below and generally parallel to cam surface 55 to assure that cam follower wheel 104 remains generally in contact with cam surface 55 or secondary cam surface 58 as cam follower wheel 104 moves from the first end 48 to the second end 49 of track 50 . A secondary cam surface 58 can be used when the pivot point of tilt-up door 10 is near or below the vertical mid-point of tilt-up door to preclude the cam follower wheel 104 from dropping out of contact with cam surface 57 due to a nearly balanced tilt-up door 10 about the pivot point or unbalanced weight of tilt-up door 10 above the pivot point. Secondary cam surface 58 can be vertically spaced from cam surface 55 sufficiently to allow cam follower wheel 104 roll freely along cam surface 55 and or secondary cam surface 58 . Thus, in the embodiment illustrated in FIG. 10A , cam surface 55 and secondary cam surface 58 can form a track or channel for cam follower wheel 104 that can prevent the cam follower wheel 104 from losing contact with the cam surface 55 and/or secondary cam surface 58 regardless of the vertical location of the pivot point of tilt-up door 10 or adverse weather conditions.
Turning to FIGS. 10B and 12A an alternate track 450 is illustrated that can be attached to a juxtaposed vertical member 22 , that can be an I-beam, adjacent the top end of vertical member 22 on each side of door opening 19 . The first end 448 of track 450 can be connected to vertical member 22 generally adjacent the top of tilt-up door 10 when tilt-up door 10 is in the closed lowered position. Track 450 can be a fabricated steel beam including a back member 447 , a first end member 448 that can be welded to one end of back member 447 and a second end member 449 that can be welded to an opposite end of back member 447 . Top member 452 can be welded to the top edge of back member 447 and a bottom flange 452 can be welded to the bottom edge of back member 447 . Top member 452 can be a square or rectangular box member. A suitable mounting bracket 464 can be attached to vertical member 22 and can have openings 466 , not visible, for mounting bolts 465 to secure track 450 to a vertical member 22 . In addition, as described below in connection with FIG. 12A , tilt-up door 10 can be used in combination with buildings that do not have trusses or other supports positioned above track 450 . The length of track 450 can be determined based on the overall height of tilt-up door 10 and the pivot point that determine how far tilt-up door 10 will extend into building 20 when tilt-up door 10 is in the open position.
Track 450 can include a cam 455 that can have plural segments. A first segment 454 can be formed by the inside surface 453 of first end member 448 . A second segment 456 and third segment 457 can be formed by a plate member. Segment 456 can be welded to back member 447 and segment 457 can be welded to back member 447 and top member 452 . Segments 456 and 457 can be a formed continuous plate member or can be separate plate members as desired. Cam 455 can also have a curved segment 462 positioned between second segment 456 and first segment 454 that can be a continuation of second segment 456 and welded to back member 447 and first end member 448 . Door frame 16 can have a horizontally extending cam follower 95 that can be connected to vertical member 18 of door frame 16 generally adjacent the top horizontal member 17 as described in detail above. Similar to the embodiment illustrated in FIGS. 10 and 11 , cam follower wheel 104 can engage cam 455 as tilt-up door moves from the closed position shown in FIG. 10B to the open position. When the pivot point of the tilt-up door 10 is above the vertical center of tilt-up door 10 , cam follower wheel 104 can be biased into contact with cam 455 by the unbalanced weight of tilt-up door 10 with respect to the pivot point about pivot shaft 71 . As described above, when an upwardly directed motive force acts upon the tilt-up door 10 pushing tilt-up door 10 upward, door frame 16 moves upward and tilt-up door 10 rotates inward as cam follower wheels 104 roll along cams 455 that can be positioned on opposite sides of door opening 19 . As tilt-up door 10 moves upward, tilt-up door 10 rotates approximately 90° as shown in FIGS. 2 and 3 .
A second cam 458 can be positioned below and generally parallel to cam 455 to assure that cam follower wheel remains generally in contact with cam 455 or second cam 458 as cam follower wheel 104 moves from the first end 448 to the second end 449 of track 450 . Second cam 458 can prevent cam follower wheel 104 from moving out of contact with cam 455 allowing tilt-up door 10 to lift and rotate cam flower wheel 104 out of contact with cam 455 as might occur in a high or gusty wind condition and to help prevent tilt-up door 10 from bouncing up and down when substantially open as might occur in high or gusty wind conditions. A second cam 458 can be used when the pivot point of the tilt-up door is near or below the vertical mid-point of tilt-up door 10 to preclude the cam follower wheel 104 from dropping out of contact with cam 455 due to a nearly balanced tilt-up door 10 about the pivot point or unbalanced weight of tilt-up door 10 above the pivot point. Second cam 458 can be vertically spaced from cam 455 sufficiently to allow cam follower wheel 104 to roll freely along cam 455 and or second cam 458 . Thus, in the embodiment illustrated in FIG. 10B , cam 455 and second cam 458 can form a track or channel for cam follower wheel 104 that can prevent the cam follower wheel 104 from losing contact with the cam 455 and/or second cam 458 regardless of the vertical location of the pivot point of tilt-up door 110 or adverse weather conditions.
Referring again to FIGS. 10B and 12A , cam 455 can have a first steep inclined segment 454 , a second inclined segment 456 and a third segment 457 . First steep inclined segment 454 can extend generally vertically so that tilt-up door 10 can initially move generally vertically for the first few inches from the closed position as tilt-up door 10 opens and can move generally vertically over the last few inches to the closed position as tilt-up door 10 closes. An advantage of generally vertical movement from and to the closed position is that material lying against the outside surface of tilt-up door 10 such as snow or ice does not need to be moved by the door opening mechanism as tilt-up door 10 initially rises vertically. An additional advantage of vertical movement at the beginning of an opening cycle and the end of a closing cycle is that a mechanical latch arrangement can be employed to secure the bottom edge 37 of tilt-up door in the closed position as described in detail above. Second inclined segment 456 can be generally linear, and third segment 457 can be generally horizontal. Cam 455 can have a curved segment 462 positioned between the first steep inclined segment 454 and second inclined segment 456 that can allow cam follower wheel 104 to roll from first steep inclined segment 454 to inclined segment 456 , and vice versa, as tilt-up door 10 is moved from the closed lowered position to the open position and back.
Second cam 458 can have a first steep inclined portion 459 , a second inclined portion 460 and a third portion 461 . Second portion 460 and third portion 461 can be square or rectangular box members and can be welded to back member 447 . Similar to second inclined segment 456 , second inclined portion 460 can be generally linear. Similar to third segment 457 , third portion 461 can be generally horizontal. First steep inclined portion 459 can be a surface of bracket 463 positioned between the second portion 460 and bottom flange 451 as shown in FIG. 10B or can be integrally formed as part of cam 458 . As can be seen in FIG. 10B , mounting bolts 465 can be used to secure bracket 463 to back member 447 and bottom flange 451 to mounting bracket 464 . Mounting holes 466 can be provided in the bottom flange 451 adjacent mounting bracket 464 and in back member 447 , not visible, to accommodate mounting bolts 465 . Those with ordinary skill in the art will understand that track 450 can be a beam having a configuration other than configuration illustrated in FIG. 10B as desired to provide first and second cams as described above.
As noted above, a tilt-up door 10 can be used in combination with storage buildings that do not have a building truss spanning the building adjacent to top of the door opening. Turning to FIG. 12 , an alternate I-beam and track arrangement can be seen in schematic form. Building 120 can have a roof 121 supported by roof trusses 123 that do not extend horizontally at the top of door opening 119 . I-beam 122 can be similar to I-beam 22 in the embodiment of FIGS. 1-11 and 13 and can include a hydraulic cylinder and carriage mechanism as described above but not shown in FIG. 12 . I-beam 122 can have a support plate 152 that can be similar to support plate 42 as illustrated in FIG. 4 and can support an actuator 39 or a hydraulic cylinder, not shown in FIG. 12 that can be similar to hydraulic cylinder 40 as illustrated in FIG. 4 . Track 150 can be attached to I-beam 122 as described above in the embodiment of FIGS. 1-11 and 13 . In absence of a building truss or beam to secure track 150 to, as in the embodiment described above, a support tube 125 can be provided to support the end 151 of track 150 opposite I-beam 122 . Support tube 125 can be a square or rectangular tube, or could be an I-beam as desired, and can be attached to the floor 124 with mounting bolts 126 or other fasteners in a manner similar to I-beam 22 . As above, an I-beam 122 , track 150 and support tube 125 can be provided on each side of door opening 119 . In addition, a spreader 127 can be provided to connect support tubes 125 on opposite sides of door opening 119 to prevent tracks 150 from moving horizontally apart in operation since tracks 150 are not attached to the building structure adjacent to the inner end 151 as in the embodiment of FIGS. 1-11 and 13 described above. The alternate I-beam and track arrangement described above can also be used with the alternate pivotal mounting arrangements and operating mechanisms described below.
Turning to FIG. 12A , a track 450 can be used in combination with a building 120 that can have a roof 121 supported by roof trusses 123 that do not extend horizontally at the top of door opening 119 . Vertical member 122 can be an I-beam and can be similar to vertical member 22 in the embodiment of FIG. 10B and can include a hydraulic cylinder and carriage mechanism as described above but not shown in FIG. 12A . Vertical member 122 can have a support plate 152 that can be similar to support plate 42 as illustrated in FIG. 4 and can support an actuator 39 or a hydraulic cylinder, not shown in FIG. 12A that can be similar to hydraulic cylinder 40 as illustrated in FIG. 4 . Track 450 can be attached to vertical member 122 as described above in connection with FIG. 10B . As above, vertical member 122 and a track 450 can be provided on each side of door opening 119 . If desired, a spreader 127 can be provided to connect tracks 450 on opposite sides of door opening 119 to prevent tracks 450 from moving horizontally apart in operation. The alternate vertical member and track arrangement described above can also be used with the alternate pivotal mounting arrangements and operating mechanisms described below.
Turning to FIGS. 4 and 14 a hydraulic circuit 132 for supplying hydraulic cylinders 40 when the tilt-up door actuator 39 consists of one or more hydraulic cylinders will be described. A control panel 130 can be provided to support controls and hydraulic circuit components. While control panel 130 is shown adjacent door opening 19 in FIG. 4 those skilled in the art will understand control panel can be located at other positions in building 20 or mounted to columns or I-beams as desired. A pump and motor 135 can be mounted on control panel 130 adjacent a spool valve 137 and a hydraulic fluid tank 139 . Hydraulic fluid tank 139 can be sized to hold sufficient hydraulic fluid for the hydraulic circuit 132 and to allow for expansion of the hydraulic fluid under warm weather temperature conditions without overflowing. As illustrated in FIG. 4 , tank 139 can include a vent 148 to the atmosphere. While pump and motor 135 , spool valve 137 and relief valve 141 are illustrated as a single or combined component those skilled in the art will understand that a separate pump and motor, spool valve and relief valve can be employed if desired. Supply lines 142 can connect the “A” side of spool valve 137 to the supply port 143 of a holding valve 140 adjacent to each hydraulic cylinder 40 . In the FIGS. 16 and 17A embodiments a single linear actuator 39 can be a hydraulic cylinder that can be connected in a hydraulic circuit that can be similar to the hydraulic circuit illustrated in FIG. 14 but having a single hydraulic cylinder. In the FIGS. 16 and 17A embodiments a suitable control panel, not shown, can be similar to control panel 130 and can be located in a suitable location in building 20 . In the case of the FIG. 17A embodiment a control panel that can be similar to control panel 130 but not shown in FIG. 17A , can be located adjacent I-beam 206 if desired to minimize the length of the hydraulic lines required to connect the hydraulic cylinder to the control panel. In the embodiments described in connection with FIGS. 1-11, 14, 16 and 17A , holding valves 140 can be a well known holding valve such as a Gresen Holding Valve model MHB-015-LEAE-51E-00. While holding valves 140 and hydraulic cylinders 40 are illustrated as separate components, those skilled in the art will understand that a suitable holding valve can be incorporated in the hydraulic cylinder. Supply lines 142 can be arranged to supply the hydraulic cylinders 40 from a center point, when more than one hydraulic cylinder is employed, so that length of the supply lines 142 from spool valve 137 to supply ports 143 of holding valves 140 to hydraulic cylinder 40 for each of the hydraulic cylinders 40 can be equal. Supply lines 142 can be ½″ steel lines. Release lines 144 can connect the “B” side of spool valve 137 through “B” port relief valve 141 to the release port 145 of holding valves 140 . Release lines 144 can be ⅜″ steel lines. Whenever hydraulic cylinders 40 are partially or fully extended by operation of pump and motor 135 and actuation of spool valve 137 , holding valves 140 prevent reverse flow from hydraulic cylinders 40 and thereby prevent pistons 141 from retracting regardless of whether pump and motor 135 are operating, or even if one or more of supply lines 142 is opened or damaged leading to loss of hydraulic fluid from the supply lines 142 .
In order to retract pistons 141 and lower tilt-up door 10 , pump and motor 135 can be restarted and spool valve 137 can be moved to the “B” position to pressurize release ports 145 on holding valves 140 to allow reverse flow of hydraulic fluid from hydraulic cylinders 40 back to tank 139 and thereby allow pistons 141 to retract into hydraulic cylinders 40 . “B” port relief valve 141 can be provided to reduce the fluid pressure in the release lines 144 from the supply lines 142 pressure since the pressure applied to release ports 145 can determine the reverse flow rate through holding valves 140 , and thus can determine the closure rate for tilt-up door 10 . For example, the pressure in supply lines 142 applied to the hydraulic cylinders 40 can be in the range of 1,200 to 1,500 psi, the pressure applied to release ports 145 can be on the order of 500-800 psi. Those skilled in the art will understand that the supply lines pressure and release lines pressure can be higher or lower than the pressures mentioned above as an example depending on the application and components used in the hydraulic circuit. “B” port relief valve 141 can be adjustable to allow the user to select and set the pressure in the release lines that can be applied to release ports 145 . “B” port relief valve 141 can have an adjustment screw 147 that can have a jam nut to secure adjustment screw 147 when the release line pressure has been adjusted to provide the desired descent rate for tilt-up door 10 . Since release lines 144 supply pressure to release ports 145 without flow of hydraulic fluid through release lines 144 the length of release lines 144 to release ports 145 of holding valves 140 do not need to be equal as can be the case of supply lines 142 . While a manually controlled spool valve is illustrated in FIGS. 4 and 14 , those skilled in the art will understand that electrically or electronically controlled spool valves can be used to control operation of hydraulic cylinders 40 if desired. An electrical circuit breaker box 146 can be mounted on control panel 130 if desired to provide power to pump motor 135 and any other electrical components mounted on or powered through control panel 130 . The embodiments illustrated in FIG. 16 when the linear actuator 39 is a hydraulic cylinder and FIG. 17A can similarly be provided with controls for the hydraulic circuit. When the linear actuator is other than a hydraulic cylinder a control panel similar to control panel 130 can be provided for the control devices for the linear actuator.
Turning to FIGS. 4A-4E and 14A-14C an alternate hydraulic circuit 332 for supplying hydraulic cylinders 40 ′ when the tilt-up door actuator 39 consists of one or more hydraulic cylinders 40 ′ will be described. FIGS. 4A and 14A illustrate an embodiment including two hydraulic cylinders 40 ′, however, an alternate hydraulic circuit 332 and hydraulic cylinders 40 ′ can be employed as a tilt-up door actuator employing one or more that two hydraulic cylinders 40 ′ if desired. FIG. 4B illustrates a submersible hydraulic pump 334 and motor 335 that can be mounted in a hydraulic fluid tank 339 to form a hydraulic pump assembly 330 . A pilot operated check valve 354 can be provided adjacent an upper wall 339 ′ of tank 339 that can be connected to hydraulic line 336 from pump 334 and to hydraulic line 336 ′ leading to hydraulic line connector 339 ′ at the top of hydraulic pump assembly 330 . Pilot operated check valve 354 can be a DECVC-30 valve. A return hydraulic line 336 ″ can lead from check valve 354 to the interior of tank 339 . Pilot operated check valve 354 can close when pump 334 starts sending hydraulic fluid from hydraulic pump 334 to hydraulic line 342 when the pump 334 is operated by motor 335 . When pump 334 shuts down pilot operated check valve 354 opens and hydraulic fluid in hydraulic line 342 can flow through check valve 354 to hydraulic line 336 ″ into tank 339 . Accordingly, after operation of pump 334 to operate hydraulic cylinders 40 ′, pilot check valve 354 can open allowing hydraulic fluid in hydraulic lines 342 to drain back to tank 339 with tilt-up door being held open by hydraulic cylinders 40 ′ as will be described in detail below. Hydraulic fluid tank 339 can be sized to hold sufficient hydraulic fluid for the hydraulic circuit 332 and to allow for expansion of the hydraulic fluid under warm weather temperature conditions without overflowing. Submersible pump 334 and motor 335 can be a conventional submersible hydraulic pump and motor as are well known in the art. For example, hydraulic pump 334 can be a DFP-A2PL-8 pump and motor 335 can be a WEG 5 hp motor. If desired, hydraulic pump assembly 330 can include a suitable pressure relief valve, not shown, that can be similar to pressure relief valve 341 illustrated in FIG. 4C to bypass hydraulic fluid from hydraulic lines 336 or 336 ′ back into tank 339 in the event pressure in the hydraulic circuit rises above a predetermined limit such as if tilt-up door 10 is blocked during an opening cycle or if the hydraulic pump assembly 330 continues to operate after tilt-up door is fully opened. While submersible pump 334 and motor 335 and hydraulic fluid tank 339 are illustrated in FIGS. 4 and 14 as an assembly those skilled in the art will understand that a separate, submersible or non-submersible, pump and motor can be employed if desired.
Hydraulic lines 342 can connect the hydraulic pump assembly 330 at hydraulic line connector 339 ′ to a supply port 343 that can be provided in a hydraulic cylinder housing extension 340 adjacent the bottom of each hydraulic cylinder 40 ′. Hydraulic cylinders 40 ′ can be similar to hydraulic cylinders 40 described above and, in addition, can have a housing extension 340 adjacent the bottom of the hydraulic cylinder 40 ′. As can be seen in schematic FIG. 4C , hydraulic cylinder 40 ′ can include a flow control valve 337 connected between the supply port 343 and a check valve 345 . Check valve 345 can be connected to flow control valve 337 and to the bottom of hydraulic cylinder 40 ′ at 349 . Flow control valve 337 can permit free flow of hydraulic fluid (illustrated with a solid arrow) from supply port 343 to check valve 345 and can permit a controlled flow of hydraulic fluid (illustrated with a dashed arrow) from check valve 345 to supply port 343 . The flow rate from check valve 345 to supply port 343 can be adjusted by an adjusting mechanism that can include a screw 338 so that adjusting screw 338 can function as a closing speed adjustment for tilt-up door 10 . Check valve 345 can permit free flow of hydraulic fluid (illustrated with a solid arrow) from flow control valve 337 to the check valve connection 349 into hydraulic cylinder 40 ′ and can have a solenoid 347 that, when actuated, can allow reverse flow of hydraulic fluid (illustrated with a dashed arrow) from hydraulic cylinder 40 ′ to flow control valve 337 . Unless solenoid 347 is actuated hydraulic fluid cannot flow through check valve 345 from hydraulic cylinder 40 ′ to supply port 343 through flow control valve 337 . In addition, a pressure relief valve 341 can be connected to hydraulic cylinder at 351 and to a hydraulic line at 353 to allow bypass flow of hydraulic fluid from cylinder 40 ′ to supply port 343 in the event the pressure inside hydraulic cylinder 40 ′ exceeds a predetermined limit. For example, pressure in hydraulic cylinder 40 ′ could increase in the event the ambient temperature to which hydraulic cylinders 40 ′ are exposed increases causing the hydraulic fluid to expand in the confined volume of the hydraulic cylinder 40 ′. For example, flow control valve 337 can be a Vonburg 226-08 valve, check valve 345 can be a Delta DES2A-00 valve and pressure relief valve can be a Delta DERCA-2800 valve.
As illustrated in FIGS. 4C, 4D and 4E , flow control valve 337 , pressure relief valve 341 and check valve 345 can be mounted in hydraulic cylinder housing extension 340 and check valve solenoid 347 can be mounted below housing extension 340 on the lower side of support plate 42 on which hydraulic cylinder 40 ′ is supported. Adjustment screw 338 can extend outwardly from the hydraulic cylinder extension 340 to facilitate adjustment of the closing speed of tilt-up door 10 when closing is selected and check valve solenoids 347 operate check valves 345 . While flow control valve 337 , pressure relief valve 341 and check valve 345 can be mounted in a hydraulic cylinder housing extension 340 as illustrated in FIGS. 4A-4E , one or more of the valves 337 , 341 and 345 and supply port 343 and associated connections can be positioned separately adjacent hydraulic cylinder 40 ′ if desired.
Turning to FIG. 14A , hydraulic line first portion 342 ′ can be arranged to supply the hydraulic cylinders 40 ′ from a center point 344 through hydraulic line second portions 342 ″ when more than one hydraulic cylinder is employed, so that length of the hydraulic lines 342 ″ from the center point 344 to supply ports 343 for each of the hydraulic cylinders 40 ′ can be substantially equal. Hydraulic lines 342 can be ½″ steel lines. A low voltage DC supply 331 can be provided to power a low voltage circuit 329 connecting solenoids 347 at connector 348 with a control switch 333 to operate check valve solenoids 347 to operate check valves 345 with control switch 333 . Control switch 333 can be mounted on control panel 130 , or can be incorporated in a controller for the tilt-up door 10 as desired. Control switch 333 can include switch operators 333 ′ that can be “open”, close” and “stop” buttons for operating the hydraulic pump assembly 330 to open the tilt-up door 10 , operating the check valve solenoids 347 to lower the tilt-up door 10 , or de-energizing the hydraulic pump assembly 330 and check valve solenoids 347 to stop movement of the tilt-up door 10 by stopping flow of hydraulic fluid in hydraulic circuit 332 . Control switch 333 can also activate a low voltage beeper 327 connected to low voltage circuit 329 when check valve solenoids 347 are energized to warn any persons in the vicinity of tilt-up door 10 that tilt-up door 10 is closing. Similarly, control switch 333 can be arranged to activate low voltage beeper 327 when pump and motor 335 are activated to warn any persons in the vicinity of tilt-up door 10 that tilt-up door 10 is opening if desired.
In order to open tilt-up door 10 with alternate hydraulic circuit 332 , an operator can operate the “open” control switch operator 333 ′ to energize submersible pump 334 and motor 335 to pump hydraulic fluid to close pilot operated check valve 354 for hydraulic fluid to flow through hydraulic lines 342 to hydraulic cylinder supply ports 343 . Hydraulic fluid can flow freely through flow control valve 337 and check valve 345 (illustrated by the solid arrows) into the hydraulic cylinders 40 ′ causing pistons 41 to rise lifting door 10 from the closed to the open position as described above. When tilt-up door 10 is fully opened the “open” control switch operator 333 ′ can be released or the “stop” control switch operator 333 ′ can be manually or automatically operated to stop motor 335 and submersible pump 334 . As noted above, when pump 334 stops pilot operated check valve 354 can open allowing hydraulic fluid in the hydraulic lines to flow back into tank 339 . Since hydraulic fluid cannot flow from hydraulic cylinders 40 ′ unless solenoids 347 are energized operating check valves 345 , hydraulic fluid cannot flow out of hydraulic cylinders 41 ′ and tilt-up door 10 is held in the open position without pump 334 and motor 335 operating.
In order to retract pistons 41 and lower tilt-up door 10 , the “close” control switch operator 333 ′ can be operated to energize check valve solenoids 347 to operate check valves 345 to allow reverse flow of hydraulic fluid (illustrated by the dashed arrows) from hydraulic cylinders 40 ′ to tank 339 . With check valves 345 operated hydraulic fluid can flow out of hydraulic cylinders 40 ′ through flow control valves 337 and through hydraulic lines 342 to pilot operated check valve 354 . With check valve 354 “open” due the pump 334 no longer running, hydraulic fluid can flow from hydraulic lines 342 into tank 339 through hydraulic line 336 ″ rather than back to hydraulic pump 334 through hydraulic line 336 . The force of gravity on tilt-up door 10 can cause reverse flow of hydraulic fluid and thereby allow pistons 41 to retract into hydraulic cylinders 40 ′. As noted above, the reverse flow rate through flow control valves 337 can be adjusted with flow control adjustment screws 338 to control the flow rate of hydraulic fluid from the hydraulic cylinders 40 ′ back to the tank 339 and thereby the closing rate of the tilt-up door 10 . An electrical circuit breaker box 146 can be mounted on control panel 130 if desired to provide power to pump motor 135 , low voltage supply 331 for low voltage circuit 329 and any other electrical components mounted on or powered through control panel 130 .
In FIGS. 8B-8E and 16-18 other embodiments of pivotal mounting arrangements and operating mechanisms for a tilt-up door 10 for a building 20 are illustrated. Turning to FIGS. 8B-8E and 16-18 , tilt-up door 10 can be pivotally mounted to a building 20 as described above with FIGS. 1-3 and 9-11 . However, in the alternate embodiments of FIGS. 8B-8E and 16-18 , carriages 160 can be operated by a single actuator 39 via cables 168 instead of hydraulic cylinders 40 as illustrated in FIG. 3 . Carriage 160 can be similar to carriage or push block 60 shown in FIGS. 8 and 8A except that piston connector 74 on end plate 68 ( FIGS. 8 and 8A ) can be replaced by cable bracket. In the embodiment of FIGS. 8B and 8C carriage 160 can have a cable bracket 162 on opposite end plate 66 . Cable bracket 162 can have an opening, not visible, to receive clevis pin 166 to attach clevis 164 to cable bracket 162 . The remaining elements of carriage 160 can be the same as the corresponding elements of carriage or push block 60 and are identified with the same reference numeral as in FIGS. 8 and 8A and will not be described again. A steel cable 168 can be connected to carriage 160 with a clevis 164 connecting loop 170 in cable 168 to cable bracket 162 with a clevis pin 166 . While loop 170 is shown without a thimble clip those skilled in the art will understand that a thimble clip can be used in forming loop 170 if desired to strengthen and extend the working life of loop 170 . Loop 170 as shown in FIGS. 8B and 8C can be formed with a loop crimp 172 . Those skilled in the art will understand that instead of a loop crimp 172 a loop sleeve or rope clip can be used to form loop 170 if desired. Referring to FIGS. 8D and 8E alternate arrangements to connect cable 168 to a carriage 160 can be seen. FIGS. 8D and 8E are partial views of a carriage 160 that can be similar to carriage 60 as shown in FIG. 8B except for an alternate cable bracket and cable connecting mechanism. Other than the differing cable connection arrangements the embodiments illustrated in FIGS. 8D and 8E carriage 160 can be similar to carriage 160 illustrated in FIGS. 8B and 8C . In the embodiment of FIG. 8D , a generally U-shaped cable bracket 163 can be connected to end plate 66 and can include an hole 161 to allow cable 168 to pass through cable bracket 163 so that cable termination 167 can secure cable 168 to carriage 160 . Cable termination 167 can be any well known wire rope termination and can be crimped or otherwise affixed to cable 168 . Cable bracket 163 can be welded to end plate 66 as illustrated, or alternately can be provided with flanges and attached to end plate 66 with suitable fasteners as is well known in the art. In the embodiment of FIG. 8E , a pair of spaced cable brackets 165 can be connected to end plate 66 of carriage 160 that can be similar to cable bracket 162 and can have a hole 159 arranged to receive pin 169 . Cable 168 can have a connector 173 affixed to the end of cable 168 . Connector 173 , like cable brackets 165 can have a hole 178 to receive pin 169 to attach cable 168 to carriage 160 . Wire rope cable connectors 173 are well known in the art, as are methods of attaching such connectors to wire rope cables. Thus, carriages 160 in the embodiments illustrated in FIGS. 8B-8E can be lifted by cable as illustrated in the embodiments of FIGS. 15-18 .
Turning to FIGS. 15 and 16 , a portion of an I-beam 156 that can be similar to I-beam 22 in the embodiment of FIGS. 1-11 and 13 can be seen looking in through door opening 19 in building 20 having a tilt-up door 10 as described above, but not shown in FIGS. 15, 16 and 16A . As in the embodiment illustrated in FIGS. 1-11 and 13 , an I-beam 156 can be provided on both sides of door opening 19 and can have flanges 31 forming a channel 32 as described above. Portions of flange 31 in FIG. 15 are cut away to show carriage 160 in channel 32 and pulley 174 . I-beam 156 can be part of a building framework 28 and can be an I-beam or other structure forming a U-shaped channel 32 all as described above in connection with FIGS. 1-11 and 13 . In the embodiment of FIGS. 15, 16 and 16A , I-beams 156 can extend above track 50 and can support a pulley 174 on shaft 175 . Pulley shaft 175 can be supported by I-beam 156 or can be supported by a bracket mounted to I-beam 156 as will be obvious to one having ordinary skill in the art. Pulley 174 can be positioned above track 50 so that cable 168 will not interfere with the top edge 36 of tilt-up door 10 , not shown in FIGS. 15, 16 and 16A , as tilt-up door 10 is opened and closed as described above. A building truss 180 is illustrated spanning I-beams 156 in FIGS. 16 and 16A although the building structure or roof trusses, not shown, may include different elements to support the upper ends of I-beams 156 , or the alternate arrangement described above in conjunction with FIG. 12 can be used.
Turning to FIGS. 16 and 16A embodiments of an actuator 39 for the alternate embodiment operating mechanisms will be described. As illustrated in FIG. 16 , cables 168 can pass over pulleys 174 associated with I-beams 156 toward the center of door opening 19 . A building truss 182 can be provided extending into the building from door opening 19 adjacent and above door opening 19 and can provide support for an actuator 39 . In the embodiment of FIG. 16 the actuator 39 can be a linear actuator 190 that can have a fixed portion 192 that can be connected to building truss 182 and can have a movable portion 194 . Movable portion 194 can have a cable connector 196 . In the embodiment illustrated in FIG. 16 linear actuator 190 can be a hydraulic cylinder 192 having a piston 194 . Cables 168 can pass over pulleys 176 and can be connected to cable connector 196 in a manner similar to the cable connection to carriage 160 as shown in FIGS. 8B-8E , or other well known cable connections. Cables 168 can include a turnbuckle, not shown, to permit ready adjustment of the length of cables 168 for the tilt-up door 10 so that the carriages 160 supporting opposite sides of tilt-up door 10 move together when linear actuator 190 is activated. Linear actuator 190 can be a hydraulic cylinder as shown or can be a rack and pinion, a power screw, ball screw linear actuator or other well known linear actuator that can have a suitable electric motor to operate the linear actuator, as is well known in the art, to draw cables 168 upward to lift or lower carriages 160 to move tilt-up door 10 . While linear actuator 190 is illustrated in FIG. 16 having fixed end 192 positioned away from the door opening 19 so that the movable portion 194 is extended when tilt-up door 10 is closed, those skilled in the art will understand that, if desired, linear actuator 190 can be repositioned in the opposite direction so that movable portion is extended to open tilt-up door 10 rather than be retracted. In the event linear actuator is repositioned in the opposite direction the connection for cables 168 can be arranged to space cables 168 from linear actuator 190 so the cables 168 can pass along side linear actuator 190 . A suitable control circuit, not shown, can be provided to operate the linear actuator can be provided on a control panel that can be similar to control panel 130 as described in conjunction with the embodiment of FIGS. 1-11 and 13 . A hydraulic cylinder linear actuator can have a hydraulic circuit 132 and control similar to that illustrated in FIG. 14 , again as is well known in the art. An electrically operated linear actuator can be provided with an electric release brake to prevent tilt-up door 10 from closing in the event of interruption of electric power to the control circuit similar to the operation of the holding valves 140 in the hydraulically operated embodiments.
In the actuator 39 embodiment illustrated in FIG. 16A a winch 200 can be mounted on a building truss 184 that can be connected to the framework of building 20 . Building truss 184 can be positioned above and adjacent door opening 19 in a position where it will not interfere with tilt-up door 10 , not shown in FIG. 16A , as tilt-up door 10 is opened and closed as described above. Winch 200 can have a cable drum 202 and an electric motor 204 . Cables 168 can be attached to opposite ends of cable drum 202 so that as cable drum 202 is rotated by electric motor 204 cables 168 are wound on cable drum 202 thus lifting carriages 160 , and accordingly tilt-up door 10 , or unwound from cable drum 202 thus lowering carriages 160 , and accordingly tilt-up door 10 . Winch motor 204 can have a control circuit, not shown, that can allow an operator to activate winch motor 204 to open or close tilt-up door 10 . Winch 200 can be provided with a suitable electric release brake to prevent the tilt-up door 10 from inadvertently closing in the event of loss of electric power to the control circuit, not shown, or to the winch 200 . Alternately, winch 200 can be a hydraulic winch as are well known in the art and can be powered by a hydraulic circuit and control that can be similar to hydraulic circuit 132 illustrated in FIG. 14 .
Turning to FIGS. 17A and 17B another cable operated embodiment can be seen. A portion of an I-beam 206 that can be similar to I-beam 22 in the embodiment of FIGS. 1-11 and 13 can be seen looking in through door opening 19 in building 20 having a tilt-up door 10 as described above, but not shown in FIGS. 17A and 17B . As with I-beam 22 in the embodiment illustrated in FIGS. 1-11 and 13 , an I-beam 206 can be provided on opposite sides of door opening 19 and can have a web 30 and flanges 31 forming a channel 32 as described above. Portions of flange 31 in FIG. 17A are cut away to show carriage 160 in channel 32 . I-beam 206 can be part of a building framework 28 and can be an I-beam or other structure forming a U-shaped channel 32 all as described above in connection with FIGS. 1-11 and 13 . In the embodiment of FIGS. 17A and 17B , I-beams 206 can extend above track 50 and can support pulleys 174 on shafts 175 . Pulley shafts 175 can be supported by I-beam 206 or can be supported by a bracket mounted to I-beam 206 as will be obvious to one having ordinary skill in the art. Pulleys 174 can be positioned above track 50 to avoid cables 168 interfering with the top edge 36 of tilt-up door 10 , not shown in FIGS. 17A and 17B , as tilt-up door 10 is opened and closed as described above. The right hand I-beam 206 in FIG. 17 A can include a first cable 168 connected to carriage 160 movably carried in I-beam 206 that passes over two pulleys 174 mounted at the top of column 206 and down to linear actuator 190 . The left hand I-beam 206 ′ can have a single pulley 174 carried on shaft 175 at the top of I-beam 206 to carry a cable 168 from the carriage 160 , not shown in FIG. 17B , but similar to that shown in FIG. 17A , movably carried in I-beam 206 ′ across door opening 19 to I-beam 206 . A building truss 180 is illustrated spanning I-beams 206 in FIG. 17B although the building structure or roof trusses, not shown, may include different elements to support the upper ends of I-beams 206 , or the alternate arrangement described above in conjunction with FIG. 12 can be used. The I-beam 206 (on the right hand side of FIG. 17B ) can include an actuator 190 that can be seen in the cut-out portion of I-beam 206 . Linear actuator 190 can be a hydraulic cylinder or other linear actuator as described above in connection with FIG. 16 and can be provided with a suitable control, again as described above in connection with FIG. 16 . Fixed portion 192 of linear actuator 190 can be attached to I-beam 206 similar to the mounting arrangement described above in connection with FIG. 4 . The distal end of movable portion 194 of linear actuator 190 can have a suitable cable bracket 196 to connect cables 168 from I-beams 206 and 206 ′ to linear actuator 190 .
Turning to FIG. 18 an alternate I-beam or U-shaped column can be seen in partial schematic form. A portion of an I-beam 208 that can be similar to I-beam 22 in the embodiment of FIGS. 1-11 and 13 can be seen looking at door opening 19 in building 20 having a tilt-up door 10 as described above, but not shown in FIGS. 17A and 17B . As with I-beam 22 in the embodiment illustrated in FIGS. 1-11 and 13 , an I-beam 208 can be provided on opposite sides of door opening 19 and can have a web 30 and flanges 31 forming a generally U-shaped channel 32 as described above. The embodiment of FIG. 18 can employ a cable system and a block or pulley carried by movable carriage 160 that can be used to reduce the force required to open a tilt-up door 10 . Such an arrangement can be advantageous in the case of large tilt-up doors by providing a two-time mechanical advantage to facilitate lifting the tilt-up door although the opening time can be increased depending on the speed of the actuator 39 . While a two to one mechanical advantage arrangement is illustrated in FIG. 18 , those skilled in the art will understand that a three to one or greater mechanical advantage arrangement can be employed as desired.
As in the case of the embodiments described above, an I-beam 208 can be located on both sides of door opening 19 , not shown. Carriage 160 can have a block bracket 214 connected to end plate 66 that can support block or pulley 212 . I-beam 208 can have a cable anchor 210 adjacent the top end of I-beam 208 and can be located so that anchor 210 is above block 212 when tilt-up door 10 , not shown in FIG. 18 , is fully opened. The first end 211 of cable 168 can be secured to anchor 210 and can pass over block 212 and then to pulley 174 mounted on shaft 175 adjacent to top of I-beam 208 . Cables 168 from the opposite sides of the door opening 19 can be connected at their second end 213 as illustrated in of the embodiment illustrated in FIG. 16A to an electric or hydraulic winch 200 as desired.
To open tilt-up door 10 from the closed position to the open position an actuator 39 such as illustrated in FIGS. 16, 16A, 17A and 18 can be activated by a control circuit as described above to draw cables 168 away from door opening 19 thus causing cables 168 to lift carriages 160 pivotally attached to opposite sides of tilt-up door 10 similar to the operation of hydraulic cylinders 40 as described above in detail. To close the tilt-up door 10 actuator 39 can be activated to allow the cables 168 to extend toward the door opening 19 thus allowing cables 168 to lower carriages 160 pivotally connected to opposite sides of tilt-up door 10 . Thus, in the embodiment of FIGS. 8B-8E, 15, 16, 16A, 17A, 17B and 18 a single actuator 39 can lift and lower carriages 160 by cables 168 while in the embodiment of FIGS. 3, 4, 5-7, 8 and 8A carriages or push blocks 60 are pushed upward and lowered by an actuator 39 comprising two hydraulic cylinders 40 . Carriages 60 and 160 can operate in the channel formed by the respective I-beams or columns in conjunction with the cam surface(s) in tracks 50 in a similar manner to lift and tilt door 10 to the open position and return tilt-up door 10 to the closed position.
Turning to FIGS. 19A-19D an alternate I-beam or U-shaped channel and alternate actuating mechanism can be seen. In the embodiment of FIGS. 19A-19D a linear actuator 220 can be mounted in I-beam or U-shaped channel 222 that can be similar to I-beam 22 described above. As in the embodiment illustrated in FIGS. 1-11 and 13 , an I-beam or U-shaped channel member 222 can be provided on both sides of a door opening 19 , not shown, and can have a web 230 and flanges 231 forming a generally U-shaped channel 232 . Portions of flanges 231 are cut away to show carriage 160 and pulley block 242 in channels 232 and 232 ′. In the embodiment of FIGS. 19A-19D instead of a two to one or greater mechanical advantage as illustrated in the embodiment of FIG. 18 , the alternate actuating mechanism can be a one to two mechanical advantage that, while requiring generally two times the force to lift the door 10 , provides carriage travel that is two times the travel of the linear actuator. A one to two mechanical advantage arrangement as illustrated in FIGS. 19A-19D can be desirable for use with tilt-up doors to reduce the required travel of the linear actuator. Turning to FIGS. 19A and 19C , a linear actuator 220 can be positioned in channel 232 ′ on one side of I-beam 222 adjacent the web 230 opposite the vertical channel 232 facing door opening 19 and mounted on an actuator mounting bracket 234 at one end and can include an actuator securing bracket 236 adjacent the upper end of linear actuator 220 similar to the hydraulic cylinder mounting arrangement described above in connection with FIG. 4 . An anchor bracket 228 can be attached to I-beam 222 adjacent the top of linear actuator 220 and can be arranged for connection of a first end 252 of flexible link 240 , that can be a flat chain or cable, to I-beam 222 as is well known in the art. Mounting bracket 234 and actuator securing bracket 236 can be connected to I-beam 222 as described above in connection with FIG. 4 . I-beam 222 can have a web 230 that can include a slot 224 extending from adjacent the top of linear actuator 220 to adjacent track 50 that can be secured to I-beam 222 adjacent the top of I-beam 222 .
Turning to FIGS. 19A and 19B , U-shaped channel 232 of I-beam 222 facing the door opening 19 can be seen with carriage 160 that can be similar to carriage 160 illustrated in FIG. 8D and can include a cable bracket 163 that can be arranged for connection of a second end 253 of flexible link 240 to carriage 160 as is well known in the art. Carriage 160 can be similar to carriage 160 described above and to carriage 60 described above except for flexible link connection apparatus and will not be described in further detail. Turning to FIGS. 19A and 19D , a pulley block 242 can be slidably carried in slot 224 and can have a connector 247 that can be connected to the distal end 245 of linear actuator 220 similar to the arrangement illustrated in FIGS. 8A and 8B . Pulley block 242 can be a generally rectangular hollow box having sides 243 and ends 244 dimensioned to be slidably carried in slot 242 and can have an axle 246 mounted to sides 243 to rotatably carry a pulley 248 that can be arranged for use with a flexible link 240 as desired. Connector 247 can be carried by the bottom end 244 as illustrated in FIG. 19D . Pulley blocks 242 can also have a guide bar or flange 250 that can be attached to pulley block 242 to the top end wall 244 or other desired part of pulley block 242 and can be positioned to slide on one surface of web 230 . Guide bar 250 can have a low friction surface that can be similar to low friction surface or pad 90 on carriage 60 . If desired a guide bar or flange 250 can be provided for pulley block 242 to engage both sides of web 230 as illustrated in FIG. 19A or on one side of web 230 . If guide bars or flanges 250 are provided to engage both sides of web 230 , one or both of the guide bars or flanges 250 can be removably mounted to pulley block 242 to facilitate assembly and removal of pulley block 242 to beam 222 . Guide bar(s) 250 can help maintain pulley block 242 aligned in slot 244 as linear actuator 220 moves pulley block 242 up and down to lift and lower carriage 160 and accordingly door 10 , not shown in FIGS. 19A-19D . Thus, in operation linear actuators 220 carried by the I-beams 222 on opposite sides of door 10 , not shown, can be actuated to cause the linear actuators 220 to lift pulley blocks 242 in slots 224 in I-beams 222 . As pulley blocks 242 are lifted in slots 224 , carriages 160 are lifted twice as far in channels 232 as the movement of linear actuator 220 by flexible links 240 . Linear actuators 220 can be hydraulic cylinders as illustrated in FIGS. 19A-19C connected to a hydraulic circuit similar to the hydraulic circuit illustrated in FIG. 14 , or can be other linear actuators as described above in connection with FIG. 16 . Thus, in the embodiment of FIGS. 19A-19D the linear actuators 220 can be connected to carriages 160 by a flexible link 240 arranged to provide a one to two mechanical advantage that provides a carriage travel that is two times the linear actuator travel.
The tilt-up door 10 should not be understood to be limited to the use of hydraulic cylinders as illustrated in the embodiments of FIGS. 3, 4, 5-7, 8, 8A and 19A-19D the linear actuators of the embodiments of FIGS. 16, 17A and 18 or the winch embodiment of FIG. 16A , but can be used in connection with any desired actuator 39 to move carriage or push blocks 60 and 160 vertically in channels 32 , 232 to move a tilt-up door 10 from the closed position of FIG. 1 to the open position of FIG. 3 . Further, a linear actuator can be positioned at other locations adjacent door opening including, but not limited to, a wall of building 20 if desired.
While the tilt-up door has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation.
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A tilt-up door for a building having an opening including a door frame with vertical track members, cam surfaces extending laterally from the vertical tracks at the upper portion of the tracks and a door sized to span the opening. The door can be pivotally coupled with rollers disposed within the vertical tracks and cam followers extending laterally from the upper portion of the door to contact the cam surfaces. The cams can include a first steep inclined segment, a second inclined segment and a third segment. When an upwardly directed motive force acts on the door the cam followers come into engagement with the cam surface to lift the door generally vertically and then rotate the door inwardly as the door is raised into an open raised position.
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CROSS REFERENCES
[0001] The present application claims priority from Chinese Patent Application No. 200810198567.9 filed Sep. 10, 2008.
FIELD OF APPLICATION
[0002] The present application relates to a floor panel which has coupling devices to couple a plurality of separated smaller floor panels into a larger area of floor covering. Such floor panel is usually made of solid wood or synthetic fiber board and has generally the shape of a rectangle. The coupling devices usually are provided respectively in at least a longer side and a shorter side of the smaller floor panel, are used to detachably couple adjacent floor panels to form a larger area of floor covering when a floor decoration of indoor environment such as living-room or office is under way.
BACKGROUND
[0003] As a kind of indoor flooring material, wooden floor is widely used. Such wooden floor is generally assembled by coupling a plurality of smaller size floor panels together. It is known that such floor panels can be coupled in various ways. According to a first possibility, the floor panels are attached on the underlying floor or support frame, either by gluing or by nailing them on. This technique has a disadvantage in that it is rather complicated and that subsequent changes can only be made by breaking out the floor panels. According to a second possibility, the floor panels are installed loosely onto the sub-flooring, whereby the floor panels mutually match into each other by means of a tongue and groove coupling. For example, CN02803650.6 discloses a rectangular floor panel having coupling devices in form of tongues and grooves. Such floor panel comprises an undercut groove on one long side and a projecting tongue on an opposite long side of the floor panel. The undercut groove has a corresponding upward inner locking surface at a distance from its tip. Tongue and undercut groove are formed to be brought together and pulled apart by pivoting motion with a center close to the intersection between the surface planes and the common joint plane of two adjoining floor panels. Such floor panel has an advantage in that it is much cheaper and convenience to install and repair. But a disadvantage of such floor panel is that an unreasonable design of the tongue and groove possibly results in that the floor panels cannot be coupled tightly when gaps between the floor panels or bumps on the coupling surfaces occur. These defects not only affect the appearance and use of the floor covering but shorten the lifespan of the floor covering.
SUMMARY
[0004] It is aimed to provide an improved floor panel having coupling device with which a plurality of separated smaller floor panels can be coupled into a larger area of floor covering. Such floor panels can be coupled to each other in an optimum manner and adapt to an uneven floor surface, and whereby preferably one or more of the aforementioned disadvantages are excluded.
[0005] According to a first aspect, there is provided a floor panel with coupling device. The floor panel includes an upper side which is used for treading, an underside which contacts the underlying floor and a first end wall and a second end wall which are parallelly located at a distance from each other and extend in the direction perpendicular to the upper side. A groove is provided in the first end wall and adjacent the underside. The groove extends perpendicularly into the first end wall along the intersection between the upper side and the first end wall. A third end wall is formed between the groove and the underside and perpendicular to the upper side. A tongue is provided in the second end wall and adjacent the underside. The tongue extends perpendicularly outward from the second end wall along the intersection between the upper side and the second end wall. A fourth end wall is formed between the tongue and the underside and perpendicular to the upper side. The first end wall, the third end wall and the fourth end wall are parallel to each other. The groove orderly includes a first slot wall, a second slot wall, a third slot wall, a fourth slot wall, a fifth slot wall and a sixth slot wall. The first slot wall connects the first end wall and is formed by a protrusion with a curved shape which protrudes downward towards the entrance of the groove. The second slot wall, the fourth slot wall and the sixth slot wall are parallel to the upper side. The third slot wall is parallel to the first end wall and extends in the direction that the entrance of the groove dwindles to the inner bottom of the groove. The fifth slot wall is parallel to the first end wall. The tongue orderly includes a first side, a second side, a third side, a fourth side, a fifth side and a sixth side. The first side connects the second end wall and is formed by a recess with a curved shape. The second side, the fourth side and the sixth side are parallel to the upper side. The third side is parallel to the second end wall and extends in the direction that the bottom portion of the tongue dwindles to the distal tip of the tongue. The first slot wall has the same diameter and arc length as the first side of the tongue so that they can be meshingly engaged when adjacent identical ones of the floor panel are coupled together. The total length of the second slot wall and the fourth slot wall is longer than that of the second side and the fourth side of the tongue.
[0006] Preferably, the joint portion of the first slot wall and the second slot wall aligns to the plane of the third end wall in the direction perpendicular to the first end wall. The joint portion of the first side and the second side aligns to the plane of the fourth end wall in the direction perpendicular to the second end wall.
[0007] Preferably, a seventh slot wall is provided between the sixth slot wall and the third end wall of the floor panel which widens the entrance of the groove. A seventh side is provided between the sixth side and the fourth end wall so as to reinforce the bottom portion of the tongue. The seventh slot wall inclines at the same angle as the seventh side.
[0008] Preferably, the edges between the second and third sides, the fourth and fifth sides, and the fifth and sixth sides are rounded.
[0009] Preferably, the edges between the second and third sides, the fourth and fifth sides, and the fifth and sixth sides are chamfered respectively to form corresponding skew walls which maintain certain angles with their adjacent sides.
[0010] Preferably, the length of the fourth slot wall is longer than that of the fourth side.
[0011] Preferably, when the floor panel is coupled and interlocked with another identical floor panel, a gap is formed between the third end wall of the floor panel and the fourth end wall of another identical floor panel in the direction perpendicular to the first end wall of the floor panel.
[0012] The coupling devices of the floor panels are configured to enable the floor panels to be interlocked together by locking elements which include a curved protrusion which is formed on the lower wall of the upper lip of the groove and adjacent to the entrance of the groove and a curved recess which is formed in the upper side of the tongue and can match with the curved protrusion. Under the cooperation of the elastic deformation of the upper lip of the groove and the engagement of the locking elements, the adjacent floor panels can be coupled together by exerting them a horizontal pressing force and interlocked tightly by meshing engagement of the curved protrusion and the curved recess without glue or other auxiliary binding material so as to ensure that the adjacent floor panels can not move in both horizontal direction and vertical direction. The configuration of the coupling device is in such a way that the entrance of the groove is larger than its inner bottom and the tongue has the corresponding structures that the distal tip of it is smaller than its bottom portion making it easy to guide the tongue into the groove of the floor panel, which improves the location of adjacent floor panels in the direction perpendicular to the upper side of the floor panel. Meantime, the assembly of the panels with such configuration can be achieved just by exerting on the floor panels a horizontal pressing force, which permits an operator to complete the flooring at a restricted room and speeds up the coupling work. Additionally, such configuration that the lower lip of the groove is shorter than its upper lip making the lower lip more stress-tolerant and the floor covering more resistant to an uneven sub-floor surface, which promotes the floor panel's adaptability to different sub-floor surfaces. Based on the above configurations, the gaps can be formed between the groove and the tongue by regulating the length of related elements of the coupling devices. The gaps provide an operator supporting points which make it easier to couple and detach the floor panels and thus prevent the floor panels from being deadlocked.
[0013] The floor panel will be further explained in connection with the following figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of a floor panel before the coupling devices are formed thereon;
[0015] FIG. 2 is a perspective view of the floor panel formed with the coupling devices according to an embodiment disclosed in the present application;
[0016] FIG. 3 is a cross sectional view of the floor panel with the coupling devices;
[0017] FIG. 4 is an enlarged cross sectional view of a groove of the coupling device of the floor panel;
[0018] FIG. 5 is an enlarged cross sectional view of a tongue of the coupling device of the floor panel;
[0019] FIG. 6 shows the first stage when the floor panel with coupling devices of FIG. 2 is coupled to another identical floor panel;
[0020] FIG. 7 shows the second stage when the floor panel with coupling devices of FIG. 2 is coupled to another identical floor panel; and
[0021] FIG. 8 shows an interlocking stage when two identical floor panels with coupling devices of FIG. 2 are coupled together.
DETAILED DESCRIPTION
[0022] Different aspects of the floor panel with coupling devices will now be described in more detail with reference to the accompanying figures. The elements, characteristics or structures of the floor panel that are equivalent to those of the floor panels in all figures have been given the same reference numbers. The floor panel with coupling devices is in no way limited to the forms of embodiment described by way of example and represented in the figures if the floor panel d can be embodied in various forms and dimensions without departing from the scope of the appended claims. For example, the various characteristics which are described by means of the represented embodiments or examples may be selectively combined with each other. Any technical solutions that are equivalent or similar to those of the floor panel with coupling devices in the present application fall into the scope of the appended claims. In addition, the describing of public-known functions and structures in the description are simplified or ignored for conciseness.
[0023] FIGS. 1 , 2 , 3 , 4 and 5 represent a floor panel d. As shown in FIG. 1 , the floor panel d may be in the form of a substantial rectangular solid where the coupling devices of the floor panel are not formed yet. FIG. 2 shows the floor panel d where the coupling devices have been formed. FIGS. 3 , 4 and 5 represent the cross section of the floor panel with coupling devices in direction z. For better describing the examples, the coordinate system shown in FIGS. 1 , 2 , 3 , 4 and 5 is chosen as the reference directions of the floor panel d. The reference directions are corresponding to the actual directions of the floor panel d under installing posture as follows: the direction x in the figures is corresponding to the direction perpendicular to the upper side 101 of the floor panel d, and the direction y in the figures is corresponding to the direction that is simultaneously parallel to the upper side 101 and the short side 102 of the floor panel d, and the direction z in the figures is corresponding to the direction that is simultaneously parallel to the upper side 101 and the long side 103 of the floor panel d. The upper side of the panel d is parallel to the horizontal plane when the floor panel d is installed.
[0024] Generally, the floor panel d may be made of solid wood, synthetic fiber board, or any other suitable material. As shown in FIG. 1 , the floor panel d may be in the form of a flat rectangular solid before its coupling devices are formed. The floor panel d may include an upper side 101 , an underside 107 and four lateral walls. The upper side 101 is usually provided with a decorative layer and used to contact and support a man walking on it or other articles; and the underside 107 is provided to contact the underlying floor or supporting frame. The upper side 101 and underside 107 are parallel to each other. The lateral walls 104 and 105 are corresponding to the longer edge 103 and another two lateral wall are corresponding to the shorter edge 102 . All the four lateral walls can be perpendicular to the upper side 101 , i.e. the four lateral walls are parallel to the direction x. The lateral walls 104 and 105 corresponding to the longer edge 103 are parallel to the direction z and perpendicular to another two lateral walls that are corresponding to the shorter edge 102 . And the two lateral walls corresponding to the shorter edge 102 are parallel to the direction y.
[0025] As represented in the FIGS. 2 to 5 , the lateral walls 104 and 105 corresponding to the longer edge 103 of the floor panel d can be configured respectively as described below (the lateral walls corresponding to the shorter edge 102 can also have the similar configurations).
[0026] The portion of the lateral wall 104 adjacent to the upper side 101 can be provided as the first end wall 106 . The portion of the lateral wall 104 adjacent to the underside 107 is cut away to form the third end wall 108 which is parallel to the first end wall 106 . A groove 109 is provided between the first end wall 106 and the third end wall 108 and extends to the two lateral walls corresponding to the shorter edge 102 in the direction z. In other words, the groove 109 may have the same length as the lateral wall 104 and recesses the floor panel d in the direction y.
[0027] The groove 109 may include a first slot wall 110 , a second slot wall 111 , a third slot wall 112 , a fourth slot wall 113 , a fifth slot wall 114 , a sixth slot wall 115 and a seventh slot wall 116 . In the direction y that is also the direction that the tongue of the floor panel d is inserted into the groove 109 , the upstream end of the first slot wall 110 connects to the lower side of the first end wall 106 ; the downstream end of the first slot wall 110 connects to the upstream end of the second slot wall 111 ; the downstream end of the second slot wall 111 connects to the upper side of the third slot wall 112 ; the lower side of the third slot wall 112 connects to the upstream end of the fourth slot wall 113 ; the downstream end of the fourth slot wall 113 connects to the upper side of the fifth slot wall 114 ; the lower side of the fifth slot wall 114 connects to the downstream end of the sixth slot wall 115 ; the upstream end of the sixth slot wall 115 connects to the downstream end of the seventh slot wall 116 ; the upstream end of the seventh slot wall 116 connects to the upper side of the third end wall 108 ; and the lower side of the third end wall 108 connects to the underside 107 .
[0028] The first slot wall 110 may be formed by a protrusion with a curved shape which protrudes downward towards the entrance of the groove 109 . The second slot wall 111 , the fourth slot wall 113 and the sixth slot wall 115 are parallel to the upper side 101 . The third slot wall 112 may be located substantially in the middle portion of the groove in the direction y is parallel to the first end wall 106 and extends in the direction that the entrance of the groove 109 dwindles to the inner bottom of the groove 109 which is corresponding to the fifth slot wall 114 . The fifth slot wall 114 is also parallel to the first end wall 106 . The seventh slot wall 116 can be configured in the form of a skew wall which inclines from the sixth slot wall 115 to the third end wall 108 or the underside 107 so that the entrance of the groove 109 is widened so as to easily guide the tongue 119 . The joint portion of the downstream of the first slot wall 110 and the upstream of the second slot wall 111 aligns to the third end wall 108 in the direction y. In other words, the first slot wall 110 is in the upstream side of the third end wall 108 in the direction y. Thus, the first end wall 106 is farther away from the inner bottom of the groove 109 than the third end wall 108 in the direction y.
[0029] The portion of the lateral wall 105 adjacent to the upper side 101 can be provided as a second end wall 117 . A fourth end wall 118 may be formed on an extra part that is filled up on the portion of the lateral wall 105 adjacent to the underside 107 . The extra part may be made of the same material as the floor panel d. Herein the extra part is described in relation to the lateral wall 105 , and actually, the extra part can also be looked as the original parts of the floor panel d. The fourth end wall 118 is parallel to the second end wall 117 . A tongue 119 can be provided between the second end wall 117 and the fourth end wall 118 and protrudes outward from the lateral wall 105 in the direction of y. The tongue 119 extends in the direction z to the two lateral walls which are corresponding to the shorter edge 102 . In other words, the tongue 119 has the same length as the lateral wall 105 and the groove 109 in the direction z.
[0030] The tongue 119 may include a first side 120 , a second side 121 , a third side 122 , a fourth side 123 , a fifth side 124 , a sixth side 125 and a seventh side 126 . In the direction of y which is also the direction that the tongue 119 is inserted into the groove 109 , the upstream end of the first side 120 connects to the lower side of the end wall 117 ; the downstream end of the first side 120 connects to the upstream end of the second side 121 ; the downstream end of the second side 121 connects to the upper side of the third side 122 by a skew wall 127 ; the lower side of the third side 122 connects to the upstream end of the fourth side 123 ; the downstream end of the fourth side 123 connects to the upper side of the fifth side 124 by a skew wall 128 ; the lower side of the fifth side 124 connects to the downstream end of the sixth side 125 by a skew wall 129 , the upstream end of the sixth side 125 connects to the downstream end of the seventh side 126 ; and the upstream end the seventh side 126 connects to the upper side of the fourth end wall 118 .
[0031] The skew walls 127 , 128 and 129 can be configured to maintain certain angles with their adjacent sides. Alternatively, the skew walls 127 , 128 and 129 can be configured in a round chamfering form. The first side 120 may be formed by a downward recess with a curved shape. The second side 121 , the fourth side 123 and the sixth side 125 are parallel to the upper side 107 . The third side 122 may be located substantially in the middle portion of the tongue 119 in the direction y is parallel to the second end wall 117 and extends in the direction that the bottom portion of the tongue 119 dwindles to the distal tip of the tongue 119 which is corresponding to the fifth side 124 . The fifth side 124 is parallel to the second end wall 117 . The seventh side 126 may be configured in the form of a skew wall which inclines from the sixth side 125 to the fourth end wall 118 or the underside 107 so as to reinforce the bottom portion of the tongue 119 . The joint portion of the downstream of the first side 120 and the upstream of the second side 121 aligns to the fourth end wall 118 in the direction y. In other words, the fourth end wall 118 is in the downstream side of the second end wall 117 in the direction y.
[0032] The first slot wall 110 of the groove 109 may have the same arc length and diameter of the curved surface as the first side 120 of the tongue 119 . The seventh slot wall 116 is parallel to the seventh side 126 , i.e. the angle between the seventh slot wall 116 and the sixth slot wall 115 is equal to the one between the seventh side 126 and the sixth side 125 . The total length of the second slot wall 111 and the fourth slot wall 113 may be longer than that of the second side 121 and the fourth side 123 so that a gap 130 can be formed between the fifth slot wall 114 of one floor panel and the fifth side 124 of another identical floor panel in the direction y when the two same floor panels are coupled together, as shown in FIG. 8 . Of course, the gap 130 between the fifth slot wall 114 and the fifth side 124 of two floor panels can also be formed by the fourth slot wall 113 configured longer than the fourth side 123 in the same floor panel.
[0033] The FIGS. 6 , 7 and 8 show three different stages of the coupling of two floor panels with coupling devices.
[0034] As represented in FIG. 6 , before coupling two identical floor panels d and d′, an operator firstly aligns the tongue 119 of the floor panel d with the groove 109 of the floor panel d′ and exerts a horizontal force to move the floor panel d towards the floor panel d′ in the direction y.
[0035] As shown in FIG. 7 , when the floor panel d is coupled to the floor panel d′, the second side 121 of the floor panel d contacts the first slot wall 110 of the floor panel d′ first. Then, with the tongue 119 of the floor panel d moving on, the sixth side 125 of the floor panel d is guided by the skew wall 129 into the groove 109 of the floor panel d′ and contacts the sixth slot wall 115 of the floor panel d′. At the same time, the second side 121 of the floor panel d forces the upper lip where the first slot wall 110 of the floor panel d′ is located deformed elastically in the direction of x so that the tongue 119 of the floor panel d can be inserted further towards the inner bottom of groove 109 of the floor panel d′.
[0036] As shown in FIG. 8 , when the two floor panels d and d′ are coupled together completely, the deformed upper lip where the first slot wall 110 is located returns to its normal appearance and the first slot wall 110 of the floor panel d′ engages with the first side 120 of the floor panel d, which ensures that the two floor panels coupled to each other can not move laterally in the direction y with respect to each other. Meanwhile, the second end wall 117 of the floor panel d comes in contact with the first end wall 106 of the floor panel d′. In this engaged condition of the two floor panels, the difference of the length between the fourth slot wall 113 and the fourth side 123 of a floor panel, as shown in FIGS. 4 and 5 , results in that the gap 130 is formed in the direction y between the fifth side 124 of the floor panel d and the fifth slot wall 114 of the floor panel d′ when the two identical floor panels d and d′ are coupled together. Similarly, the gap 131 can be formed in the direction y between the fourth end wall 118 of the floor panel d and the third end wall 108 of the floor panel d′ in the coupled condition of the two floor panels.
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A floor panel with coupling devices is provided. The coupling devices have locking elements which include a curved protrusion which is formed on a lower wall of an upper lip of a groove and adjacent to the entrance of the groove, and a curved recess which is formed in an upper side of a tongue and can match with the curved protrusion. Under the cooperation of the elastic deformation of the upper lip of the groove and the engagement of the locking elements, adjacent floor panels can be coupled together by exerting on them a horizontal pressing force and interlocked tightly by meshing engagement of the curved protrusion at the groove and the curved recess in the tongue without glue or other auxiliary binding material so as to ensure that the adjacent floor panels can not move in both horizontal direction and vertical direction. The floor panels are usually used in a floor decoration of indoor environment and have the advantages of easy installation and tight coupling.
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TECHNICAL FIELD
[0001] The present invention relates to a water catchment pipe burying assistance instrument used to bury a water catchment pipe in the ground and a water catchment pipe burying method employing the same.
BACKGROUND ART
[0002] Up to now, construction work for burying a water catchment pipe in the ground has been performed for the purpose of land improvement in a well or a soft ground, and various construction methods, burying apparatuses, and the like for burying such a water catchment pipe have been proposed.
[0003] For example, Japanese Patent Laid-Open No. 9-291779 proposes a well drilling method including the steps of: (1) drilling a hole up to a predetermined depth by means of an inner rod and an outer rod constituting a double pipe, with the use of a rotary percussion drill, and then pulling out only the inner rod; (2) inserting a water catchment pipe up to a predetermined depth in the outer rod, the water catchment pipe including: a plurality of openings that are provided in a protruding manner on the outer circumferential surface on the lower end side thereof; and a cylindrical protective pipe filter that is made of loofa-brush-like fibers and is attached to the outer circumferences of the openings; (3) pulling out the outer rod; (4) inserting a seal ring from above along the outer circumference of the water catchment pipe up to a predetermined depth of a hole upper portion, and sealing a gap between the inner wall of the hole and the outer circumference of the water catchment pipe; (5) pouring a solidifying agent onto the seal ring and filling the gap up to the land surface with the solidifying agent; and (6) inserting a water lifting pipe into the water catchment pipe up to a predetermined depth and connecting a well pump to the water lifting pipe (Patent Literature 1). According to Patent Literature 1, the well drilling method enables easily providing a small-diameter deep well used in a household and the like.
CITATION LIST
Patent Literature
[0000]
Patent Literature 1: Japanese Patent Laid-Open No. 9-291779
SUMMARY OF INVENTION
Technical Problem
[0005] The invention described in Patent Literature 1 does not have a problem in the case where a vertical hole such as a well is drilled and where a water catchment pipe is buried. However, the invention described in Patent Literature 1 has the following problem in the case where the drilling direction is a horizontal direction or an upward direction as in land improvement work and the like. That is, if the inner rod is pulled out after the step described in (1), earth and sand flow into the outer rod, and prevent the insertion of the water catchment pipe in the step described in (2). Hence, there is a problem that, if a general water catchment pipe such as a vinyl chloride pipe is forcedly inserted into the outer rod, the water catchment pipe is damaged as illustrated in FIG. 16 .
[0006] In this case, if the water catchment pipe is made of a material having a high degree of hardness such as a steel pipe, the water catchment pipe can be inserted by pushing-in in some cases, but the use of the steel pipe is extremely costly, and is not economically viable. Accordingly, first, a water catchment pipe such as a vinyl chloride pipe is tried to be actually inserted. Then, in the case where the water catchment pipe may be damaged by pushing-in due to obstruction of earth and sand and the like on the way, the water catchment pipe is pulled out to be replaced with a water catchment pipe such as a steel pipe, which is not damaged even by pushing-in, and the steel pipe needs to be inserted again.
[0007] Meanwhile, a budget of construction work in recent years is created on the assumption that a resin pipe such as an inexpensive vinyl chloride pipe is used for a water catchment pipe for budget reasons. Hence, in the case where a vinyl chloride pipe cannot be inserted and is thus replaced with a steel pipe, the work time is wasted, and, in addition, the cost may exceed the budget. In this case, because an extra budget needs to be applied each time, there is a problem that a considerable waste of time occurs.
[0008] Further, steel pipes have high strength, but have a problem in durability against corrosion. Hence, customers strongly desire to use resin water catchment pipes excellent in corrosion durability.
[0009] The present invention, which has been made in order to solve the above-mentioned problems, has an object to provide a water catchment pipe burying assistance instrument that can bury a resin water catchment pipe without damaging the water catchment pipe even if earth and sand have flown into a prepared hole, as well as a water catchment pipe burying method employing the same.
Solution to Problem
[0010] A water catchment pipe burying assistance instrument according to the present invention is a water catchment pipe burying assistance instrument used to bury a water catchment pipe in a prepared hole drilled in ground, including: a leading end cap that is formed in a cylindrical shape having a closed leading end and an opened base end, the leading end cap including a water catchment pipe coupling portion that allows the water catchment pipe to be fitted thereinto for coupling; and a separable pipe that is formed into a cylindrical shape into which the water catchment pipe is insertable, the separable pipe being attached to the base end of the leading end cap and being separated from the leading end cap after the inserted water catchment pipe is coupled to the leading end cap.
[0011] Further, according to an aspect of the present invention, the water catchment pipe burying assistance instrument may further include a separable pipe press-holding member that press-holds the separable pipe in a state where a leading end of the separable pipe is attached to the base end of the leading end cap.
[0012] Moreover, according to an aspect of the present invention, the separable pipe press-holding member may include: a flanged press-holding portion that presses frontward a protruding portion provided on an inner circumference on the leading end side of the separable pipe and press-holds the separable pipe to the base end of the leading end cap; a coupling shaft that protrudes from the press-holding portion toward the leading end cap and is coupled to the leading end cap by screwing; and a rotation transmitting shaft that transmits, to the coupling shaft, rotational force obtained from a rotation transmitting tool inserted from a base end side of the separable pipe, and cancels the coupling to the leading end cap by descrewing.
[0013] Further, according to an aspect of the present invention, the leading end of the leading end cap may be provided with a jet hole for jetting water for removing earth and sand in the prepared hole by water pressure.
[0014] Moreover, according to an aspect of the present invention, the inner circumference on the leading end side of the separable pipe may be provided with an earth and sand blocking member that is slid while sealing a gap between the inserted water catchment pipe and the separable pipe, to thereby block earth and sand from flowing in, when the separable pipe is separated from the leading end cap.
[0015] Further, according to an aspect of the present invention, the water catchment pipe coupling portion may include a round screw whose screw mountain part and screw valley part are substantially circular in cross section.
[0016] Further, a water catchment pipe burying method according to the present invention is a water catchment pipe burying method for burying a water catchment pipe in ground with the use of the water catchment pipe burying assistance instrument, the method including: a prepared hole drilling step of drilling a prepared hole in the ground; an assistance instrument inserting step of inserting the water catchment pipe burying assistance instrument into the prepared hole; a water catchment pipe coupling step of inserting the water catchment pipe into the water catchment pipe burying assistance instrument and coupling a leading end part thereof to the water catchment pipe coupling portion of the leading end cap; and a separable pipe pulling-out step of separating the separable pipe from the leading end cap and pulling out the separable pipe from the prepared hole.
[0017] Moreover, a water catchment pipe burying method according to the present invention is a water catchment pipe burying method for burying a water catchment pipe in ground with the use of the water catchment pipe burying assistance instrument, the method including: a prepared hole drilling step of drilling a prepared hole in the ground with the use of a double pipe type hole drilling machine including an outer rod and an inner rod, the outer rod including an outer bit for hole drilling at a leading end thereof, the inner rod being placed inside of the outer rod and including an inner bit for hole drilling at a leading end thereof; an inner rod pulling-out step of pulling out the inner rod from the outer rod; an assistance instrument inserting step of inserting, into the outer rod, the water catchment pipe burying assistance instrument in which the separable pipe is attached to the leading end cap; an outer rod pulling-out step of pulling out the outer rod from the prepared hole; a water catchment pipe coupling step of inserting the water catchment pipe into the water catchment pipe burying assistance instrument and coupling a leading end part thereof to the water catchment pipe coupling portion of the leading end cap; and a separable pipe pulling-out step of separating the separable pipe from the leading end cap and pulling out the separable pipe from the prepared hole.
Advantageous Effects of Invention
[0018] According to the present invention, a resin water catchment pipe can be buried without being damaged even if earth and sand have flown into a prepared hole.
BRIEF DESCRIPTION OF DRAWINGS
[0019] FIG. 1 is a front view illustrating a first embodiment of a water catchment pipe burying assistance instrument according to the present invention.
[0020] FIG. 2 is a front longitudinal sectional view illustrating a water catchment pipe burying assistance instrument of the first embodiment.
[0021] FIG. 3 is a perspective assembly view illustrating the water catchment pipe burying assistance instrument of the first embodiment.
[0022] FIG. 4 is a front view illustrating a separable pipe press-holding member in the first embodiment.
[0023] FIG. 5 is a front view illustrating a rotation transmitting tool in the first embodiment.
[0024] FIG. 6 is a schematic view illustrating a hole drilling operation in a prepared hole drilling step in the first embodiment.
[0025] FIG. 7 is a schematic view illustrating an insertion operation in an assistance instrument inserting step in the first embodiment.
[0026] FIG. 8 is a schematic view illustrating an operation of detaching the separable pipe press-holding member in the first embodiment.
[0027] FIG. 9 is a schematic view illustrating a coupling operation in a water catchment pipe coupling step in the first embodiment.
[0028] FIG. 10 is a schematic view illustrating a pulling-out operation in a separable pipe pulling-out step in the first embodiment.
[0029] FIG. 11 is a front view illustrating a state where a water catchment pipe is buried in a prepared hole in the first embodiment.
[0030] FIG. 12 is a schematic view illustrating an operation in an inner rod pulling-out step in a second embodiment.
[0031] FIG. 13 is a schematic view illustrating a coupling operation in a water catchment pipe coupling step in the second embodiment.
[0032] FIG. 14 is a schematic view illustrating an operation in an outer rod pulling-out step in the second embodiment.
[0033] FIG. 15 is a front longitudinal sectional view illustrating a water catchment pipe coupling portion in another embodiment.
[0034] FIG. 16 is a photograph showing a state where a water catchment pipe is damaged as a result of using a conventional water catchment pipe burying method.
DESCRIPTION OF EMBODIMENTS
[0035] Hereinafter, a first embodiment of a water catchment pipe burying assistance instrument and a water catchment pipe burying method employing the same according to the present invention is described with reference to the drawings. FIG. 1 is a front view illustrating a water catchment pipe burying assistance instrument 1 of the first embodiment, and FIG. 2 is a longitudinal sectional view thereof. Further, FIG. 3 is a perspective assembly view illustrating the water catchment pipe burying assistance instrument 1 of the first embodiment.
[0036] As illustrated in FIG. 1 to FIG. 3 , the water catchment pipe burying assistance instrument 1 of the first embodiment mainly includes: a leading end cap 2 that is formed in a cylindrical shape having a closed leading end and an opened base end; and a separable pipe 3 attached to the base end of the leading end cap 2 . Hereinafter, each configuration is described in detail.
[0037] The leading end cap 2 is made of a steel pipe or the like having strength higher than that of a vinyl chloride pipe or the like in order to prevent damage when the water catchment pipe burying assistance instrument 1 is pushed into a prepared hole H. The leading end cap 2 functions as part of a stopper for attaching the separable pipe 3 , and also functions as a cap for preventing earth and sand from flowing in from the leading end of a water catchment pipe P after coupling of the water catchment pipe P. As illustrated in FIG. 2 and FIG. 3 , the leading end cap 2 in the first embodiment includes: a cap main body 21 formed into an elongated cylindrical shape; a discoid press-holding member coupling portion 22 to which a separable pipe press-holding member 4 to be described later is coupled; and a cylindrical water catchment pipe coupling portion 23 to which the leading end part of the water catchment pipe P is coupled.
[0038] The cap main body 21 is formed into the elongated cylindrical shape having a closed leading end surface and an opened base end surface, and the inside of the cap main body 21 is hollow. Hence, even if earth and sand invade, the cap main body 21 can store the earth and sand, and prevents the earth and sand from flowing into the water catchment pipe P. Further, as illustrated in FIG. 2 and FIG. 3 , a holding groove 24 for locking and holding the press-holding member coupling portion 22 is formed on the inner circumferential surface of the cap main body 1 , a female screw 211 is formed on the inner circumferential surface thereof behind the holding groove 24 , and the water catchment pipe coupling portion 23 is screwed therewith.
[0039] Further, a plurality of (in the first embodiment, two) jet holes 25 capable of jetting hole drilling water poured from behind the separable pipe 3 are formed on the leading end surface of the cap main body 21 , and earth and sand in the prepared hole H are removed by water pressure. Note that the number and positions of the formed jet holes 25 are not limited to those in the first embodiment, two or more jet holes 25 may be formed, and the jet holes 25 may be formed on the outer circumferential surface on the leading end side.
[0040] As illustrated in FIG. 2 and FIG. 3 , the press-holding member coupling portion 22 is made of a discoid steel material at the central position of which a female screw hole 221 is formed, and is coupled to the separable pipe press-holding member 4 to be described later by screwing. Then, the press-holding member coupling portion 22 serves to hold the separable pipe 3 together with the separable pipe press-holding member 4 , and also serves to dam earth and sand that have invaded the inside of the cap main body 21 from the jet holes 25 . Further, two water flowing holes 26 are formed around the female screw hole 221 of the press-holding member coupling portion 22 , and the hole drilling water poured from behind the separable pipe 3 is circulated to the jet holes 25 .
[0041] As illustrated in FIG. 2 , the press-holding member coupling portion 22 is inserted into the base end of the cap main body 21 , a front outer circumferential part of the press-holding member coupling portion 22 abuts against the holding groove 24 , and a back outer circumferential surface thereof is pressed by the leading end of the water catchment pipe coupling portion 23 , whereby the press-holding member coupling portion 22 is sandwiched therebetween.
[0042] Note that a method of fixing the press-holding member coupling portion 22 is not limited to sandwiching by the water catchment pipe coupling portion 23 . For example, although not illustrated, a male screw may be formed on the outer circumferential surface of the press-holding member coupling portion 22 , and the press-holding member coupling portion 22 may be screwed with the cap main body 21 . Alternatively, the press-holding member coupling portion 22 may be completely fixed thereto by welding or the like. Alternatively, the press-holding member coupling portion 22 may be formed integrally with the cap main body 21 .
[0043] As described above, the water catchment pipe coupling portion 23 serves to fix the press-holding member coupling portion 22 , also serves as a member to which the separable pipe 3 is fitted for attachment, and further serves as a member with which the water catchment pipe P is screwed to be coupled to the leading end cap 2 .
[0044] As illustrated in FIG. 1 to FIG. 3 , the water catchment pipe coupling portion 23 in the first embodiment is formed into a cylindrical shape. A female screw 231 that is engaged with a male screw 7 formed on the water catchment pipe P is formed on the inner circumferential surface on the leading end side of the water catchment pipe coupling portion 23 . A male screw 232 that is engaged with the female screw 211 formed on the cap main body 21 is formed on the outer circumferential surface on the leading end side of the water catchment pipe coupling portion 23 . Further, as illustrated in FIG. 2 , a fitting groove 27 for fitting the separable pipe 3 is provided on the inner circumferential surface on the base end side of the water catchment pipe coupling portion 23 . Moreover, a plurality of engagement protrusions 28 that protrude backward and are engaged with the separable pipe 3 are formed at the base end of the water catchment pipe coupling portion 23 .
[0045] The engagement protrusions 28 are respectively engaged with a plurality of engagement grooves 31 formed on the outer circumferential surface on the leading end side of the separable pipe 3 to be described later, to thereby couple the water catchment pipe coupling portion 23 to the separable pipe 3 and enable integrated rotation of the two. With this configuration, for example, in the case where the leading end cap 2 is inserted into the prepared hole H and where earth and sand that have flown in are removed by the water pressure of the hole drilling water, the leading end cap 2 and the separable pipe 3 can be inserted while the jetting direction of the hole drilling water is changed by rotating the two in an integrated manner.
[0046] Note that, in the first embodiment, as described above, the leading end cap 2 includes the cap main body 21 , the press-holding member coupling portion 22 , and the water catchment pipe coupling portion 23 , which are may be integrally formed.
[0047] The separable pipe 3 is made of a steel pipe or the like having high strength similarly to the leading end cap 2 . The separable pipe 3 is attached to the base end of the leading end cap 2 , and is inserted into the prepared hole H. At the time of insertion of the water catchment pipe P, the separable pipe 3 allows the water catchment pipe P to be inserted thereinto, to thereby function as a guide. After completion of the insertion of the water catchment pipe P, the separable pipe 3 is separated from the leading end cap 2 , and is pulled out.
[0048] As illustrated in FIG. 2 and FIG. 3 , the separable pipe 3 in the first embodiment is formed such that the outer diameter on the leading end side thereof is thinner, in order to enable the separable pipe 3 to be fitted into the fitting groove 27 of the water catchment pipe coupling portion 23 . The plurality of engagement grooves 31 that are respectively engaged with the engagement protrusions 28 of the water catchment pipe coupling portion 23 are formed on the base end side of this portion having the thinner outer diameter. Further, as illustrated in FIG. 2 , a protruding portion 32 that abuts against and holds the separable pipe press-holding member 4 is provided on the inner circumference on the leading end side of the separable pipe 3 .
[0049] Moreover, an earth and sand blocking member 33 is provided on the inner wall on the leading end side of the separable pipe 3 . When the separable pipe 3 is separated from the leading end cap 2 and is pulled out, the earth and sand blocking member 33 is slid backward while sealing a gap between the internally inserted water catchment pipe P and the separable pipe 3 , to thereby block earth and sand from flowing in. As illustrated in FIG. 2 and FIG. 3 , the earth and sand blocking member 33 in the present embodiment is made of one O-ring, which is buried in the inner wall of the separable pipe 3 . Not limited thereto, the earth and sand blocking member 33 may be selected as appropriate from other seal materials, and a plurality of seal materials may be buried.
[0050] Note that the separable pipe 3 has a length equivalent to that of the buried water catchment pipe P, and pipes each having a predetermined length may be prepared as needed, and may be coupled as appropriate so as to have a desired length.
[0051] Next, the separable pipe press-holding member 4 is described. The separable pipe press-holding member 4 serves to press-hold and couple the leading end of the separable pipe 3 to the base end of the leading end cap 2 . The separable pipe press-holding member 4 also serves to cancel the press-holding state by an operation from the outside and make the separable pipe 3 separable from the leading end cap 2 .
[0052] As illustrated in FIG. 2 to FIG. 4 , the separable pipe press-holding member 4 in the first embodiment abuts against the protruding portion 32 formed on the inner circumference on the leading end side of the separable pipe 3 , and is screwed with the female screw hole 221 formed in the press-holding member coupling portion 22 of the leading end cap 2 , to thereby couple the separable pipe 3 to the leading end cap 2 . Then, the separable pipe press-holding member 4 includes: a flanged press-holding portion 41 that abuts against the protruding portion 32 ; a coupling shaft 42 including a male screw 421 engaged with the female screw hole 221 of the press-holding member coupling portion 22 ; and a rotation transmitting shaft 43 that transmits rotational force to the coupling shaft 42 .
[0053] The press-holding portion 41 has an outer diameter that enables a peripheral part thereof to abut against the protruding portion 32 of the separable pipe 3 , and is formed by fitting a discoid steel material to the coupling shaft 42 , in the first embodiment. A plurality of circulation holes 44 are formed in the press-holding portion 41 , and allow the hole drilling water to circulate therethrough.
[0054] The coupling shaft 42 is coupled to the leading end cap 2 , to thereby push the press-holding portion 41 against the protruding portion 32 of the separable pipe 3 . The male screw 421 engageable with the female screw hole 221 of the press-holding member coupling portion 22 is formed on the leading end side of this steel shaft.
[0055] The rotation transmitting shaft 43 is fixed to the base end of the coupling shaft 42 , is coupled to a rotation transmitting tool 5 inserted from the base end side of the separable pipe 3 , and transmits the rotational force of the rotation transmitting tool 5 to the coupling shaft 42 . As illustrated in FIG. 2 , a female screw 431 is formed on the inner circumferential surface of a cylindrical steel pipe as the rotation transmitting shaft 43 in the first embodiment, and a male screw 52 of the rotation transmitting tool 5 is engaged with the female screw 431 , whereby the rotation transmitting shaft 43 is coupled to the rotation transmitting tool 5 . Further, the tightening direction of the female screw 431 is opposite to the tightening direction of the male screw 421 formed at the leading end of the coupling shaft 42 , and the rotation direction in which the rotation transmitting tool 5 is operated by screwing is the same as the direction in which the coupling shaft 42 is detached from the press-holding member coupling portion 23 by descrewing.
[0056] As illustrated in FIG. 5 , the rotation transmitting tool 5 includes the male screw 52 at the leading end thereof, and the male screw 52 is engaged with the rotation transmitting shaft 43 . A plurality of guide blades 51 are radially provided for central position alignment in order to reliably engage the male screw 52 with the female screw 431 of the rotation transmitting shaft 43 .
[0057] Note that a method of coupling the rotation transmitting shaft 43 and the rotation transmitting tool 5 to each other is not limited to such screwing. For example, the rotation transmitting shaft 43 and the rotation transmitting tool 5 may be coupled to each other by fitting convex and concave parts having quadrangular shapes, hexagonal shapes, or the like such that the rotational force can be transmitted.
[0058] Further, each screw used in the water catchment pipe burying assistance instrument 1 of the first embodiment is formed as a round screw having high tightening strength with respect to a predetermined pitch and including a screw mountain part and a screw valley part that are substantially circular in cross section.
[0059] Further, the water catchment pipe P in the first embodiment is a rigid resin pipe that includes a plurality of water catchment holes and is made of vinyl chloride, and a raised material for enhancing water catchment capability by means of surface tension is attached to the outer circumferential surface of the water catchment pipe P. Further, the male screw 7 coupled to the water catchment pipe coupling portion 23 is provided at the leading end of the water catchment pipe P.
[0060] Note that the water catchment pipe P is a generally used pipe, is not limited to a pipe made of vinyl chloride, and is selected as appropriate from, for example, a steel pipe, a schedule pipe, a V throttle pipe, and a CP drain pipe.
[0061] Next, an action of each configuration in the water catchment pipe burying assistance instrument 1 of the first embodiment and a water catchment pipe burying method employing the water catchment pipe burying assistance instrument 1 are described.
[0062] The water catchment pipe burying method includes: a prepared hole drilling step of drilling the prepared hole H in the ground; an assistance instrument inserting step of inserting the water catchment pipe burying assistance instrument 1 into the prepared hole H; a water catchment pipe coupling step of inserting the water catchment pipe P into the water catchment pipe burying assistance instrument 1 and coupling the leading end part thereof to the water catchment pipe coupling portion 23 ; and a separable pipe pulling-out step of separating the separable pipe 3 from the leading end cap 2 and pulling out the separable pipe 3 from the prepared hole H. Hereinafter, each step is described in detail.
[0063] First, the prepared hole H is drilled in the ground (prepared hole drilling step). Here, a machine that drills the prepared hole H is not particularly limited, and is selected as appropriate from, for example: a rotary boring machine that drills by rotating the tip of a rod having a leading end with a bit; a percussion boring machine that drills by striking a rod having a leading end with a bit; and a rotary percussion boring machine that drills by striking a rod having a leading end with a bit while applying rotational force to the rod. Further, the rod is selected as appropriate from a single pipe type made of one rod, a double pipe type made of an outer rod and an inner rod, and the like. Moreover, the direction of the drilled prepared hole H is selected as appropriate in accordance with the intended use of the water catchment pipe P, and may be a vertical direction, a horizontal direction, and an upward direction.
[0064] In the prepared hole drilling step in the first embodiment, as illustrated in FIG. 6 , a double pipe type hole drilling machine 6 is used. The double pipe type hole drilling machine 6 includes: an outer rod 62 including an outer bit 61 for hole drilling at the leading end thereof; and an inner rod 64 that is placed inside of the outer rod 62 and includes an inner bit 63 for hole drilling at the leading end thereof. The double pipe type hole drilling machine 6 inserts the rods 62 , 64 into the ground while rotating the rods 62 , 64 , to thereby drill the prepared hole H up to a predetermined depth. Then, after the prepared hole H is drilled, the rods 62 , 64 are pulled out of the prepared hole H.
[0065] Next, as illustrated in FIG. 7 , the water catchment pipe burying assistance instrument 1 is inserted up to a predetermined depth of the drilled prepared hole H (assistance instrument inserting step). At this time, the separable pipe 3 is press-held to the leading end cap 2 by the separable pipe press-holding member 4 , and is thus prevented from coming off the leading end cap 2 . Further, because the water catchment pipe burying assistance instrument 1 is made of a steel pipe or the like having high strength, even if the hole wall of the prepared hole H collapses to some extent or if earth and sand flow therein to some extent, the water catchment pipe burying assistance instrument 1 can be pushed in without being damaged. Moreover, in the first embodiment, the hole drilling water poured from the base end side of the separable pipe 3 passes through the circulation holes 44 provided in the press-holding portion 41 of the separable pipe press-holding member 4 and the water flowing holes 26 opened in the press-holding member coupling portion 22 , and is jetted into the prepared hole H from the jet holes 25 formed at the leading end of the leading end cap 2 . In this state, the water catchment pipe burying assistance instrument 1 is inserted while the earth and sand and the like are moved by the water pressure of the hole drilling water. Accordingly, the water catchment pipe burying assistance instrument 1 can be reliably and stably inserted into the prepared hole H.
[0066] Further, in the first embodiment, after the water catchment pipe burying assistance instrument 1 is inserted into the prepared hole H, the separable pipe press-holding member 4 is detached using the rotation transmitting tool 5 . Specifically, the rotation transmitting tool 5 is inserted from the base end side of the separable pipe 3 , and is then rotated in a predetermined direction upon abutment against the rotation transmitting shaft 43 of the separable pipe press-holding member 4 , whereby the male screw 52 at the leading end of the rotation transmitting tool 5 is completely engaged with the female screw 431 of the rotation transmitting shaft 43 . Then, if the rotation transmitting tool 5 is further rotated in this direction, the resultant rotational force is transmitted from the rotation transmitting shaft 43 to the coupling shaft 42 , so that the coupling shaft 42 is rotated. As described above, the screws respectively provided to the rotation transmitting shaft 43 and the leading end of the coupling shaft 42 are oppositely threaded. Hence, as illustrated in FIG. 8 , the male screw 421 at the leading end of the coupling shaft 42 is disengaged from the female screw hole 221 formed in the press-holding member coupling portion 22 , and the press-holding force on the separable pipe 3 is cancelled.
[0067] The guide blades 51 of the rotation transmitting tool 5 in the first embodiment make the central position of the male screw 52 of the rotation transmitting tool 5 coincident with the central position of the female screw 431 of the rotation transmitting shaft 43 , and hence the rotation transmitting tool 5 is reliably screwed with the rotation transmitting shaft 43 .
[0068] Next, as illustrated in FIG. 9 , the water catchment pipe P is inserted into the water catchment pipe burying assistance instrument 1 , and the leading end part thereof is coupled to the water catchment pipe coupling portion 23 (water catchment pipe coupling step). At this time, the water catchment pipe P is inserted while being guided inside of the separable pipe 3 , and the leading end part thereof reaches the water catchment pipe coupling portion 23 . Then, in the first embodiment, the leading end of the water catchment pipe P is fitted into the water catchment pipe coupling portion 23 , and the water catchment pipe P is rotationally screwed therewith for coupling. The female screw 231 of the water catchment pipe coupling portion 23 and the male screw 7 at the leading end of the water catchment pipe P are each formed as a round screw, and thus have high tightening force, and do not easily come off.
[0069] Next, as illustrated in FIG. 10 , the separable pipe 3 is separated from the leading end cap 2 and is pulled out of the prepared hole H (separable pipe pulling-out step). At this time, the earth and sand blocking member 33 provided on the inner circumference on the leading end side of the separable pipe 3 is slid backward while sealing a gap between the water catchment pipe P and the separable pipe 3 , and thus can block earth and sand from flowing in through the gap. Then, if the separable pipe 3 is completely pulled out of the prepared hole H, as illustrated in FIG. 11 , the water catchment pipe P and the leading end cap 2 are left in the prepared hole H, and the work of burying the water catchment pipe P in the ground is completed.
[0070] The water catchment pipe burying assistance instrument 1 and the water catchment pipe burying method employing the same according to the first embodiment as described above can produce the following effects.
[0071] 1. The water catchment pipe burying assistance instrument 1 has high strength, and cannot be damaged at the time of insertion into the prepared hole H.
[0072] 2. The water catchment pipe burying assistance instrument 1 is inserted into the prepared hole H while the hole drilling water is jetted therefrom to remove earth and sand and the like. Hence, damage of the water catchment pipe burying assistance instrument 1 can be reliably avoided, and the water catchment pipe burying assistance instrument 1 can be stably inserted.
[0073] 3. When the water catchment pipe burying assistance instrument 1 is inserted, the leading end cap 2 and the separable pipe 3 are fixed to each other by the separable pipe press-holding member 4 . Hence, the two are not separated from each other in the course of the insertion.
[0074] 4. The water catchment pipe P is inserted while being guided inside of the separable pipe 3 . Hence, the water catchment pipe P can be reliably and safely inserted into the prepared hole H.
[0075] 5. The earth and sand blocking member 33 blocks earth and sand from flowing into the gap between the water catchment pipe P and the separable pipe 3 . Hence, the earth and sand are prevented from invading the working side, and the separable pipe 3 can be smoothly pulled out.
[0076] 6. The separable pipe 3 can be repetitively reused after its removal, which is economical.
[0077] 7. Each screw is formed as a round screw. Hence, the tightening force is strong, and occurrence of chips and the like can be suppressed at the time of manufacture.
[0078] Next, a second embodiment of the water catchment pipe burying method according to the present invention is described with reference to the drawings. Note that redundant description of steps equivalent or corresponding to the steps in the first embodiment, of steps in a water catchment pipe burying method of the second embodiment, is omitted.
[0079] The water catchment pipe burying method of the second embodiment includes: a prepared hole drilling step of drilling the prepared hole H in the ground with the use of the double pipe type hole drilling machine 6 including the outer rod 62 and the inner rod 64 ; an inner rod pulling-out step of pulling out the inner rod 64 from the outer rod 62 ; an assistance instrument inserting step of inserting the water catchment pipe burying assistance instrument 1 into the outer rod 62 ; an outer rod pulling-out step of pulling out the outer rod 64 from the prepared hole H; a water catchment pipe coupling step of inserting the water catchment pipe P into the water catchment pipe burying assistance instrument 1 and coupling the leading end part thereof to the water catchment pipe coupling portion 23 ; and a separable pipe pulling-out step of separating the separable pipe 3 from the leading end cap 2 and pulling out the separable pipe 3 from the prepared hole H.
[0080] In the prepared hole drilling step in the second embodiment, as illustrated in FIG. 6 , the prepared hole H is drilled with the use of the double pipe type hole drilling machine, similarly to the first embodiment.
[0081] Next, as illustrated in FIG. 12 , the inner rod 64 is pulled out of the outer rod 62 , and the outer rod 62 is left in the prepared hole H (inner rod pulling-out step). If the outer rod 62 is left in the prepared hole H in this way, in the case where the ground in which the prepared hole H is drilled is soft and where the prepared hole H may collapse, the collapse of the prepared hole H can be prevented, and the water catchment pipe burying assistance instrument 1 can be stably inserted up to a predetermined depth.
[0082] In the assistance instrument inserting step in the second embodiment, as illustrated in FIG. 13 , the water catchment pipe burying assistance instrument 1 in which the separable pipe 3 is attached to the leading end cap 2 is inserted into the outer rod 62 left in the prepared hole H. In the case where earth and sand and the like have flown into the outer rod 62 from the leading end side, the water catchment pipe burying assistance instrument 1 is inserted while the hole drilling water is jetted, similarly to the first embodiment, whereby the water catchment pipe burying assistance instrument 1 can be more reliably inserted into the outer rod 62 .
[0083] Next, the outer rod 62 is pulled out of the prepared hole H (outer rod pulling-out step). If the outer rod 62 is pulled out in this way, the state where the water catchment pipe burying assistance instrument 1 is inserted in the prepared hole H can be made similarly to the state after the assistance instrument inserting step in the first embodiment.
[0084] Note that the separable pipe press-holding member 4 may be detached before the outer rod pulling-out step, and may be detached after the outer rod pulling-out step.
[0085] Then, the steps after the outer rod pulling-out step are similar to those in the first embodiment. As illustrated in FIG. 9 to FIG. 11 , the water catchment pipe coupling step and the separable pipe pulling-out step are performed, and the work of burying the water catchment pipe P in the prepared hole H is completed.
[0086] According to the water catchment pipe burying method employing the water catchment pipe burying assistance instrument 1 of the second embodiment described above, the water catchment pipe P can be reliably buried in the case where the ground is soft and where the prepared hole may collapse.
[0087] Note that the water catchment pipe burying assistance instrument 1 and the water catchment pipe burying method employing the same according to the present invention are not limited to the above-mentioned embodiments, and can be changed as appropriate.
[0088] For example, it is possible to adopt a configuration in which: the leading end cap 2 and the separable pipe 3 are coupled to each other; the separable pipe press-holding member 4 can be broken by an operation of applying a predetermined load; and the press-holding state can be cancelled by the breakage. Alternatively, it is also possible to adopt a configuration in which: the leading end cap 2 and the separable pipe 3 are coupled to each other by screws; the water catchment pipe P is fixed to the leading end cap 2 ; then, only the separable pipe 3 is rotated while the water catchment pipe P is held; and the separable pipe 3 is thus separated.
[0089] Further, as illustrated in FIG. 15 , a seal material 29 such as an O-ring may be provided on the inner wall on the base end side of the water catchment pipe coupling portion 23 . The seal material 29 is slid while sealing a gap between the water catchment pipe coupling portion 23 and the separable pipe 3 , to thereby block earth and sand from flowing in, until the separable pipe 3 is completely separated from the water catchment pipe coupling portion 23 .
[0090] Moreover, the water catchment pipe burying assistance instrument 1 and the water catchment pipe burying method employing the same according to the present invention may be applied to not only burying of a water catchment pipe but also burying of an underground pipe for heat exchange, burying of measurement instruments such as a dipmeter and a strainmeter for geological observation, burying of a lightning rod, burying of an anchor used in slope work, and the like.
REFERENCE SIGNS LIST
[0000]
1 water catchment pipe burying assistance instrument
2 leading end cap
3 separable pipe
4 separable pipe press-holding member
5 rotation transmitting tool
6 double pipe type hole drilling machine
7 male screw
21 cap main body
22 press-holding member coupling portion
23 water catchment pipe coupling portion
24 holding groove
25 jet hole
26 water flowing hole
27 fitting groove
28 engagement protrusion
29 seal material
31 engagement groove
32 protruding portion
33 earth and sand blocking member
41 press-holding portion
42 coupling shaft
43 rotation transmitting shaft
44 circulation hole
51 guide blade
52 male screw
61 outer bit
62 outer rod
63 inner bit
64 inner rod
211 female screw
221 female screw hole
231 female screw
232 male screw
421 male screw
431 female screw
P water catchment pipe
H prepared hole
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[Problem] To provide a water catchment pipe burying assistance instrument and a water catchment pipe burying method employing same with which it is possible to bury a resin water catchment pipe without damaging same even when dirt flows into a lead hole. [Solution] Provided is a water catchment pipe burying assistance instrument ( 1 ) which is used to bury a water catchment pipe (P) in a lead hole (H) which is drilled in the ground, comprising: a leading end cap ( 2 ), which is formed in a cylindrical shape, the leading end side of which is closed and the aft end of which is open, and which further comprises a catchment pipe coupling part ( 22 ) which latches and couples with the water catchment pipe (P) on the inner side thereof; and a separation cap ( 3 ) which is formed in a cylindrical shape which the water catchment pipe (P) is capable of being inserted into and which is mounted on the aft end side of the leading end cap ( 2 ), and which is separated from the leading end cap ( 2 ) after the inserted water catchment pipe (P) is coupled to the leading end cap ( 2 ).
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CROSS-REFERENCE TO RELATED APPLICATIONS
Under 35 U.S.C. §120, this application is a continuation patent application and claims the benefit of priority to U.S. patent application Ser. No. 10/733,055, filed Dec. 11, 2003, entitled “Computer Product And System For Establishing Network Connections”, all of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to computer network systems and in particular to a method and system for establishing a network connection between a client system and the network.
BACKGROUND OF THE INVENTION
Despite advances in hardware and software technology, computer users frequently encounter situations in which they cannot establish a connection to a service provider or network. What is meant by establishing a connection in the context of the present application is either creating a first connection to a network or repairing a connection to a network. Repairing a connection to a network can be the result of an improperly installed or configured software program or device driver, or the device being used to attempt the connection may simply be disabled. In the case of a wired connection, the problem may be caused by a defective interconnect cable, or in the case of a wireless connection, a bad transmitter or antenna connection. In addition to such defects, other problems in the network can prevent the user from getting connected. For example, in the case of an Ethernet network, the failure of the network's Dynamic Host Configuration Protocol, or DHCP server, can prevent the user from getting connected to the network.
Because the majority of these problems are not communicated to the user, the user cannot determine the cause, and sees the problem as simply “no connection.” Moreover, even if the user was able to determine the source of the problem, e.g., through an error message generated by the system, he or she would most likely not know how to resolve the problem.
Accordingly, what is needed is a system and method for determining the cause of a connectivity problem and repairing the connection. The system and method should be automatic and transparent to the user. The present invention addresses such a need.
SUMMARY OF THE INVENTION
A method, computer readable medium and computer system for establishing a network connection between a client system and a network is disclosed. In a first aspect, the method preferably includes collecting real time connectivity information by the client system and utilizing the real time connectivity information by the client system to establish a connection with the network. In a second aspect, a computer system coupled to a network includes at least one network adapter for monitoring and collecting real time connectivity information from the network, memory for storing the real time connectivity information, and a processor coupled to the memory and to the at least one network adapter, where the processor is configured to execute program instructions for utilizing the real time connectivity information to repair a failed network connection between the computer system and the network.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a block diagram of a system configuration for a preferred embodiment of the present invention.
FIG. 2 is a block diagram of a client system according to a preferred embodiment of the present invention.
FIG. 3 illustrates a logical software block diagram of the preferred embodiment of the present invention.
FIG. 4 is a flowchart illustrating a process for establishing a network connection according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION
The present invention relates to computer network systems, and in particular to a method and system for establishing a network connection between a client system and the network. The following description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements. Various modifications to the preferred embodiment and the generic principles and features described herein will be readily apparent to those skilled in the art. Thus, the present invention is not intended to be limited to the embodiment shown but is to be accorded the widest scope consistent with the principles and features described herein.
The preferred embodiment of the present invention determines the cause of a connectivity problem and attempts to repair the connection by applying changes to the operating software and/or device configuration in an iterative fashion until a connection is established. It determines the types of changes or repairs to make by collecting information related to the network and to the status of system components, and based in part on that information, begins an iterative process of attempting to establish the connection. The system and method according to a preferred embodiment of the present invention includes an inference engine that determines the cause of the connection failure and the appropriate corrective action based on information contained in several sources, including but not limited to, a local persistent knowledgebase, a real time network list, a set of local rules, and a server-resident database. In a preferred embodiment, the system and method of the present invention evaluates the conditions of a particular connection, and by consulting one or more of the above listed sources, determines a hierarchy of potential solutions and applies each potential solution iteratively until a connection is established. The result of each iterative attempt is monitored, and if unsuccessful, the result, e.g., an error message, is used as feedback to the inference engine.
FIG. 1 illustrates a block diagram of a system configuration for a preferred embodiment of the present invention. Preferably the present invention is implemented on client computer systems 100 a and/or 100 b . As is shown, a first client computer system 100 a is coupled to a public network 120 , such as the Internet. A second client computer system 100 b is coupled to a private network 110 such as a Local Area Network (LAN). The private network 110 is coupled to the public network 120 via a gateway 103 . Nonetheless, those skilled in the art appreciate that a client system 100 (i.e., either client computer system 100 a or client computer system 100 b ) can be coupled to either a private or public network, and not necessarily to both. The client computer system 100 can be mobile, e.g., a laptop or handheld personal computer, or a stationary desktop. A user uses the client computer system 100 to perform information management tasks, including sending and receiving electronic mail from a mail server 140 or from a company server 112 , retrieving web pages from a web server 150 , and sending and receiving data files from a file server 130 or the company server 112 . The client 100 includes an operating system and appropriate hardware adapters such as a dial-up modem or wireless card, or a network adapter such as Token Ring or Ethernet that allows connection to a network 110 , 120 through a cable modem, DSL modem, hub, or switch.
FIG. 2 is a block diagram of the client computer system 200 according to a preferred embodiment of the present invention. The client 200 includes a processor or central processing unit (CPU) 212 that is coupled to memory 214 (e.g., system, RAM, ROM), a display device 216 , input/output devices 218 , and two network adapters 219 and 219 a for connecting the client 200 to the network 220 , e.g., via a wired or wireless connection, respectively. In the preferred embodiment, the network adapters, e.g., 219 and 219 a , are capable of monitoring and capturing network traffic in real time using a wired or wireless method, as is well known in the art.
FIG. 3 illustrates a logical software block diagram of the preferred embodiment of the present invention 300 . As is shown, the preferred embodiment of the present invention includes an inference engine 302 , a verify function 304 and a connection manager 306 . The inference engine 302 provides functionality for automatically determining the cause of a failed connection and for generating a hierarchy of solutions to repair the connection to the network 220 .
In a preferred embodiment, the inference engine 302 analyzes one or more error messages 316 generated by the client 200 relating to the failed connection to assist it in determining the cause of the connectivity failure. In addition, the inference engine 302 invokes the verify function 304 , which audits each of the communication devices to determine which, if any, can be potential candidates for connectivity. Based on the information received from the verify function 304 and on its analysis of the error messages 316 , the inference engine 102 determines the cause of the connectivity failure.
The inference engine 302 utilizes connectivity information stored in the client computer system 200 to repair the connection based on its diagnosis of the cause for failure. The connectivity information includes a set of local rules or preferences 308 , a local persistent knowledgebase 310 a real time network list 314 and optionally, a remote/server-resident knowledgebase. The local rules 308 indicate the client's 200 connection preferences. For example, if the client 200 is capable of establishing a wired and wireless connection, but prefers a wireless connection, the inference engine 302 will attempt to establish a wireless connection before other modes of connectivity. The local persistent knowledgebase 310 includes static configuration information, e.g., parameters and settings. The local persistent knowledgebase 310 can be downloaded and/or updated from the remote/server-resident knowledgebase 312 stored on the company server 112 ( FIG. 1 ).
According to a preferred embodiment of the present invention, the real time network list 314 is a weighted list that includes connectivity information gathered by the network adapter 219 ( FIG. 2 ). As stated above, the network adapter 219 monitors all network traffic, not just the traffic directed toward the client 200 , and collects certain connectivity information in real time. Such information includes addresses of DHCP servers 114 , DNS servers 160 and gateways, addresses and names of SOCKS servers, names and addresses of printers, IP addresses recently assigned by the DHCP server 114 , and other connectivity information. The list 314 is weighted such that the most popular, i.e. most utilized, addresses appear highest on the list 314 .
With the connectivity information, the inference engine 302 formulates a best solution, which is then passed to the connection manager 306 and implemented, i.e., a network connection is attempted using the solution. If the solution fails, such information is transmitted back to the inference engine 302 , e.g., via an error message 316 , so that a new diagnosis of the connection failure can be generated if necessary. This process repeats until a connection is established.
FIG. 4 is a flowchart illustrating a process for establishing a network connection according to a preferred embodiment of the present invention. Referring to FIGS. 1-4 together, the process begins at step 402 , where connectivity information is collected and stored in memory 214 ( FIG. 2 ). This step may include downloading or updating the static configuration information from the remote/server-resident knowledgebase 312 in the company server 112 for the local persistent knowledgebase 310 , and monitoring and collecting connectivity information from the network 220 via the network adapter 219 for the real time network list 314 . In step 403 , the connectivity information is utilized to make a connection. In step 404 , it is determined if a connection failure is detected by the client 200 .
If a connection error is determined then an error message is transmitted and in step 406 , the root cause of the connection failure is determined. In a preferred embodiment, the inference engine 302 is called automatically once a connection failure is detected. In another embodiment, the user can invoke the inference engine 302 . In any event, once the inference engine 302 is called, the inference engine 302 invokes the verify function 304 . The verify function 304 audits each communication device to determine its status, e.g., functional or failed, thereby determining which of them are potential candidates for connectivity. The results of the audit are returned to the inference engine 302 , which then analyzes the results and the error message(s) 316 in order to determine the root cause of the connection failure.
Once the root cause has been determined, the inference engine 102 generates a best solution (in step 408 ) using the connectivity information based on the root cause. For example, in one case, the inference engine 302 monitors the range of IP addresses that are assigned by a DHCP server 114 . It then selects an address in the range and instructs the connection manager 306 to “ping” that address to determine if it is in use. If the address is not in use, the inference engine 302 temporarily assigns the IP address to the client 200 and sets up its network settings for that connection. In another example, if the inference engine 302 determines that the root cause of a connection failure is due to a missing field, e.g., an IP address for the DHCP server 114 or DNS server 160 , from the current discovered configuration, the inference engine 302 will insert the appropriate IP address from the real time network list 314 , effectively “filling in the blanks.” Because the real time network list 314 is a weighted list, the inference engine 302 applies the most frequently utilized IP addresses, which are also those most likely to succeed.
In step 410 , the connection manager 306 implements the best solution. If the connection is unsuccessful (step 412 ), i.e., the best solution fails, then that result is passed back to the inference engine 302 which reexamines its diagnosis based, in part, on the previous unsuccessful attempt and generates a next best solution (step 414 ). The process ends when the connection is successful or when all potential solutions have been exhausted.
In summary, the preferred embodiment of the present invention automatically determines the root cause of a connection failure and attempts to repair the connection without intervention from a user. To do this, the inference engine 302 is invoked to analyze one or more error messages 316 related to the connection failure to determine the root cause of the failure. Once the cause is determined, the inference engine 302 utilizes connectivity information stored in the client 200 to repair the connection. The connectivity information includes real time network information, e.g., IP addresses of the DHCP servers and domain name servers, collected by the client's network adapter 219 . The real time network information is stored in a weighted list 314 , with the most frequently assigned addresses at the top. By utilizing the preferred embodiment of the present invention, the client 200 seamlessly and transparently repairs a failed network connection.
Although the present invention has been described in accordance with the embodiments shown, one of ordinary skill in the art will readily recognize that there could be variations to the embodiments and those variations would be within the spirit and scope of the present invention. Accordingly, many modifications may be made by one of ordinary skill in the art without departing from the spirit and scope of the appended claims.
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A method, computer readable medium and computer system for repairing a failed network connection between a client system and a network is disclosed. In a first aspect, the method preferably includes collecting real time connectivity information by the client system and utilizing the real time connectivity information by the client system to establish a connection with the network. In a second aspect, a computer system coupled to a network includes at least one network adapter for monitoring and collecting real time connectivity information from the network, memory for storing the real time connectivity information, and a processor coupled to the memory and to the at least one network adapter, where the processor is configured to execute program instructions for utilizing the real time connectivity information to repair a failed network connection between the computer system and the network.
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BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a hot extrusion forging die for use in titanium alloy. When used, the hot extrusion forging die for use in titanium alloy extrusion works a heated titanium alloy-made billet in such a manner as to diameter-reduce the billet.
Description of the Related Art
A hot extrusion forging die is equipped with a die member and a punch. The die member is for the purpose of extrusion working a billet in such a manner as to diameter-reduce the billet. And, the die member is ordinarily made of alloy tool steel.
However, this type of hot extrusion forging die had the following problem when extrusion working a titanium alloy-made billet. This problem is that the taking-out of an extruded work by a knockout device becomes impossible. The time when such an inconvenience occurs is the time when the temperature of the die member and the extruded work has been excessively lowered. This excessive drop in temperature of the die member and the extruded work occurs when the taking-out of the extruded work by the knockout device has been late. The failure of taking out the extruded work occurs for the following reason. That is, the coefficient of linear expansion of alloy tool steel is larger than that of titanium alloy. Therefore, if the temperature of the die member and the extruded work is lowered, the die member sticks to the extruded work. As a result, taking-out of the extruded work by the knockout device becomes impossible. In this connection, the coefficient of linear expansion of titanium alloy is 8.4×10 -6 /° C. The coefficient of linear expansion of alloy tool steel (e.g., SKD 61) is 10.5×10 -6 /° C.
Also, the dependency upon temperature of the deformability of titanium material is very high. For this reason, when at the time of extrusion working the surface of the material is cooled by the die member, a crack occurs (at the position of a shaft portion Wb in FIG. 1 there occurs a crack such as that wherein the upper side and the lower side separate from each other). In order to prevent the occurrence of this crack, it is necessary that the titanium alloy-made billet be heated at 900° C. or higher. Also, in order to prevent the occurrence of the crack, it is also necessary that the die member be preheated at a high temperature of 200 to 550° C. or so.
However, when the die member is made of alloy tool steel, the die member adheres to the billet due to the temperature at which the die member is preheated. That is, the titanium alloy-made billet seizes to the die member. In order to prevent this seizure, it is necessary that a lubricant of a glass system be coated onto the billet beforehand.
However, if the lubricant of a glass system is coated onto the billet, after extrusion working this lubricant must be removed. For this reason, the postworking processing necessitates time and labour very much.
SUMMARY OF THE INVENTION
An object of the present invention is to solve the above-mentioned problems. That is, another object of the present invention is to provide a hot extrusion forging die for use in titanium alloy which makes it easy to take out the extruded work. That is, this another object of the present invention is to provide a hot extrusion forging die for use in titanium alloy which can suppress the sticking of the die member onto the extruded work. Still another object of the present invention is to provide a hot extrusion forging die for use in titanium alloy which can use a lubricant, the removal of which is unnecessary. That is, this third object of the present invention is to provide a hot extrusion forging die for use in titanium alloy which can suppress the seizure of the titanium alloy-made billet onto the die member.
The above objects of the present invention can be attained by a hot extrusion forging die for use in titanium alloy which comprises a die member for extrusion working a titanium alloy-made billet in such a manner as to reduce the diameter of this billet, and the die member being made of ceramic.
And, preferably, around the die member there is caused to be disposed an inside reinforcement ring made of steel material having a toughness such that this ring has an interference with respect to the die member, and, further, around the inside reinforcement ring there is caused to be disposed an outside reinforcement ring made of steel material having a toughness such that this ring has an interference with respect to the inside reinforcement ring, and, the interference between the die member and the inside reinforcement ring is formed as an interference for shrinkage fitting.
Furthermore, preferably, the outer-peripheral surface of the die member is made straight and the inner-peripheral surface of the inside reinforcement ring is made straight in correspondence with the outer-peripheral surface of the die member.
In the hot extrusion forging die for use in titanium alloy according to the present invention, the die member for restricting the titanium alloy-made billet is made of ceramic.
The coefficient of linear expansion of ceramic (e.g., Si 3 N 4 ) is 3.0×10 -6 /° C., which is smaller than the coefficient of linear expansion (8.4×10 -6 /° C.,) of titanium alloy. For this reason, even when the taking-out of the extruded work by a knockout device immediately after the performance of the extrusion working is late with the result that the temperature of the die member has been lowered, the die member does not stick to the extruded work. As a result, the taking-out of the extruded work becomes easy.
Also, when the die member is made of ceramic, the die member is unlikely to adhere to the billet even if preheated at 200° C. or more. Therefore, the seizure of the titanium alloy-made billet to the die member becomes unlikely to occur. This makes it possible to use a graphite coating as a lubricant for use in the billet. The graphite coating or the like is not needed to be removed after working. Accordingly, a manufacturer of the work can smoothly perform the extrusion working by using the lubricant not needed to be removed such as the graphite coating without spending time and labour very much.
Accordingly, when used, the hot extrusion forging die for use in titanium alloy according to the present invention makes it possible to suppress the sticking of the die member onto the extruded work to thereby make it easy to take out the extruded work. Also, when used, the hot extrusion forging die for use in titanium alloy according to the present invention makes it possible to suppress the seizure of the titanium alloy-made billet, with the result that there can be used the lubricant for which the removing operation is not needed to be done.
And, if the forging die is constructed as follows, further merits can be brought about. That is, around the die member, there is disposed the inside reinforcement ring made of steel material having a toughness such that this ring has an interference with respect to the die member. Further, around the inside reinforcement ring, there is disposed the outside reinforcement ring made of steel material having a toughness such that this ring has an interference with respect to the inside reinforcement ring. And, the interference between the die member and the inside reinforcement ring is formed as an interference for shrinkage fitting. If the arrangement is made like this, it is possible to ensure a large interference at even the time of preheating with respect to the die member without damaging this die member. Also, it is possible to ensure a high strength of the extrusion working die member.
The reason for this is as follows. In a case where only one reinforcement ring is provided around the ceramic-made die member, there arises the necessity of preheating also this one reinforcement ring at 200° C. or more. However, in the case of only the reinforcement ring alone made of steel material having a toughness, for example, alloy tool steel, when this ring is preheated at a temperature of 550° C. or so, the interference becomes inconveniently small at the preheating time. This is because the coefficient of linear expansion of ceramic is small (the coefficient of linear expansion of, for example, Si 3 N 4 is 3.0×10 -6 /° C.) and the coefficient of linear expansion of steel is large (the coefficient of linear expansion of, for example, SKD 61 is 10.5×10 -6 /° C.). For this reason, in the case where only one reinforcement alone is provided around the ceramic-made die member, a large interference becomes necessary. However, shrinkage fitting is a mode of fitting in which the ring is assembled by being shrunk after having been thermally expanded. That is, the application of shrinkage fitting cannot ensure a large interference. Therefore, it results that in order that a large interference can be ensured, assembling is performed by force-insertion (taper force-insertion) utilizing a taper surface. However, when ensuring a large interference by such a taper force-insertion, microcracks occur in the outer-peripheral surface of the ceramic-made die member. And, during the use thereof, the cracks are grown with the result that the die member is inconveniently broken early.
For example, in a case where the material quality of the reinforcement ring is alloy tool steel, in order to ensure the strength at the time of quenching the shrinkage fitting is performed at 600° C. or so lower than the tempering temperature. Therefore, when preheating is performed at a temperature of 550° C., the temperature difference between the tempering temperature and the preheating temperature is only 50° C. As a result, with the shrinkage fitting of alloy tool steel, it is impossible to ensure a large interference.
In contrast to this, if the inside reinforcement ring is assembled around the die member by shrinkage fitting and further around this inside reinforcement ring there is assembled the outside reinforcement ring made of alloy tool steel such that this ring has an interference, the following merits are produced. That is, the inside reinforcement ring is not only caused to act on the die member but the interference of the outside reinforcement ring can also be caused to act thereon through the inside reinforcement ring. Therefore, a large interference can be ensured with respect to the die member at the preheating time. And, since the inside reinforcement ring is assembled to the die member by shrinkage fitting, the inside reinforcement ring has a small interference, with the result that there is no likelihood of the die member being broken. Conversely, the inside reinforcement ring can serve as a cushion for a pressing force applied by the interference of the outside reinforcement ring to the die member and can buffer this pressing force. For this reason, the inside reinforcement ring can contribute to preventing the die member from being broken due to the interference of the outside reinforcement ring. That is, even when the outside reinforcement ring is assembled to the inside reinforcement ring by the taper force-insertion enabling its ensurement of a large interference with respect to the inside reinforcement ring, the die member is not broken. And, the outside reinforcement ring can ensure a large interference of the inside reinforcement ring with respect to the die member.
And, further, in a case where the inside reinforcement ring is assembled to the die member, if the outer-peripheral surface of the die member and the inner-peripheral surface of the inside reinforcement ring are respectively correspondingly made straight and the both are assembled together by shrinkage fitting without utilizing a taper surface, the following mertis are produced. That is, it is possible to suppress the occurrence of variation in the interference due to the error made in taper angle or reference diameter position, with the result that a stable interference can be ensured. As a result, the durability of the die member can be enhanced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view illustrating a hot extrusion forging die for use in titanium alloy according to an embodiment of the present invention; and
FIG. 2 is a sectional view illustrating a hot extrusion forging die for use in titanium alloy according to another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will now be explained with reference to the drawings. It is to be noted that the invention is not limited to the embodiments which will be described hereafter. All changes or modifications made within, or all equivalents to, the subject matter claimed in the claims are included within the scope of these claims.
As illustrated in FIG. 1, a hot extrusion forging die 1 for use in titanium alloy according to this embodiment is equipped with a substantially circular-cylindrical diamter-reducing die member 4 in order to work a titanium alloy-made circular-columnar billet B into an extruded work W. The die member 4 has a large-diameter hole portion 4a and a small-diameter hole portion 4c. A throat portion 4b shaped like a taper is disposed between the large-diameter hole portion 4a and the small-diameter hole portion 4c.
It is to be noted that the extruded work W is an unfinished product which is used as a titanium alloy-made engine valve blank. Therefore, after extrusion working, a large-diameter portion Wa of the extruded work W which is located above a shaft portion Wb thereof is swaged.
In the forging die 1, a circular-cylindrical guiding die member 2 is disposed on the upside of the diameter-reducing die member 4. The guiding die 2 is for the purpose of guiding the billet B into the die member 4. A substantially circular-cylindrical reinforcement ring 3 is assembled in such a way as to surround the die member 2.
Around the diameter-reducing die member 4, there is assembled a circular-cylindrical inside reinforcement ring 5, around which there is assembled a circular-cylindrical outside reinforcement ring 6. Further, on the underside of the die member 4 and reinforcement rings 5, 6, there is disposed a pressure receiving plate 7, on the underside of which there is disposed a cap 9. The cap 9 is fastened to a circular-cylindrical case 8 by means of bolts 10. The case 8 covers the outer-peripheral surfaces of the reinforcement rings 3, 6 and pressure receiving plate 7. By the cap 9 being fastened to the case 8, the die members 2 and 4, rings 3, 5 and 6 and the like are integrated together, and, in this condition, these are disposed on a bolster not illustrated of a presser.
The diameter-reducing die member 4 is made of silicon nitride. The guiding die member 2 and the reinforcement rings 3, 5 and 6 are each made of SKD 61 which is one of the alloy tool steels for use in hot working. For example, the die member 4 may be made of another ceramic material such as SIALON. Also, the die member 2 and the reinforcement rings 3, 5 and 6 may each be made of another alloy tool steel for use in hot working or the like such as SKD 6.
Further, the guiding die member 2 may be made of silicon nitride or ceramic material such as SIALON. In this case, it is preferable that, as illustrated in FIG. 2, the reinforcement ring 3 be composed of two members, i.e., an inside reinforcement ring 31 and outside reinforcement ring 32 each made of SKD 61 which is a steel material having a toughness, as in the case of the reinforcement rings 5 and 6. That is, around the die member 2, there is caused to be disposed the inside reinforcement ring 31 such that this inside reinforcement ring has an interference for shrinkage fitting. Further, around the inside reinforcement ring 31, there is caused to be disposed the outside reinforcement ring 32 such that this outside reinforcement ring has an interference for taper force-insertion or shrinkage fitting. If the reinforcement ring 3 is constructed as mentioned above, it is possible to prevent the reinforcement rings 31 and 32 from being loosened with respect to the die member 2 due to the difference between the coefficients of thermal expansion. Also, it is possible to ensure a high strength of the die member 2.
Also, the pressure receiving plate 7 is made of SKH 51 or the like. The case 8 is made of SKD 61 or the like. The cap 9 is made of SKD 61 or the like.
In the case of this embodiment, the die member 4 is configured such that its outer-peripheral surface is made straight along the axis of the die member 4. Also, the inner-peripheral surface of the inside reinforcement ring 5 is made straight in correspondence with the outer-peripheral surface of the die member 4. The reason why the inner-peripheral surface of the inside reinforcement ring 5 has been made straight is that it is arranged that the entire inner-peripheral surface of this ring 5 can have a prescribed dimension of interference with respect to the die member 4.
The outside diameter D0 of the die member 4 is set to be 30Φ. The inside reinforcement ring 5 is constructed such that its inside diameter D1 has a dimension of 0.15 mm (the dimension obtained by subtracting D1 from D0) as the interference available at normal temperature with respect to the outside diameter D0 of the die member 4. The inside reinforcement ring 5 is assembled to around the die member 4 by shrinkage fitting. The heating temperature at the time of shrinkage fitting is approximately 600° C.
Also, the outside diameter D2 of the inside reinforcement ring 5 is set to be approximately 45Φ. The outside reinforcement ring 6 is constructed such that its inside diameter D3 has a dimension of 0.225 mm (the dimension obtained by subtracting D3 from D2) as the interference available at normal temperature with respect to the outer-peripheral surface of the inside reinforcement ring 5. The outside diameter D4 of the outside reinforcement ring 6 is set to be 70Φ.
Further, the inner-peripheral surface of the inside reinforcement ring 5 and the outer-peripheral surface of the outside reinforcement ring 6 are correspondingly shaped like a downwardly or upwardly diverged taper. The reason why this configuration is made is to make it possible to force insert the outside reinforcement ring 6 onto the inside reinforcement ring 5.
In the case of this embodiment, first, the inside reinforcement ring 5 is disposed around the die member 4 by shrinkage fitting. Thereafter, by taper force-insertion, the outside reinforcement ring 6 is disposed around the inside reinforcement ring 5. By performing these operations, the die member 4 and the rings 5, 6 are assembled together. At this time, the interference of the inside reinforcement ring 5 and outside reinforcement ring 6 with respect to the die 4 at normal temperature (the dimension obtained by subtracting from the outside diameter D0 of the die member 4 the inside diameter D1 of the inside reinforcement ring 5 kept having the outside reinforcement ring 6 assembled thereto) was 0.258 mm. Also, the interference of the inside reinforcement ring 5 and outside reinforcement ring 6 with respect to the die 4 at a time of preheating performed at 550° C. (the dimension obtained by subtracting from the outside diameter D0 of the die member 4 the inside diameter D1 of the inside reinforcement ring 5 kept having the outside reinforcement ring 6 assembled thereto) was 0.135 mm.
For example, when only the inside reinforcement ring 5 had been assembled to the die member 4 by shrinkage fitting, as stated previously the interference of the inside reinforcement ring 5 with respect to the die member 4 at normal temperature (the dimension obtained by subtracting D1 from D0) was 0.15 mm. However, when only the inside reinforcement ring 5 had been assembled to the die member 4 by shrinkage fitting, the interference of the inside reinforcement ring 5 with respect to the die member 4 at a time of heating of 550° C. (the dimension obtained by subtracting D1 from D0) was decreased down to a remarkably small value of 0.027 mm.
On or around the case 8 of the forging die 1 according to this embodiment, there is disposed a pre-heater not illustrated such as a band heater or high frequency heater. The pre-heater is for the purpose of preheat the die member 4 and the reinforcement rings 5 and 6 to 550° C.
Next, the mode of use of the forging die 1 according to this embodiment will be explained.
First, a titanium alloy-made billet B which has been coated with graphite is heated to and kept at 1200° C. beforehand by, for example, high frequency heating. Then, the billet B is put from the guiding die 2 into the large-diameter hole portion 4a of the diameter-reducing die member 4 and is disposed in this die member 4. It is to be noted that the die member 4 and the like are also preheated at 200 to 550° C. beforehand by a pre-heater not illustrated.
Thereafter, a punch 11 is hammered into. Then, the billet B is extruded to the small-diameter hole portion 4c side of the die member 4, whereby there is manufactured an extruded work W having a large-diameter portion Wa and a shaft portion Wb.
Thereafter, by operating a knockout device not illustrated, the extruded work W is taken out. In this connection, in the forging die 1 according to this embodiment, the die member 4 for diameter reducing the titanium alloy-made billet B is made of silicon nitride which is a kind of ceramic material. The coefficient of linear expansion of the silicon nitride (Si 3 N 4 ) is 3.0×10 -6 /° C., which is smaller than the coefficient of linear expansion (8.4×10 -6 /° C.) of titanium alloy. For this reason, even when the taking-out of the extruded work W by the knockout device immediately after the performance of the extrusion working is late with the result that the temperature of the die member 4 and work W has been lowered, the die member 4 does not stick to the extruded work W. Accordingly, the taking-out of the extruded work W by the knockout device can be easily performed.
Also, when the die member 4 is made of ceramic, the die member 4 is unlikely to adhere to the work W even if preheated at 200 to 550° C. or so. Therefore, the seizure of the titanium alloy-made billet B to the die member 4 is unlikely to occur. This makes it possible to use a graphite coating as a lubricant for use in the billet B. The graphite coating is a lubricant which is not needed to be removed after working. Accordingly, in a case where manufacturing the extruded work W by performing the extrusion working of the titanium alloy-made billet B by using the forging die 1 according to this embodiment, it becomes unnecessary to perform post-working removal of the lubricant. Therefore, in the manufacturing method for manufacturing the work W, which uses the forging die 1 according to this embodiment, processing after the performance of the extrusion working can be facilitated with the result that it is possible to manufacture the extruded work W without spending time and labour very much.
In the case of this embodiment, around the diameter-reducing die member 4, there is disposed the inside reinforcement ring 5 made of alloy tool steel such that this ring 5 has an interference with respect to the die member 4. Further, around the inside reinforcement ring 5, there is disposed the outside reinforcement ring 6 made of alloy tool steel such that this ring 6 has an interference with respect to the ring 5. And, the interference between the die member 4 and the inside reinforcement ring 5 is formed as an interference for shrinkage fitting. As a result, this forging die 1 can ensure a large interference (0.135 mm) at even the time of preheating with respect to the die member 4 and without damaging this die member 4. Also, the forging die 1 can ensure a high strength of the die member 4.
The reason for this is as follows. In a case where only one reinforcement ring 5 is provided around the ceramic-made die member 4, there arises the necessity of preheating also this one reinforcement ring at 200 to 550° C. or so. However, in the case of only the reinforcement ring 5 alone made of alloy tool steel, when this ring 5 is preheated at a temperature of 550° C., the interference becomes inconveniently small (0.027 mm as referred to previously) at the preheating time. This is because the coefficient of linear expansion of ceramic is small (the coefficient of linear expansion of Si 3 N 4 is 3.0×10 -6 /° C.) and the coefficient of linear expansion of steel is large (the coefficient of linear expansion of SKD 61 is 10.5×10 -6 /° C.). For this reason, in the case where only one reinforcement 5 alone is provided around the ceramic-made die member 4, a large interference becomes necessary. However, shrinkage fitting is a mode of fitting in which the ring 5 is assembled by being shrunk after having been thermally expanded. That is, the application of shrinkage fitting cannot ensure a large interference. Therefore, it results that in order that a large interference can be ensured, the reinforcement ring 5 is disposed around the die member 4 by taper force-insertion. However, ensuring a large interference by such a taper force-insertion results in that the ceramic-made die member 4 is inconveniently broken.
In contrast to this, as in the case of this embodiment, first, the inside reinforcement ring 5 is assembled around the die member 4 by shrinkage fitting. Subsequently, around the inside reinforcement ring 5 there is further assembled the outside reinforcement ring 6 made of alloy tool steel, such that this ring 6 has an interference. That is, the inside reinforcement ring 5 is not only caused to act on the die member 4 but the interference of the outside reinforcement ring 6 is also caused to act thereon through the inside reinforcement ring 5. Therefore, a large interference (0.135 mm as referred to previously) can be ensured with respect to the die member 4 at the preheating time.
Also, the inside reinforcement ring 5 is assembled to the die member 4 by shrinkage fitting. Therefore, the inside reinforcement ring 5 has a small interference, with the result that there is no likelihood of the die member 4 being broken. Conversely, the inside reinforcement ring 5 can serve as a cushion for a pressing force applied by the interference of the outside reinforcement ring 6 to the die member 4 and can buffer this pressing force. For this reason, the inside reinforcement ring 5 can contribute to preventing the die member 4 from being broken due to the interference of the outside reinforcement ring 6. As a result, even when the outside reinforcement ring 6 is assembled to the inside reinforcement ring 5 by the taper force-insertion enabling its ensurement of a large interference with respect to the inside reinforcement ring 5, the die member 4 is not broken. And, the outside reinforcement ring 6 can ensure a large interference of the inside reinforcement ring 5 with respect to the die member 4.
It is to be noted that if a large interference is ensured, the outside reinforcement ring 6 may be assembled to the inside reinforcement ring 5 by shrinkage fitting.
And, further, in a case where the inside reinforcement ring 5 is assembled to the die member 4 by shrinkage fitting, the both may be shrinkage fitted together by utilizing a taper surface. However, if as in the case of this embodiment the outer-peripheral surface of the die member 4 and the inner-peripheral surface of the inside reinforcement ring 5 are respectively correspondingly made straight and the both are assembled together by shrinkage fitting, it is possible to suppress the occurrence of variation in the interference due to the error made in taper angle or reference diameter position. As a result, a stable interference can be ensured and also the durability of the die member 4 can be enhanced.
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When used, a hot extrusion forging die for use in titanium alloy according to the present invention extrusion works a heated titanium alloy-made billet in such a manner as to diameter-reduce the billet. The hot extrusion forging die for use in titanium alloy according to the present invention is equipped with a die member for extrusion working. The die member is made of ceramic. The forging die according to the present invention makes it possible to suppress the sticking of the die member onto an extruded work to thereby make it easy to take out the extruded work. Also, the forging die according to the present invention makes it possible to suppress the seizure of the titanium alloy-made billet, with the result that there can be used a lubricant for which the removing operation is not needed to be done.
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BACKGROUND OF THE INVENTION
This invention relates to dry wall tapes and particularly relates to a novel dry wall plastic tape which is suitable for application to inside and outside corners of coffered ceilings, bay windows, and any other angular dry wall application. This invention is also applicable for use on curved openings, arched dry wall openings and curved dry wall walls.
Currently it is very difficult to form a straight line along inside corners of rooms constructed with dry wall board. There is available beaded tape which is suitable for use on outside corners, but it takes a skilled and patient craftsman to form a uniformly straight line on an inside corners, such as are found in coffered ceilings and bay windows, and along curved arches and arched openings.
Accordingly, it is a principal object of this invention to provide a dry wall plastic tape which can be used for both inside and outside corners as well as being usable for curved or arched openings. It is a principal object of this invention to provide a dry wall tape which will allow the person taping to rapidly form a straight line on an inside corner and which tape can also be applied to outside corners. It is still a further object to provide such a tape which also is applicable to curved openings such as are found on rounded half walls, curved stair wells, and arched dry wall openings.
These and other objects and advantages will become apparent hereinafter.
SUMMARY OF THE INVENTION
The present invention comprises a tape having an outwardly arched center section and reversely curved intermediate sections with laterally extending relatively flat wings along the side edges of the tape.
The invention also consists in the parts and in the arrangements and combinations of parts hereinafter described and claimed.
DESCRIPTION OF THE DRAWINGS
In the accompanying drawings which form part of the specification and wherein like numbers and letters refer to like parts wherever they occur
FIG. 1 is an end elevational view of one form of this invention;
FIG. 2 is a top plan view of the invention shown in FIG. 1.;
FIG. 3 is a fragmentary enlarged end elevational view of a second form of the invention;
FIG. 4 is a top plan view of the form of the invention shown in FIG. 3;
FIG. 5 is a fragmentary end elevational view of the tape applied to an outside corner;
FIG. 6 is a fragmentary end elevational view of the tape applied to an inside corner; and
FIG. 7 is a fragmentary perspective view of the tape of FIGS. 1 and 2 applied to an arched opening.
FIG. 8 is a fragmentary perspective view of the tape applied to a rounded wall; and
FIG. 9 is a fragmentary enlarged perspective view of the tape applied to a curved corner joint.
DETAILED DESCRIPTION
The preferred form of the invention is shown in FIGS. 1 and 2 and the tape 10 comprises an arched center section 11 and reversely arched intermediate sections 12 and 13 connecting the arched center section 11 with outwardly extending wings 14 and 15. The arched center section 11 preferably is provided with internal serrations 16 on the inside of the arch to facilitate bending. This is shown in more detail in FIG. 3.
The top of the arch section 11 preferably is about 1/16" to about 3/32" above the plane of the wings 14, 15 as identified by the line A--A in FIG. 3. This distance is denoted by the letter "x". The outermost parts of the intermediate sections 12, 13 preferably are about 1/16" to about 3/32" below the line A--A. This distance is identified by the letter "z" in FIG. 3. The intermediate sections 12, 13 are about 5/64" to about 3/32" in width as shown by the letter "a" in FIG. 3. The arch center section 11 is about 3/32" to about 1/8" in width as shown by the letter "b" in FIG. 3.
The outwardly depending and diverging wings 14 and 15 preferably are provided with V-shaped notches 17 (FIG. 2) which have their apex 18 at the point of connection to the intermediate sections 12 and 13 and their widest part is most remote from the center arched section 11. The notches 17 thus define adjacent triangular solid members 14a and 15a on the respective wings 14 and 15.
The notches 17 in each depending wing 14 and 15 are staggered so that the apex of a notch 17 on wing 14 is aligned with approximately the center of the triangularly shaped solid member 15a of the opposed wing 15. Thus the wings 14 and 15 are formed of a continuous series of triangularly shaped pieces 14a, 15a which are connected at their widest part to the intermediate sections 12 and 13. At the point on the triangular pieces 14a, 15a which is most remote from the center section 11 and along the outer edges of the tape 10 are releasible and removable tear strips 20, 21. The purpose for the tear strips 20, 21 is to allow the notches 17 to separate when the tape 10 is applied to an arched or rounded opening or corner as shown in FIGS. 7-9. The pieces 15a on the inner side of the curved corner gather together as also seen in FIG. 9.
Preferably the wings 14 and 15 are about 3/64" to about 1/16" in thickness where they join the intermediate sections 12, 13, and taper outwardly rom this point of connection toward their connection with the tear strips 20 and 21. The tear strips 20, 21 preferably are about 1/64" to about 1/32" in thickness. Thus, it is easier to provide a smooth finish to the joint because the wings 14, 15 are very thin and get thinner the further they extend away from the corner.
The wings 14, 14a are marked with suitable indicia 22 each foot and are scribed every inch. These markings are on the tear strips 20, 21 in the form of the invention shown in FIGS. 1 and 2.
The wings 14, 15 preferably are about 11/2" to about 13/4" in width and the tear strips 20, 21 are preferably about 1/16" to about 3/32" in width. The sold triangular members 14a, 15a preferably have a width of about 3/16" to about 1/4" at their point of intersection with the intermediate members 12, 13.
The tape 10a shown in FIGS. 3 and 4 is applicable to straight line joints and is not designed for use with curved openings. In this tape 10a, the wings 30 and 31 are solid and do not have V-shaped grooves or the tear strip. The wings 30, 31 preferably are tapered however and have the same dimensions as hereinbefore discussed for the tape 10. The wings 30, 31 have indentations, serrations or perforation 33 or other roughening effects, such as that caused by chemical or physical etching randomly positioned on the outer surface to help the dry wall compound adhere to the tape.
The tapes 10, 10a preferably are made of an extruded polymeric material. The tape should have some rigidity, and should be deformable to hold the shape it is formed into on the corner and also should adhere to the dry wall compound.
FIG. 5 shows the tape 10 applied to an outside joint and in the process of applying the tape 10, dry wall compound is applied to the joint before the tape 10 is placed along the joint. After the tape 10 has been placed along the joint so that the center section 11 protrudes outwardly from the joint, the dry wall compound is applied to the outside of the tape with a tape knife. The tape knife is guided on the protruding center section 11 so that a straight line is formed at the center of the joint. The tape knife, of course, also feathers the joint compound out over the free edge of the tape wings 14 and 15.
FIG. 6 shows the tape 10 applied to an inside joint. In this application, the center arch 11 is positioned adjacent to the joint and the intermediate sections 12 and 13 protrude outwardly away from the joint. In applying the tape 10 to the inside joint, the joint compound is first applied and then the tape 10 is positioned so that the center member 11 is adjacent to the joint. The joint compound is then smoothed and formed into a straight line by guiding the taping knife on the protruding intermediate sections 12 and 13.
FIGS. 7-9 show the tape 10 of FIGS. 1 and 2 applied to curved joints. The pull away sections 20, 21 of the tape 10 are removed from that part of the tape 10 which is curved around the joint, so that it facilitates the V-shaped grooves 17 opening up or closing depending on whether they are inside or outside the curve. The taping proceeds in a similar fashion to that previously described depending on whether the curve is an inside or outside curve.
This invention is intended to cover all changes and modifications of the example of the invention herein chosen for purposes of the disclosure which do not constitute departures from the spirit and scope of the invention.
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A dry wall tape having a curved center section, reversely curved intermediate sections and outwardly tapering wings terminating in a thin edge. The tape can be used on inside and outside corner joints to obtain a straight line. Preferably the tape has triangular cut outs in the wings and removable end strips along the outer edges of the tape to facilitate taping of curved corners.
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BACKGROUND OF THE INVENTION
The present invention relates to a changer-type disk playback device capable of selectively playing back a plurality of disks.
U.S. Pat. No. 5,138,591, Japanese Laid-open Publication Number 6-36436, and U.S. Pat. No. 5,561,657 disclose changer-type disk playback devices that allow a selected disk to be played back without requiring the disk to be pulled out from its storage position. In order to make the device compact, playback means, comprising an optical pickup, a turntable, and the like, is moved horizontally between a plurality of coaxially disposed disks.
These conventional examples comprise a magazine having a plurality of mounting plates. A disk is mounted on each of these mounting plates. The magazine can be attached and removed from the device. When this magazine is outside the device, a lock mechanism locks the mounting plates so that the mounting plates do not separate from each other. When the magazine is stored in the device, the lock mechanism is released by a prescribed lock releasing mechanism in the device. During disk playback, the mounting plates are moved in a direction perpendicular to the disk surfaces, thereby providing more space. Playback mechanisms positioned at recessed positions, such as a turntable and an optical pickup, are moved in the space created by moving the mounting plates to allow disks to be played back without requiring the disks to be pulled out from the magazine.
When disks not held in the magazine are to be played back, the magazine is removed from the device, and disks are removed from the magazine. Then, the disk to be played back is mounted in the magazine, and the magazine is remounted in the device. This makes operating the device complex. Thus, there is a need for this type of changer-type disk playback device to be equipped with a loading mechanism for loading a disk inserted from a slit formed on a front panel of the device into the device. The loading mechanism can be either a pinch-roller loading mechanism where the disk surface is interposed between a drive roller and a driven roller, or a belt loading mechanism where the edges of the disk are supported by a continuous drive belt disposed along a disk transfer path.
When a disk is to be stored in a storing position using a loading mechanism, a supporting means must be disposed to support the disk at the storing position. The supporting means can take on a variety of different structures. When the recording surface or label surface of disks are mounted on a mounting plate, as in the conventional technology described above, the disk can be damaged by the sliding contact between the disk surface and the mounting surface during the loading operation. In Japanese Laid-open Publication Number 9-17171, filed by the present applicant, an arcuate disk holder that supports the disk edge over approximately 180 degrees can be used. According to this disk supporting means, the sliding contact between the disk and the disk holder takes place only at the edge, where no data is recorded. Thus, even if the disk is scratched, there is no effect on playback.
During disk playback, the disk must be moved away from the disk holder so that the disk holder and the disk are out of contact with each other. If the disk holder is disposed close to the front panel of the device, the disk would project from the front panel when the disk is pulled out. Thus, the disk holder needs to be disposed further back in the device so that there is space between the front panel and the disk holder for the disk to be pulled out.
OBJECTS AND SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a playback device which overcomes the drawbacks of the prior art.
It is a further object of the invention to provide a playback device which permits playing of a disk while an axis of the disk remains within a perimeter of stored disks.
It is a still further object of the invention to provide a disk playback device in which a spacing between disks is sufficient to permit a turntable to move to and chuck a disk stored in a disk storage device, then withdraw the disk to a playback position.
It is a still further object of the invention to provide a disk playback device in which a storage position for a turntable and optical pickup is located outside a vertical space about a disk playback position.
Briefly stated, the present invention provides a disk playback device in which a space above and below a selected disk held in a disk holder provides room for a turntable and optical pickup to move in and out of positions outside and inside the perimeter of stored disks. The turntable is moved inward in the space from a storage position to chuck, and withdraw, the selected disk from its disk holder to a playback position in which the axis of the turntable is within the outline of disks stored in disk holders. The storage position places the axis of the turntable outside the outline of disks stored in the disk holders. In a single play mode, a disk not stored in a disk holder is moved directly from outside the disk playback device to the playback position where it is chucked and played. On conclusion of single play, the disk is transported out of the disk playback device without being resident in a disk holder.
When the disk holder is moved perpendicular to the disk surface in order to play back a disk, playback means needs to be recessed to a position where there is no overlapping with the disk. The space that is needed to provide a recessed position for the playback means acts as a bottleneck in making the device more compact.
In order to achieve the object described above, a changer-type disk playback device according to the present invention comprises: a plurality of disk supporting members supporting a plurality of disks so that the disks are coaxial; disk support member transferring means transferring the plurality of disk supporting members in a direction perpendicular to the surface of the disks; disk transferring means transferring a disk between a selected disk supporting member and a disk insertion/removal position; playback means performing playback of a disk comprising at least an optical pickup and a turntable; disk withdrawing means pulling out a disk from a disk supporting member so that the disk and the disk supporting member are out of contact; and a playback means transferring mechanism moving the playback means to a recessed position and a playback position. The recessed position is a position in a flat region formed by the transfer of the disk by the disk transferring means where the turntable does not overlap with the disks held in the plurality of disk support members. The playback position is a position where the turntable overlaps with the disks held in the plurality of the disk support members.
When the playback means is at the recessed position, it is positioned between the disk insertion/removal position, which is provided by disk transferring means, and disk supporting means. Thus, there is no need to prepare a space exclusively for the recessed position of playback means.
The above, and other objects, features and advantages of the present invention will become apparent from the following description read in conjunction with the accompanying drawings, in which like reference numerals designate the same elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic plan view to which reference will be made in describing the operations of the disk playback device over time.
FIG. 2 is a schematic plan view to which reference will be made in describing the operations of the disk playback device over time.
FIG. 3 is a schematic plan drawing for the purpose of describing the operations of the disk playback device over time.
FIG. 4 is a schematic plan drawing for the purpose of describing the operations of the disk playback device over time.
FIG. 5 is a schematic plan drawing for the purpose of describing the operations of the disk playback device over time.
FIG. 6 is a schematic plan drawing for the purpose of describing the operations of the disk playback device over time.
FIG. 7 is a side-view drawing of the cam means.
FIG. 8 is a cross-section drawing along the A—A line in FIG. 1 for the purpose of describing the operations of the cam means over time.
FIG. 9 is a cross-section drawing along the A—A line in FIG. 1 for the purpose of describing the operations of the cam means over time.
FIG. 10 is a cross-section drawing along the A—A line in FIG. 1 for the purpose of describing the operations of the cam means over time.
FIG. 11 is a cross-section drawing along the A—A line in FIG. 1 for the purpose of describing the operations of the cam means over time.
FIG. 12 is a cross-section drawing along the A—A line in FIG. 1 for the purpose of describing the operations of the cam means over time.
FIG. 13 is a cross-section drawing along the A—A line in FIG. 1 for the purpose of describing the operations of the cam means over time.
FIG. 14 is a cross-section drawing along the A—A line in FIG. 1 for the purpose of describing the operations of the cam means over time.
FIG. 15 is a cross-section drawing along the A—A line in FIG. 1 for the purpose of describing the operations of the cam means over time.
FIG. 16 is a cross-section drawing along the A—A line in FIG. 1 for the purpose of describing the operations of the cam means over time.
FIG. 17 is a cross-section drawing along the A—A line in FIG. 1 for the purpose of describing the operations of the cam means over time.
FIG. 18 is a cross-section drawing along the A—A line in FIG. 1 for the purpose of describing the operations of the cam means over time.
FIG. 19 is a cross-section drawing along the A—A line in FIG. 1 for the purpose of describing the operations of the cam means over time.
FIG. 20 is a cross-section drawing along the A—A line in FIG. 1 for the purpose of describing the operations of the cam means over time.
FIG. 21 is a schematic side-view drawing for the purpose of describing the operations of the disk playback device over time.
FIG. 22 is a schematic side-view drawing for the purpose of describing the operations of the disk playback device over time.
FIG. 23 is a schematic side-view drawing for the purpose of describing the operations of the disk playback device over time.
FIG. 24 is a schematic side-view drawing for the purpose of describing the operations of the disk playback device over time.
FIG. 25 is a schematic side-view drawing for the purpose of describing the operations of the disk playback device over time.
FIG. 26 is a schematic side-view drawing for the purpose of describing the operations of the disk playback device over time.
FIG. 27 is a schematic side-view drawing for the purpose of describing the operations of the disk playback device over time.
FIG. 28 is a schematic side-view drawing for the purpose of describing the operations of the disk playback device over time.
FIG. 29 is a schematic side-view drawing for the purpose of describing the operations of the disk playback device over time.
FIG. 30 is a schematic side-view drawing for the purpose of describing the operations of the disk playback device over time.
FIG. 31 is a schematic side-view drawing for the purpose of describing the operations of the disk playback device over time.
FIG. 32 is a schematic side-view drawing for the purpose of describing the operations of the disk playback device over time.
FIG. 33 is a schematic side-view drawing for the purpose of describing the operations of the disk playback device over time.
FIG. 34 is a schematic side-view drawing for the purpose of describing the operations of the disk playback device over time.
FIG. 35 is an enlarged drawing of flange 16 .
FIG. 36 is a top-view drawing of belt drive mechanism 40 .
FIG. 37 is a cross-section drawing along the B—B line of FIG. 36 .
FIG. 38 is a top-view drawing of guide mechanism 50 .
FIG. 39 is a cross-section drawing along the C—C line in FIG. 38 .
FIG. 40 is a block diagram of the control circuit of the disk playback device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following is a description of the embodiments according to the present invention of a changer-type disk playback device capable of holding five disks.
Referring to FIG. 1, there is shown a disk playback device 1 , having a five disk capacity, in which disks are absent. Arcuate disk holders 11 - 15 (only upper disk holder 11 is seen in FIG. 1, the relative positions of the five arcuate disk holders 11 - 15 are shown in FIG. 21 ), for holding up to five disks, are disposed to support the edges of disks along an angular range of approximately 180 degrees. All of disk holders 11 - 15 are identical, therefore only first disk holder 11 , at the uppermost position is described in detail.
Four flanges 16 are disposed on disk holder 11 . A round hole 17 is formed on each flange 16 . Referring momentarily also to the enlarged drawing in FIG. 35, an engagement pin 18 projects into round hole 17 .
Returning now to FIG. 1, together with FIG. 7, each round hole 17 fits over a disk holder transferring means 30 . Each disk holder transferring means 30 includes a cylindrical part having interconnected cam grooves 33 - 34 in its surface. Engagement pin 18 fits into cam grooves 33 , 34 . Disk holder transferring means 30 , which is described later, transfers disk holders 11 - 15 in a direction perpendicular to the paper surface of FIG. 1 .
Referring now to FIG. 8, a cross-section drawing along the line A—A line in FIG. 1 shows the relationship between disk holders 11 - 15 and disk holder transferring means 30 . Disk holder 11 (as well as the remainder of the disk holders) includes disk supports 23 , 24 for supporting the edges of the label side and the recording side of a disk. A base 25 is attached integrally with disk supports 23 , 24 . A flange 16 , attached to base 25 , encircles the cylindrical portion of disk holder transferring means 30 . Engagement pin 18 extends inward into round hole 17 to engage a cam groove 33 in a first cylindrical cam 31 .
Disk holder transferring means 30 is a two-piece structure which includes first cylindrical cam 31 and a second cylindrical cam 32 having identical outer diameters. Second cylindrical cam 32 is free to rotate relative to first cylindrical cam 31 . First cylindrical cam 31 is free to rotate on a pin 35 extending upward from a chassis 4 . Cam groove 33 is formed on the outer perimeter of first cylindrical cam 31 . A second cam groove 32 is formed on second cylindrical cam 32 . Engagement pin 18 of upper disk holder 11 rides in cam groove 33 . Engagement pins 18 of disk holders 12 - 15 ride in cam grooves 34 and 33 , as will be explained. Disk holder transferring means 30 , comprising first and second cylindrical cams 31 , 32 , move disk holders 11 - 15 in the vertical directions.
Referring to FIGS. 7 and 8, cam grooves 33 , 34 have an irregular pitch. Positions P 1 -P 11 indicate positions to which engagement pins 18 , and the disk carried in their related disk holders, are moved by rotation of disk holder transferring means 30 . A pitch LI separates positions P 1 -P 5 . A pitch L 2 , larger than pitch L 1 , separates positions P 5 -P 7 . A pitch L 3 , larger than pitch L 2 , separates positions P 7 -P 8 . Pitch L 1 is also duplicated to separate positions P 8 -P 11 . First cylindrical cam 31 and second cylindrical cam 32 are positioned at rotational positions in which the connecting positions between cam grooves 32 and 33 aligned. Pitch L 1 is set so that adjacent disk holders are in close contact without a separating space. This enhances compactness of the apparatus.
A spur wheel 36 is disposed on first cylindrical cam 31 . A second spur wheel 37 is disposed on second cylindrical cam 32 . Spur wheels 36 , 37 are connected to conventional cylindrical cam driving mechanisms 83 , 82 , which may be, for example, a motor or the like. Spur wheels 36 , 37 control the rotational direction and position of first cylindrical cam 31 and second cylindrical cam 32 . Disk holder transferring means 30 are disposed on each of the four flanges 16 . Spur wheels 36 , 37 are connected to each disk holder transferring means 30 so that all four disk holder transferring means 30 are driven by cylindrical cam drive mechanisms 82 , 83 in the same direction and the same rotation angle. Rotation of disk transferring means 30 moves disk holders 11 - 15 vertically within disk playback device 1 while maintaining them parallel to each other.
Referring also to FIG. 1, a disk inserted through a slit 3 in front panel 2 of device 1 is transferred to disk holders 11 - 15 by a disk transferring means. The disk transferring means is preferably a belt drive mechanism 40 on the left side and a guide mechanism 50 on the right side. Referring to FIG. 36, which shows a topview drawing of belt drive mechanism 40 , and FIG. 37, which shows a crosssection drawing along the B—B line in FIG. 36, a pair of upper and lower guide plates 41 , 42 support the edge of a disk from above and from below. A continuous drive belt 45 is disposed between guide plates 41 , 42 . Drive belt 45 passes over a driven pulley 43 and an idler pulley 44 . Driven pulley 43 is driven in a conventional manner by a conventional pulley drive mechanism 84 such as, for example, a motor or the like. A fixing block 46 is disposed within the loop of drive belt 45 to support drive belt 45 against inward flexing.
Referring to FIGS. 38 and 39, guide mechanism 50 includes an upper guide plate 51 and a lower guide plate 52 supporting the edge of a disk. A guide wall 53 between upper and lower guide plates 51 and 52 contacts the disk edge. A connecting mechanism (not shown in the drawings) allows belt drive mechanism 40 and guide mechanism 50 to move in the direction of arrows D and E in FIG. 1 . Guide mechanism 50 and belt drive mechanism 40 are connected so that when guide mechanism 50 is moved a transverse distance in the direction of arrow E, drive mechanism 40 is moved the same distance in the opposite direction, in the direction of arrow D. Thus, a center position, equally spaced between guide mechanism 50 and belt drive mechanism 40 remains in the same transverse location, during inward and outward movement of these two elements. A belt/guide driving mechanism 85 includes a motor or the like to move belt drive mechanism 40 and guide mechanism 50 in the D-E direction.
With a disk supported between drive belt 45 and guide wall 53 , drive pulley 43 is rotated counter-clockwise by pulley drive mechanism 84 . This rotates the disk clockwise while transferring it in the direction indicated by an arrow F, which is perpendicular to the D-E direction. This transfers the disk, after insertion through slit 3 in front panel 2 , into a storage position in the selected disk holder in device 1 . Also, when drive pulley 43 is rotated clockwise by pulley drive mechanism 84 , the disk is rotated counter-clockwise to transfer it in the direction of an arrow G, which is in the opposite direction from arrow F. This moves the selected disk out from the disk holder to a position where a section of the disk projects from slit 3 , where it can be grasped by a user.
Referring to FIGS. 1 and 21, a spindle motor 62 (not shown in FIG. 1 ), which rotates a turntable 61 for mounting disks, is fixed to a chassis 63 . Turntable 61 is known as a self-chucking turntable that does not require a damper for clamping the disk to turntable 61 . A feed screw 65 is rotated by a thread motor 64 disposed on chassis 63 . The rotation of feed screw 65 causes an optical pickup to be moved between an inner perimeter and an outer perimeter of a disk. A playback means includes at least turntable 61 and optical pickup 66 to perform the known operation of beaming a laser from optical pickup 66 to a disk while rotating it using turntable 61 , and then reading the reflected light to playback data recorded on the disk.
A guide rail 67 is disposed to guide optical pickup 66 to move parallel to chassis 63 . A shaft 68 is disposed at one end of chassis 63 . Chassis 63 can rotate 45 degrees counter-clockwise from the stowage position shown in FIG. 1 around shaft 68 . From this rotated position, chassis 63 can move straight in the direction of arrow F. The motion of chassis 63 is controlled by a chassis driving mechanism 86 comprising a motor or the like. Thus, shaft 68 and chassis driving mechanism 86 serve as the playback means transferring mechanism, which transfers playback means as described above.
Turntable 61 is positioned between front panel 2 and disk holders 11 - 15 . Referring to FIG. 3, when a disk 71 is supported by disk holder 11 , turntable 61 does not overlap disk 71 . Instead, it is positioned in the loading path of disk 71 between front panel 2 and disk 71 .
Referring now to FIG. 40, there is shown a block diagram for the circuit in device 1 . Processing of data from disk 71 is performed by a conventional playback circuit 91 on the data read by optical pickup 66 . The results are then output from an output terminal 92 . A control circuit 93 , comprising a microprocessor or the like, controls playback circuit 91 and controls cylindrical cam drive mechanisms 82 , 83 , pulley drive mechanism 84 , belt/guide drive mechanism 85 , and chassis drive mechanism 86 according to the timings described below.
Referring to the following drawings, the operations of this embodiment will be described below, with reference to FIG. 1 through FIG. 6, which show schematic plan views of device 1 ; FIG. 7, which shows a side-view of disk holder transferring means 30 , which controls the vertical transfer of disk holders 11 - 15 , and which shows positions P 1 -P 11 of disk holders 11 - 15 ; FIG. 8 -FIG. 20, which show the rotation of disk holder transferring means 30 ; and FIG. 21 -FIG. 34, which show side-views of device 1 and describe the motion of the disk and disk holders 11 - 15 within device 1 .
Referring to FIG. 1, in the initial state for storage of disks, drive belt 45 of belt drive mechanism 40 and guide wall 53 of guide mechanism 50 are moved to positions where their separation is smaller than the diameter of the disk. Referring to FIGS. 7 and 8, in the initial state, engagement pin 18 , on flange 16 of first disk holder 11 is positioned at position P 6 at cam groove 33 of first cylindrical cam 31 . This positions first disk holder 11 at the same height as slit 3 in front panel 2 . Engagement pins 18 , on flanges 16 of second—fifth disk holders 12 - 15 are positioned at positions P 8 -P 11 at cam groove 34 of second cylindrical cam 32 .
From this state, disk 71 is inserted into slit 3 . The insertion force causes belt drive mechanism 40 to be moved in the direction of arrow D, and guide mechanism 50 to be moved in the direction of arrow E by the same amount, resulting in the state shown in FIG. 2 and FIG. 21 . This motion triggers pulley drive mechanism 84 to turn belt drive mechanism 40 and drive pulley 43 counterclockwise, and turn drive belt 45 counter-clockwise. Disk 71 , which is supported between drive belt 45 and guide wall 53 , is rotated clockwise and transferred in the direction indicated by arrow F. Belt drive mechanism 40 and guide mechanism 50 are moved away from each other slightly, and disk 71 is moved fully into device 1 .
Referring to FIG. 3, FIG. 9, and FIG. 22, the rotation of drive belt 45 moves disk 71 into first disk holder 11 . In this state, disk 71 is stably supported over approximately 180 degrees of its edge by disk supports 23 , 24 of disk holder 11 . To play back disk 71 after it has been loaded, the belt/guide drive mechanism first moves belt drive mechanism 40 in the direction of arrow D and guide mechanism 50 in the direction of arrow E. This moves belt drive mechanism 40 and guide mechanism 50 away from disk 71 .
Then, chassis 63 is rotated 45 degrees counter-clockwise around shaft 68 from the recessed position shown in FIG. 3 to the position shown in FIG. 4 . Chassis 63 is then moved in the direction of arrow F. Chassis drive mechanism 86 transfers chassis 63 to a position shown in FIG. 5 and FIG. 23 so that the center of rotation of turntable 61 is aligned with the center of a center hole 81 in disk 71 .
From this position, first cylindrical cam 31 is rotated 180 degrees counter clockwise by cylindrical cam drive mechanism 82 while second cylindrical cam 32 is kept stationary. This moves disk holder 11 from position P 6 to position P 7 , descending by a distance of pitch L 2 .
Referring to FIG. 10 and FIG. 24, disk 71 is mounted on turntable 61 . A conventional self-chucking mechanism, not shown in the drawings, chucks disk 71 onto turntable 61 . While disk holder 11 descends, the other disk holders 11 - 15 remain stationary, since they are positioned by second cylindrical cam 32 , which remains stationary at this time.
After disk 71 is chucked onto turntable 61 , chassis drive mechanism 86 moves chassis 63 in the direction of arrow G in FIG. 5 . This moves disk 71 out of disk holder 11 so that they are out of contact with each other. This state is shown in FIG. 6, FIG. 11, and FIG. 25 . Thus, the motion of chassis 63 from FIG. 5 to FIG. 6 moves disk 71 out from disk holder 11 . Turntable 61 , chassis 63 , and chassis drive mechanism 86 together serve as disk withdrawing means.
From this position with the disk withdrawn, cylindrical cam drive mechanism 82 rotates first cylindrical cam 31 by itself 360 degrees clockwise. Disk holder 11 is raised from position P 7 , shown in FIG. 7, for a distance two times the distance of pitch L 2 to position P 5 . This state is shown in FIG. 12 and FIG. 26 .
Referring to FIG. 6, chassis drive mechanism 86 moves chassis 63 in the direction of arrow F. Seen from above, disk 71 is moved to the same position as shown in FIG. 5 . Referring to FIG. 13 and FIG. 27, however, disk holder 11 is moved vertically above the disk surface by a distance twice that of pitch L 2 . Thus, if the surface of disk 71 is shaken or if chassis 63 is suspended, disk 71 is prevented from coming into contact with other members while it rotates, even if chassis 63 is shaken vertically by an external vibration or the like.
Referring to FIG. 1 -FIG. 3, when chassis 63 is at the recessed position, turntable 61 is positioned between front panel 2 and the disks supported by disk holders 11 - 15 . As described above, disk 71 of disk holder 11 is pulled out to a withdrawn position for playback. Thus, disk holders 11 - 15 must remain separated from front panel 2 , with a prescribed distance between the disk holders and front panel 2 .
However, in this embodiment, chassis 63 is disposed in this space made necessary for other reasons. Turntable 61 , when it is at the recessed position, is disposed in the flat region formed by the transfer of disk 71 from FIG. 2 to FIG. 3 at a position where it does not overlap with the disks in disk holder 11 - 15 . Thus, there is no need for a separate space for the recessed position of turntable 61 . This allows smaller lateral (the D-E direction in FIG. 1) and depth (the F-G direction in FIG. 1) dimensions for device 1 .
The following is a description of the procedure for storing another disk 72 in disk holder 12 after the playback of disk 71 described above has been completed. Referring to FIG. 5, FIG. 13, and FIG. 27, after playback of disk 71 is completed, chassis drive mechanism 86 moves chassis 63 in the direction of arrow G in FIG. 5 .
Referring to FIG. 6, FIG. 12, and FIG. 26, disk 71 is moved to the withdrawn position. Then, disk holder 11 is lowered from position P 5 to position P 7 shown in FIG. 11 and FIG. 27 . This is achieved by cylindrical cam drive mechanism 82 rotating cylindrical cam 31 360 degrees counter-clockwise while cylindrical cam 32 remains stationary. The rotation of cylindrical cam 31 aligns the height of disk holder 11 with disk 71 .
Chassis drive mechanism 86 then moves chassis 63 in the direction of arrow F. Referring to FIG. 5, FIG. 10, and FIG. 24, the edge of disk 71 are inserted in disk holder 11 . Then, cylindrical cam 31 is rotated 180 degrees clockwise, moving disk holder 11 from position P 7 shown in FIG. 7 to position P 6 . Referring to FIG. 9 and FIG. 23, disk 71 is raised up and the chucking between disk 71 and turntable 61 is released. Chassis drive mechanism 86 moves chassis 63 from the playback position shown in FIG. 5 to the position shown in FIG. 4 to a recessed position shown in FIG. 3 where it does not obstruct the vertical motion of the disk.
Then, cylindrical cam drive mechanism 82 rotates cylindrical cam 31 180 degrees counter-clockwise. Referring to FIG. 10, disk holder 11 is first brought back to position P 7 . Then, cylindrical cam drive mechanisms 82 , 83 rotates both cylindrical cam 31 and 32 360 degrees clockwise. This causes disk holder 11 to move from position P 7 to position P 5 , disk holder 12 from position P 8 to position P 7 , disk holder 13 from position P 9 to position P 8 , disk holder 14 from position P 10 to position P 9 , and disk holder 15 from position P 11 to position P 10 (see FIG. 7 ).
Referring to FIG. 14, cylindrical cam drive mechanism 82 is used to rotate cylindrical cam 31 180 degrees clockwise without rotating cylindrical cam 32 . This causes disk holder 12 to move from position P 7 to position P 6 (see FIG. 7 ). The height of disk holder 12 is aligned with slit 3 in front panel 2 . This state is shown in FIG. 15 and FIG. 28 .
Referring again to FIG. 1, drive belt 45 of belt drive mechanism 40 and guide wall 53 of guide mechanism 50 are moved to a separation distance smaller than the diameter of the disk. Referring to FIG. 16 and FIG. 29, disk 72 is then loaded through slit 2 and moved inward until disk 72 is supported in disk holder 12 in the same manner as described above.
Then, when disk 72 is to be played back, chassis 63 is moved (FIG. 30 ), and first cylindrical cam 31 is rotated 180 degrees counter-clockwise without rotating second cylindrical cam 32 . This causes disk 72 to be chucked to turntable 61 (FIG. 17, FIG. 31 ). Then, chassis 63 is moved so that disk 72 is withdrawn from disk holder 12 (FIG. 18, FIG. 32 ). First cylindrical cam 31 is rotated 360 degrees clockwise without rotating second cylindrical cam 32 so that disk holder 12 is moved to position P 5 in FIG. 7 and disk holder 11 is moved to position P 4 (FIG. 19, FIG. 33 ). Then, chassis 63 is moved, resulting in the playback state (FIG. 20, FIG. 34 ).
As described above, first cylindrical cam 31 can be rotated without rotating second cylindrical cam 32 . It is also possible to rotate both by the same angle. When a disk is being played back, the disk holder corresponding to the disk to be played is positioned at position P 5 (see FIG. 7 ). In order return the disk after playback to the disk holder, the disk holder is moved to a position P 7 , where its height is aligned with the playback position. During this operation, cylindrical cam 32 is not rotated. Similarly, in order to play back a loaded disk, the disk holder is moved from position P 6 , where its height is aligned with that of the loading surface, to position P 7 , which is aligned with the chucking position. In this case, only first cylindrical cam 31 is rotated counter-clockwise.
The following is a description of the sequence that takes place when disks are in all the disk holders, playback of disk 71 mounted in disk holder 11 has completed, and the disk mounted in fourth disk holder 14 , the fourth disk holder from the top, is to be played back. In this case, cylindrical cams 31 and 32 are both rotated clockwise. Disk holder 11 is moved to position P 3 , disk holder 12 to position P 4 , disk holder 13 to position P 5 , disk holder 14 to position P 7 , and disk holder 15 to position P 8 (see FIG. 7 ). Then, cylindrical cam 31 moves disk holder 14 from position P 7 to position P 6 , and then to position P 7 and then to position
By separating cylindrical cam 31 and 32 , the disk holder containing the disk to be played back can be moved to position P 7 , where it is aligned with the playback position. Then, the disk holder can be moved to position P 5 without the need to move another disk holder below this disk holder or the disk contained in the lower disk holder. Thus, the disk to be played back can be given adequate clearance below it.
In the playback means transferring mechanism of the embodiment described above, turntable 61 , optical pickup 66 , and the like are disposed on chassis 63 , which is rotated 45 degrees counter-clockwise and then moved. This causes turntable 61 to move from the recessed position where it does not overlap the disk to the disk playback position. However, the present invention is not restricted to this, and the playback means transferring mechanism can use different methods to move the playback means.
Furthermore, in the embodiment described above, the playback position of the disk is coplanar with the holding position of the disk. However, the present invention is not restricted to this. The playback position can also be the position shown in FIG. 6, FIG. 11, and FIG. 25 where the disk is withdrawn from the disk holder.
In the embodiment described above, the disk holder transfer mechanism includes cylindrical cams 31 , 32 , which engage disk holders 11 - 15 . However, the present invention is not restricted to this, and other mechanisms that can perform similar operations can be used.
In the embodiment described above, disk transferring means includes drive belt 45 , which engages with the edge of the disk. However, the present invention is not restricted to this. For example, a pair of rollers that support the recorded surface and the label surface of the disk can also be used.
In the embodiment described above, the disk support member includes a disk holder that supports the edge of the disk over a range of approximately 180 degrees. However, other structures can be used, such as a plate on which the disk is mounted. In this case, if the disk is mounted on the plate so that the recorded surface of the disk faces the plate, the plate and the plate below it are lowered after the chucking operation. A first and a second disk support member transfer mechanism must be structured so that during this lowering operation, the plate above the mounted plate does not come near the plate on which the disk is chucked.
During disk playback, the disk and the disk support member are moved away from each other by the chassis drive mechanism to move the disk, which is chucked to the turntable. However, it would of course also be possible to use the transferring means that transfers the disk into the device to move the disk to the withdrawn position.
As described above, according to the present invention, a playback means is disposed so that a recessed position, where the turntable does not overlap with the disks held inside a plurality of disk supporting members, is positioned inside a space for withdrawing a disk, which is provided to move the disk away from the disk supporting member. Thus, there is no need to provide a separate space for the recessed position of the playback means.
As described above, playback includes moving disks between stored positions in disk holders and the playback position. A single-play mode is also possible. Referring to FIG. 34, in single-play mode, even if all disk holders are full, or if storage of a disk to be played is not desired, disk 72 may be moved from slit 3 directly to the play position, where it is chucked and played. At the conclusion of play, disk 72 is moved directly outward through slit 3 without residence time in a disk holder.
Having described preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims.
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A disk playback device provides a space above and below a selected disk held in a disk holder. A turntable and optical pickup reside within the space. The turntable is moved inward in the space from a storage position to chuck, and withdraw, the selected disk from its disk holder to a playback position in which the axis of the turntable is within the outline of disks stored in disk holders. The storage position places the axis of the turntable outside the outline of disks stored in the disk holders. In a single play mode, a disk not stored in a disk holder is moved directly from outside the disk playback device to the playback position where it is chucked and played. On conclusion of single play, the disk is transported out of the disk playback device without being resident in a disk holder.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 593,851 filed Oct. 5, 1990 by the same inventor herein and entitled "Composite Gas Filtering Unit"now U.S. Pat. No. 5,120,331, in turn is a continuation-in-part of application Ser. No. 474,989 filed Feb. 6, 1990 by the same inventor herein and entitled "Composite Gas Filtering Unit", now abandoned.
FIELD OF THE INVENTION
The present invention relates in general to an air filtering unit as well as a method for removing contaminants from the air. Specifically the invention relates to a filtering unit and its filter cartridge and a method that is effective and efficient in the filtration of a wide range of particle sizes in a unitized structure that uses an efficient and direct transfer of air from the impeller into the singular filter module. Further, the air handling system is an integral part of the filtering module and adds to the efficiency of the filtration process and the filtering module is an integral part of the air handling system and adds to the efficient use of electric power.
SUMMARY OF THE PRIOR ART
Particulate contaminants are usually removed from air by three principal types of mechanisms: mechanical devices, electrostatic precipitators and media filtration. The appropriate use for each mechanism is, in general, based on the particle size, the quantity of particulates to be removed and the percentage of particles that are required to be removed.
Normally, mechanical devices are most frequently used for the larger sized particles, usually greater than 10 microns in diameter and where a large volume of particulate matter is to be removed. With mechanical devices, in general, the efficiency of removal for particles 5 to 20 microns in size is about 50 to 80 per cent but increases to 80 to 95 per cent for 15 to 50 micron particles. With mechanical devices static pressure does not substantially increase as the system loads with the captured particulate material. The resulting low energy cost is the primary advantage of mechanical devices
Because electrostatic filters require sophisticated maintenance and also generate ozone, they are not practical in a portable filtration system designed to return filtered air to the room.
Media filtration is highly effective in removing both large and small particles. Not only can the large particles be removed but particles of less than 1 micron in diameter can be removed with an efficiency up to 99.99 percent. The main disadvantage of media filters is that as the filter loads with particles, the pressure required to move the air through the system increases, with a concomitant increase in the energy requirement.
Most portable filtration units use media filtration to remove both large and small particles. In general, these systems contain a blower and filter enclosed in the same housing. They usually return the filtered air back into the room and operate independent of the buildings ventilation system.
Many industrial processes, such as welding and grinding, generate harmful airborne particulates. The ventilation system of most buildings is not designed to remove these additional particles in a safe and efficient manner; therefore, it is generally recommended that these operations be performed in areas of the building where hoods or canopies can be installed to capture and duct these airborne particulates to a removal system. A problem arises when maintenance welding and or grinding must be done in a location where a canopy and exhaust system can not be located for physical or economic reasons. One method to solve this problem is to use a capture-at-the-source portable air filtration unit. These self contained units trap and filter the airborne particulate material, returning clean air back into the work area. Portable source capture filtration units, in addition to allowing work to be done in areas where the building ventilation system is not adequate, save energy by not exhausting conditioned air from the workspace.
Currently available portable source capture air filtration units use the same type of filters and blower motor components designed for permanent building ventilation systems. Buildings are designed with dedicated space to use these components properly, but adequate space is not available in a compact portable source capture systems, as discussed below.
Building ventilation systems may utilize a blower wheel enclosed in a scroll housing designed to direct and push the air through long duct runs. Scroll blower housings gather and direct this air through a small defined discharge area of the blower housing, which usually is about the same diameter as the duct. The air is forced out of the blower housing under the high velocity needed to deliver the air throughout a building's duct system. A major problem of incorporating a scroll blower housing in a portable source capture unit is that it doesn't have any space for a straight duct run at the discharge end of the blower housing. The air from the blower wheel is thus not allowed to smooth out and become non-turbulent. The straight duct length required is a minimum of two times the diameter of the blower wheel; without this the blower discharges turbulent air causing the system to run inefficiently with an increase in both noise level and static resistance.
Most ventilation systems use dry media filters which expose a large surface area of filter medium to the air stream. The filter medium is contained in a rigid frame, allowing the filter to be sealed within a flow-through housing. Long smooth transitions are used in building ventilation systems to keep the airflow non-turbulent, both as it enters and leaves the filter bank. The major problem with portable source capture air filtration systems is, in order to make the unit as small as possible, there is no room for these transitions to and from the filter. Source capture systems discharge air from the scroll blower housing directly at the filter surface. To overcome resistance caused by this inefficient placement, more energy must be used to achieve the desired airflow rates.
Pre-filters and final filters used in both portable source capture air filtration systems and building ventilation systems expose essentially a flat surface to the rapidly flowing airstream. This flat surface accounts for a large part of the static resistance present even with a new filter.
Some portable source capture air filtration units use vacuum cleaner motor blowers which, while capable of overcoming high static pressures, are not effective in providing the volume of air needed in all but the smallest portable capture canopy. In addition, vacuum cleaner motors are loud; use brushes that spark and need frequent changing; and have high electrical consumption requirements. They often overload electrical outlets, especially when used in conjunction with other electric maintenance equipment, such as the welders that are commonly used.
The size of airborne particles found in welding and grinding operations range from sub-micron aerosols of welding fume to particles large enough to be easily seen. Rigid frame media filters are usually manufactured from one type of medium designed to remove only a selected range of particle sizes. Filters designed to remove and hold large particles are not efficient at removing sub-micron particles or aerosols. A filter designed to remove sub-micron aerosols can also remove large particles but these larger particles will rapidly load the filter, markedly shortening its life. To solve the problem of removing a wide range of particle sizes from one airstream, it is common to use two or more filters in series. The first functions as a high capacity prefilter designed to capture the larger sized particles. The prefilter extends the life and protects the final filter which removes the smaller and sub-micron particles. Based on the contaminant load, the prefilter and the final filter are selected to obtain the degree of cleanliness required to return the air to the work space.
Dry media prefilters and dry media final filters are made from a variety of materials. The prefilters are usually flat sheets of rough spun glass, open cell foams, expanded metal or screens. Final filters are usually extended surface area or pleated glass fibers, wet-laid cellulose paper or ultra-fine glass fiber paper commonly called HEPA's. The loading characteristics of both prefilters and final filters are similar: as the media collects particles from the air flowing through the filter, the resistance to the airflow increases. Portable source capture systems currently used for welding require a very efficient final filter to remove the submicron sized welding fume and also require frequent changing of the prefilter to handle the tremendous amount of dirt and debris associated with welding. Currently available portable systems require the user to frequently check and clean or change the prefilter. This usually is not done and the airflow through the unit may become obstructed. To avoid the nuisance of changing the prefilter, it is not uncommon for the user to simply remove it, substantially shortening the life of the final filter.
SUMMARY OF THE INVENTION
The present invention is directed to a comprehensive particulate filtering unit in which the filter includes bag like elements secured to infuser members which surround a blower and motor, designed to operate and be used as a compact portable unit without a pre-filter More specifically, the present invention includes using rectangular sheets to form flexible, coilable, permeable bag like filter medium elements which are attached at equally spaced intervals to nonpermeable rigid and smooth airflow infuser wings. The infuser wings, with the bags of attached filter fabric, are circularly aligned and incorporate a central open area that houses the air moving impeller wheel. The wings are spaced apart to provide airflow channels for the direct infusion of the particulate laden air from the impeller wheel into the air filtering bags. The bags are formed by using sheets of filtering material folded back upon itself and attached to the infuser wings. When the edges of the filter fabric are sealed, multiple filtering bags are formed around the central manifold. The central manifold is defined by the inner edges of the infuser wings which in turn define the outer portion of the central open area. Spacers are employed inside the filtering bags between the inside adjacent layers of filtering fabric to physically separate same and support the air flow bags in the correct spatial relationship. Spacers are also employed on the outside of the filtering bags between outside adjacent layers of the filtering fabric. These outside spacers physically separate and help maintain the structure of the filtering bags. They also provide an air flow channel for the air leaving the filtering bags. The filtering bags, with both the inside and outside spacers, are wound around the central manifold forming curved filtering bags. In addition to separating the layers inside the filtering bags, the inside spacers are placed to maximize the capture of particles by settling and inertial impaction. This serves the same function as a prefilter, but differing by not having to be changed. This is because, as the spacers load and trap more particles, the static resistance of the unit does not increase since the air is not dependent on passing through a membrane pre-filter. Spacers located both inside and outside of the bag can also be made from adsorptive, absorptive, chemisorbtive or reactive agents to remove gases and odors. An additional sheet of particulate filtering material is optionally employed around the assembly of wound bag filters as a final filter and protective wrap. It allows for ease in handling and also enhances the appearance of this package. The complete filter cartridge comprised of the airflow infuser wings, the filtering media bags, both types of spacers and the final particulate wrap are potted into opposed end caps. This seals the edges of the filtering fabric from which the bags are formed. In addition, potting provides structural and pneumatic integrity to the filter cartridge. The method of the invention relates to filtering ambient air by utilizing a blower in the housing in which a plurality of infuser wings having a curvilinear face are spaced to conform the air discharged from the blower into curvilinear spiral-like paths. Thereafter, the method contemplates encapsulating the end portions of the infuser wings with pairs of filtering material closed on both edges and end portion to define a bag; and positioning spacers variously to optionally space the exterior and interior portions of the bags.
OBJECTS OF THE INVENTION
In view of the foregoing, it is an object of the present invention to provide a particle filtration unit and method of filtering particles that utilize a combination of particle filtration practices and theories in a singular structure.
Another object of the present invention is to provide a particle filtering unit that can remove a wide range of particle sizes in a singular structure.
Another object of the present invention is to provide a singular particle filtering unit that contains a very efficient final filter with its own built in spacers which function as prefilters and where these spacers do not substantially increase the pressure drop of the system as they load and protect the final filter and preclude monitoring or changing of prefilters.
Another object of the present invention is the efficient use of a blower wheel without a scroll housing where the blower wheel aids in the filtration process and where the airflow infuser wings of the filter aid in the efficient flow of air from the blower into the filter.
Another object of the present invention is the efficient use of a portable filtering device in which the blower and the filter are an integrated and matched system, eliminating the need for air flow plenums or transition structures. Placement of all filtering and air handling components are calculated, thus minimizing static pressure losses and allowing the device to be highly energy efficient.
Another object of the present invention is the placement of the filtering structure around the blower and motor to effectively muffle blower and motor noise and provide a compact and lightweight design without adversely effecting its efficiency.
A further, but not final object, is the provision of a particle filtration unit that contains a minimum of components, several of which have multiple functions, and a device that is easily maintained in various environments by both skilled and unskilled personnel.
A further object, is the provision of a portable unit that does not require the additional housings traditionally used to hold and seal a blower and multiple filters. Typical units weigh between 15 and 35 pounds, and thus can be easily carried by one person.
Another object of the present invention is to provide a singular filtering unit in which the bags, spacers, and end wrap can easily be constructed from a variety of materials depending on the nature of the contaminant. The bags, spacers, and end wrap can also be manufactured from materials that remove odors and gases, as well as particles.
A further object, is the provision of a portable unit that does not require the additional housings traditionally used to hold and seal a blower and multiple filters, thus eliminating sources of air leakage.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and advantages of the present invention will be readily understood as the following description proceeds, taken in conjunction with the following drawings, in which:
FIG. 1 is a perspective view of the filtering unit, illustrating the outer casing, and a capture canopy;
FIG. 2 is a transverse sectional view of the unit taken across the center of the unit of FIG. 1 but in enlarged scale;
FIG. 3 is an exploded isometric view of the central manifold structure, motor and blower, illustrating the view of a final filtering media without the end caps and with the outside spacers and inside spacers attached;
FIG. 4 is the unfolded view of part of the final filtering fabric material attached to an airflow infuser wing and showing placement of the inside spacers;
FIG. 5 is a perspective view of a composite filter cartridge;
FIG. 6 is a showing of an alternative embodiment illustrating the use of an off-center air intake forming a spark arrester; and
FIG. 7 is taken from the same section as FIG. 6 but without the spark arrester.
DESCRIPTION OF PREFERRED EMBODIMENTS
In broad outline, the illustrative embodiment of various phases of the invention include a plurality of bags surrounding an air handling impeller wheel that can operate efficiently without being placed in a scroll housing, e. g., backward inclined, which is positioned in a central core. Infuser wings in terms of their length, curvature and alignment are matched to the impeller wheel to assure that controlled air enters the bag filters.
The particulate laden air is drawn into the filtering unit by negative pressure. To minimize the generation of static resistance the principal directional change of the air stream occurs at the impeller wheel. The air is turned and pushed out by the impeller wheel under positive pressure into the manifold which, in this invention, comprises the airflow infuser wings. These efficiently direct and curve the air into the air filtering bags with minimal loss of pressure.
The largest particles thrown out by the impeller wheel do not turn with the curved flow of air. Instead they hit the airflow infuser wings, falling and settling to the bottom of the filter where they are trapped by the spacers specially angled and located at the bottom of the bags. This action is similar to a mechanical filtering gravitational settling chamber and acts as a prefilter for very large particles.
Many large particles turn with the airstream through the airflow infuser wings and impact on the wall of the filter bag in the pathway of the curving air stream. This action is similar to a mechanical filtering centrifugal separator and also functions as a prefilter for these large particles.
Both of these methods of mechanical filtration are utilized due to the central placement of the impeller wheel. The air continues to follow its spiral path as it flows through the bags and around the spacers. Medium and large sized particles can not negotiate the continually turning path that the air makes. The momentum of each particle will determine its path and whether it will impact into the filtering spacers or the walls of the filter bag. This type of inertial impaction along with the settling chamber effect and centrifugal separation action serve the function of a prefilter but have the distinct advantage of not having to be changed or monitored.
Thus, filtration practices are utilized which remove the majority of medium, large, and very large particles without increasing the pressure drop of the filter as it loads. The air which now contains smaller particles travels through the remaining area of the bag filters. In practice, the proximal portion of the bag filters with its spacers load with the larger particles, while the remaining distal portions remove the smaller particles.
More specifically, the preferred embodiments of the present invention are best understood by referring to FIGS. 1-7 of the drawings, like numerals being used for like and corresponding parts of the various drawings. FIG. 1 is a complete portable source capture air filtration unit 11. A fume/particulate capture canopy 12 is supported by an adjustable flexible air duct 13. A metal goose-neck microphone stand is placed inside an equal length of air hose 14 forming the air duct 13 which connects the fume/particulate capture canopy 12 of the unit 11.
A plurality of airflow infuser wings 17 are employed to form a central manifold structure 18. These wings 17 are nonpermeable, and typically formed from a smooth plastic material such as polypropylene. The infuser wings 17 have a slight curvature. For details of formulae for generating the curvature of the infuser wings, see patent application Ser. No. 593,851. The inside lengthwise edge 19 of each infuser wing 17 is aligned at a substantially equidistant intervals around the inside of the central manifold 18. The outside lengthwise edge 20 of each infuser wing 17 is aligned so as to form a circle with a larger diameter then the interior circle, thus forming the outside of the central manifold structure 18. The central manifold structure 18 is the start of the airflow channels 21 which lead into the filter bags 24. The filter bags 24 are attached to the central manifold structure 18 at the outside lengthwise edge 20 of the airflow infuser wing 17. The infuser wings 17 are equally vertically spaced and attached with staples or hot melt glue to the sheet of particle filtering media 22.
The length of filtering media 22 spaced between the airflow infuser wings 17 determines the length of the filtering bags 24. The filter bag 24 is formed as the filter media is folded back and attaches to the next outside edge 20 of the airflow infuser wing 17. The dimensions of the filtering media 22 may vary considerably according to: the nature and concentration of the particulates; the volumes of air to filtered; and the quantity and configuration of the filtering spacers 23. The particle filtering medium 22 is typically easily coilable, flexible and gas permeable. One example is 1/4 to 1/2 inch thick fiberglass filter medium; however, filters have been made from HEPA filter medium, blown synthetic microfiber medium, or carbon impregnated fabric. Any filter medium or combination thereof found in pleated box filters or flexible bag filters can be used.
Inside spacers 23 are employed to physically separate the inside adjacent layers of the filtering bags 24 allowing air to continue on the path initiated by the airflow infuser wings 17. Outside spacers 26 are used to physically separate the outside adjacent layers of the filtering bags 24. Both inside and outside spacers can also be gas filtering by utilizing various combinations of adsorptive, absorptive, chemisorptive or reactive agents. The complete filter comprised of filter bags 24 with attached spacers 23 and 26 are spirally wound around the central manifold structure 18. The filter bags are wound around the central manifold structure 18 to keep the assembly compact. An additional sheet of filtering material is utilized as a filter protective wrap 28 around the outside of the assembly of wound filter bags 24. This protective wrap 28 is typically a prefilter material with a scrim or screen affixed to its outer layer.
The complete filter comprising the plurality of airflow infuser wings 17 , the bag filters 24 with the corresponding spacers 23 and 26 and the filter protective wrap 28 are potted into end caps 29. The end caps are nonpermeable and solid and may be formed by an appropriate sealing or potting material such as a hot melt glue or an epoxy. The structural integrity of the filter cartridge is now insured with the fixed placement of the airflow infuser wings 17. Further, the end caps 29 seal the top and bottom edges of the filter media 22 forming and sealing the bag filters 24 and preventing unfiltered air from leaking out of the cartridge.
A backward inclined impeller wheel 31 is situated in the center core surrounded by the central manifold structure 18. The impeller wheel 31 is attached to a motor 32 which is typically located in the center core below the impeller wheel 31. The impeller wheel 31 and the motor 32 are secured to the base of the outer structural housing 33.
The impeller wheel 31 directs the particulate laden air at the central manifold structure 18. The airflow infuser wings 17 of the central manifold structure 18 are formed to the optimal curve that most efficiently collects, turns and discharges smooth air into the wound around filtering bags 24. The filtering bags 24 are wound in order to keep the filter cartridge compact and allow for centrifugal filtering actions to take place. Large particles hit the airflow infuser wings 17 and fall to the bottom of the filter bag 24 where they are trapped by the inside spacers 34 located at the bottom of the bags. These are typically a cut strip of polyester prefilter material hot melt glued to the filter media 22 at the proper angle. Additional large particles are impacted into the filtering medium 22, primarily at the centrifugal impaction zone 35. Particles are impacted into the other spacers 23 primarily at the inertial impaction zone 36. These other inside spacers are of the same material and also hot melt glued to the filtering media 22 at the proper angle and alignment.
In the embodiment shown in FIG. 6, it will be seen that the canopy 12 receives air which goes into an upper plenum chamber 16 and impacts on a spark arrester 25 and thereafter rolls over the air intake 15 into the impeller wheel 31 as driven by the motor 32. The air thereafter passes through the infuser wings 17 and filter cartridge as previously described.
METHOD
The method of the invention relates to filtering particulates from ambient air by utilizing a blower in the housing in which a plurality of infuser wings having a curvilinear face are spaced to conform the air discharged from the blower into curvilinear spiral-like paths. Thereafter, the method contemplates encapsulating the end portions of the infuser wings with pairs of filtering material closed on both edges and end portion to define a bag; and positioning spacers variously to optionally space the exterior and interior portions of the bags.
Although particular embodiments of the invention have been shown and described in full here, there is no intention to thereby limit the invention to the details of such embodiments. On the contrary, the intention is to cover all modifications, alternatives, embodiments, usages and equivalents of the subject invention as fall within the spirit and scope of the invention, specification, and appended claims.
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A comprehensive particulate filtering unit in which the filter includes bag like elements secured to infuser members which surround a blower and motor, designed to operate and be used as a compact portable unit.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an improved furnace roller to advance a metallic workpiece through a reheat furnace and more particularly to a tire construction and securement structure for mounting the tire to an arbor which includes the provision of a core buster for cooling of the arbor.
2. Description of Related Art
Furnace rollers are used to support and guide metallic workpieces through a furnace. U.S. Pat. No. 4,991,276 discloses of one type of furnace roller that is applicable to the present invention. The furnace roller includes a plurality of wheel members welded at spaced apart locations along to an outer tubular member used to form the arbor. The wheel member includes inner hub sections formed of a plurality of angularly spaced-based members. Each base member has a toe portion and head portion separated by a gap extending in the direction of the arbor. A short length of weld at the lateral side of each toe portion interconnects the toe portion to the outer tubular member. The head portion is unattached and free to slide relative to the outer tubular member of the arbor in response to the effect of differential expansion caused by a relatively large thermal gradient in the roller and the bending effect by the weight of the strip upon the roller. A web portion extends from each base member. Each web portion is angularly separated from an adjacent web section by an elongated open space that projects outward slightly short of the inner radius of the rim. The open space further serves to reduce and impede heat flow to the arbor by way of the base member. Apertures are provided in the web portion to provide passage for metal rods used to secure a complement of thermally-insulating discs between the wheel members and thereby provide thermal protection from the high temperature environment in the furnace.
A different furnace roller construction uses castable refracting to form the insulation barrier between wheels is initially covered with a thermal resistant insulating material as disclosed in U.S. Pat. No. 5,230,618. When the roller is used in furnaces operating at approximately 2000° F. or higher, the insulating material can be damaged and separate from the roller in the vicinity of a tire the edge by a terminal or leading edge of a strip. Exposure of the tire's radial sides to the furnace operating temperatures causes thermally induced metal fractures to occur between the open spaces and apertures in the wheel hub. When multiple fractures between the open spaces and apertures the fractures lead to the separation of the rim from its hub.
Research into the causes of the metal fracture led to the apertures and constructing the head portions of the base members flush with the hub. With furnaces operating at temperatures above 2100° F., this design results in occasional fracturing across the tire's rim without protective insulating material. One particular thermal study of this furnace roller in a 2100° F. atmosphere with the toe portion of the base member welded to a water-cooled shaft revealed the following conditions. The rim temperature was 2026° F. with a radial displacement of the rim equal to 0.1228-inch on its radius. The temperature of the toe portion at the weld connection to a watered-cooled shaft was 400° F., with a displacement of 0.008-inch and a bending stress in the base member of 76,212 psi. With this configuration, the 400° F. base members restrain the wheel rim from expanding. This phenomenon accounts for the rim fractures observed in actual furnace operations. An advantage exists, therefore, for a tire that will permit the rim to expand to prevent rim fractures from occurring when operating in an environment with temperatures above 2000° F. The use of weld metal to establish a metal-to-metal connection between the wheels and the arbor of a furnace roller when eliminated will permit the wheel's rim to expand when operating in the extreme temperature environment to which reference has been made.
It is therefore an object of the present invention to provide an improved tire that eliminates the base member with direct toe connection of the tire to the shaft of the furnace roll and allows the rim of the tire to expand to prevent fractures from occurring when operating in the extreme temperature environment to which reference has been made.
It is another object of the present invention to provide improved furnace rollers using the improved tires of the present invention that will allow operation of the rollers in the extreme temperature environment to which reference has been made for long periods of operating times without fracturing of the tires.
BRIEF SUMMARY OF THE INVENTION
More particularly according to the present invention there is provided a cast tire for use in a furnace roller to support and advance a workpiece in a furnace, the cast tire including, a rim portion having an annular peripheral tire face to engage and support a workpiece during conveyance thereof in a heated chamber of a furnace, and a continuous web portion having an inner most annular surface contiguous with the outer rim portion, the inner most annular surface defining a load-bearing seat for load-bearing support by an axle, the continuous web having oppositely directed radial face surfaces forming boundaries of angularly spaced pockets bounded by radial edges generally perpendicular to the inner most annular surface, the radial edges being elongated to form moment arms to transmit torque from an applied force by an axle to rotate the continuous web and the rim portion for conveying a workpiece.
The present invention further provides a furnace roller for supporting a workpiece in a furnace, the furnace roller including a rotatable arbor, a number of tires having substantially equal radial extending rim portions at axially spaced apart sites along the arbor for engaging a workpiece, each tire further comprising a continuous web portion having an inner most annular surface contiguous with the outer rim portion, the inner most annular surface defining a load-bearing seat for load-bearing support by an axle, the continuous web having oppositely directed radial face surfaces forming boundaries of angularly spaced pockets bounded by radial edges generally perpendicular to the inner most annular surface, the radial edges being elongated to form moment arms to transmit torque from an applied force by an axle to rotate the continuous web and the rim portion for conveying a workpiece, a plurality of anchor members seated in the pockets and drivingly secured to the arbor for rotation by the arbor; and thermal insulation supported by the arbor to provide a thermal barrier to extend radially between the tires, the insulation having a thickness terminating with an outer surface extending radially at least a substantial portion but less than the entire radii of the tires.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
For the purpose of illustrating the invention, there is shown in the drawings a form which is presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.
FIG. 1 is a plan view of a radial side of the tire of the present invention;
FIG. 2 is a sectional view taken along lines A—A of FIG. 1;
FIG. 3A is a plan view of the pocket used with the tire of the present invention;
FIG. 3B is a sectional view taken along lines B—B of FIG. 3A;
FIG. 4 is a cross sectional view of the tire of the present invention installed on the arbor of a furnace roller;
FIG. 5 is an elevational view illustrating the furnace roller of the present invention in its operative state forming part of a tunnel furnace;
FIG. 6 is an elevational view partly in section illustrating spaced apart tires on an arbor for the furnace roller of FIG. 5;
FIG. 7 is a sectional view illustrating final assembly of the furnace roller assembly depicted in FIG. 5;
FIG. 8 is a sectional view taken along lines VIII—VIII of FIG. 7; and
FIG. 9 illustrates an elongated core buster forming part of the furnace roller shown in FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
A furnace roller of the present invention embodies a novel design for a cast wheel or tire shown in FIG. 1 and 2. The tire 10 is cast from a thermally dimensionally stable and heat-resistant metal material such as a high temperature nickel-chrome alloy or cobalt-chrome alloy, or the like, to minimize thermal effects of operating in a high temperature environment at temperatures above 2000° F. The tire 10 includes an enlarged outer rim portion 15 providing an annular peripheral tire face surface 17 for engaging and supporting a metal workpiece such as a strip during conveyance of the workpiece in the heating chamber of a furnace particularly a tunnel furnace.
The cast tire 10 essentially also includes a thinner, as compared to the thickness of rim portion 15 as shown in FIG. 2, a continuous web portion 20 continuous with the rim portion 15 . The continuous web portion 20 has an inner most annular surface 22 appearing as a central opening and a load-bearing seat for load-bearing support by an axle, preferably an arbor with the tire forming one of a number of such tires on an arbor as part of a furnace roller, as will be described in greater detail hereinafter. The continuous web 20 is further defined by oppositely directed radial face surfaces 24 and 26 each containing angularly spaced pockets 30 bounded by radial edges 31 generally perpendicular to the inner most end annular surface 22 . The radial edges 31 of each pocket are elongated to form moment arms to develop torque from an applied force to an axle to rotate the continuous web portion 20 and thereby also the rim portion 15 for conveying a workpiece. The pockets 30 are used to seat anchor members 40 as further described below. The pockets 30 are axially spaced around the annular surface 22 on each radial side of the hub portion 20 . In the preferred embodiment, all pockets 30 are substantially equal in size and the axial spacing between all adjacent pockets on each radial side of the hub portion are equal. Furthermore, in the preferred embodiment, pockets on the opposing sides of the hub portion 20 are axially offset by a spacing substantially equal to half the axial spacing between adjacent pockets. The pockets 30 for the opposing side of the cast tire 10 are shown in phantom in FIG. 1 . In the preferred embodiment shown in FIGS. 1 and 2 with three pockets on each of the two sides of the tire, the slots are spaced apart by 120 degrees and radially offset from each other by 60 degrees. Each pocket 30 has an arcuate top surface 32 between the radial edges 31 .
As shown in FIGS. 3A and 3B, an anchor member 40 , preferably of the same material as the cast tire 10 , has the form defining a circular ring sector with inner surface 42 and outer boundary surface 41 defined by radii one of which conforms to the radius of the outside diameter of an arbor used to support the tire and the other radius of outer boundary surface 41 conforms to the radius of the arcuate top surface 32 of pocket 30 . The arcuate bottom surface 42 of the anchor member substantially conforms to the curvature of the radial surface defining the central opening of the hub portion of the tire. The rear top edge 48 of the anchor member is beveled to properly seat against the radial edges 31 of the pocket. The radial face surfaces forming boundaries of the angularly spaced pockets have their radial edges elongated to form moment arms to transmit torque from an applied force by the axial to rotate the tire and thus also the furnace roller. The front bottom edge 47 of the anchor member is beveled to accommodate the composite zone of a weld as further described below. Opposing end surfaces 46 of the anchor member are flat and join top surface 41 in an arcuate surface conforming to the shape of the pocket 30 . The anchor member's opposing front and back sides 43 and 44 , respectively are substantially flat. The overall dimensions of an anchor member 40 are such that it conforms to fill the space defined by pocket 30 with the following exceptions. As best shown in FIG. 4, the overall width of the anchor member 40 from front side 43 to back side 44 is longer in width than the depth of the pocket 30 and substantially equal to the width of the rim portion 15 of the tire. Additionally, a clearance gap 59 exists between the top surface 32 and rounded inner edge 34 of the pocket 30 , and the outer boundary surface 41 and rear top edge 48 of the anchor member 40 .
The cast tire 10 of the present invention can be used with a furnace roller 50 shown in FIG. 5 includes a plurality of spaced apart workpiece supporting tires 10 . FIG. 4 illustrates a tire 10 supported by an outer tubular surface of an arbor 58 also forming part of the furnace roller. The anchor member 40 is inserted into each pocket 30 on the tires. The anchor members 40 are welded to the outer tubular surface of an arbor 58 . The composition zone of the weld 60 is substantially disposed within the beveled lower bottom edge of each anchor member 40 . The anchor members 40 will keep the tires 10 in alignment (at 90 degrees to the axis of the arbor) and transmit the required torque from the rotating arbor primarily by the contact of the ends 46 of the anchor members 40 with the corresponding radial edges 31 to propel the strip product though the furnace. The width of the anchor member within the pocket, and consequently the depth of the pocket, is primarily determined by the magnitude of the required torque transmission. A design safety factor may be added to the depth of the pocket.
A spacing material 62 , such as masking tape, can be placed between the back side 44 of the anchor member and the inner radial surface of the pocket 30 . The spacing material 62 provides clearance between the surface of the pocket and rear surface of the anchor member 40 to allow for thermal expansion of the width of the tire 10 between the anchor members 40 that are welded to the arbor 58 and located on the opposing radial sides of the tire. Upon reaching operating temperature, the spacing material 62 will compress or burn off.
As shown in FIGS. 5 and 6, four tires 10 are installed at spaced apart locations along the arbor 58 in the manner as just described. After installation of the cast tires 10 on the arbor 58 as shown in FIGS. 7 and 8, a body of castable insulation 64 separated by spacers from the arbor and the side wall of the tires is formed at each of the three locations between the tires. Additionally, a body of insulation 66 separated by spacers from the arbor and the side wall of the tires is formed along each of the terminal end portions of the arbor. In a manner known per se, anchors 68 affixed to the arbor along the length thereof serve to hold the castable insulation on the arbor. As shown in FIG. 5, the castable insulation and tires therebetween are located in a furnace between spaced apart furnace side walls 70 which are provided with apertures to allow arbor shaft extensions 72 A and 72 B to extend to support bearings 74 and 76 are mounted on pedestals 78 and 80 . Outwardly of bearing 76 , pedestal 80 supports a motor 82 connected by a coupling 84 to arbor shaft extensions 72 B. Outwardly of bearing 74 , the terminal end portion of arbor shaft is provided with a rotary coupling 86 for the supply and delivery of coolant water. The rotary coupling communicates with the internal cavity in a core buster segment 90 . Spacers 92 projecting from the outer surface of the core buster segment at spaced locations along the length thereof, form a flow channel for coolant water emerging from a passageway 94 . This passageway is elongated to take the form of a notch, the terminal end portion of which drivenly engages with a key 96 projecting from the inner face of arbor shaft extensions 72 B. Arbor shaft extensions 72 A has an internal threaded end portion 72 C to receive a threaded end plug which abuts against lugs 98 on the core buster for retaining the core buster in seated engagement within the internal cavity of the arbor 58 .
In one particular embodiment when a water-cooled furnace roller is exposed to a 2200° F. atmosphere, the tire temperature at the outer tubular member 58 of the arbor is approximately 1400° F., whereas the anchor members 40 are at a temperature of approximately 730° F. The thickness of the spacing material 90 compensates for the thermal expansion difference between the width of the 1400° F. tire and the 730° F. anchor member welded to the outer tubular member 58 of the arbor. Thus, a furnace roller using the cast tires 10 of the present invention results in a significant increase in thermal resistance between the tire and the outer tubular member of the arbor.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. Accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.
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There is provided a cast tire for use with a furnace roller. The cast tire has at least three of annular spaced pockets located around the central opening of the tire on each radial side. When the tires are installed on a furnace roller with arbor means, pockets are inserted into the annular spaced pockets. The pockets are secured only to the arbor means of the roller. Rotation of the arbor means results in rotation of the cast tires by transmission of torque from the pockets to the to the tire without direct attachment of the tire to the arbor means.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not applicable
BACKGROUND OF THE INVENTION
[0003] The present invention is related to a horizontal order-picker with an operating platform and a load section which is provided for accommodating at least one order-picking container.
[0004] During the process of order picking, the operator drives the order-picker to a predetermined location, from where the goods to be commissioned can be put into the order-picking container. In the technical language of the field, this location is designated as pick-up point or pick. Statistics furnish evidence that for the overall commissioning process, approximately 60% of the time is spent for commissioning, namely for picking up the goods from the storage facility and stowing them into the order-picking containers, and 40% for travelling between the pick-up points. At big storage facilities, in which several millions of goods are commissioned per week, statistics yielded the result that each second of time saving in commissioning results in quite significant cost-saving with respect to the year.
[0005] In the conventional commissioning process, the operator has to cover the distance between the pick-up point and the order-picking container several times, as well as one time that between the order-picking container and the operating platform of the horizontal order-picker. This movement between the three points is time-consuming.
[0006] From the USA, a horizontal order-picker is known with a function in which the driver jumps out of the travelling vehicle, and the vehicle continues to travel a certain distance automatically by the blocking of the brake. Thus, the order-picking container which is normally situated behind the operator in the travel direction, is brought nearer to the position of the driver. Such a function, where a driver leaves the travelling vehicle, is not compatible with German and European safety regulations for floor conveyors.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention is based on the objective to provide a horizontal order-picker which reduces the distance between the pick-up point and the order-picking container in a manner that is compatible with the safety regulations.
[0008] According to the present invention, the objective is achieved by a horizontal order-picker having the features of patent claim 1 Advantageous embodiments form the subject matter of the sub-claims.
[0009] The horizontal order-picker of the present invention has an operating platform and a load section, which is provided to accommodate at least one order-picking container. Usually, the operating platform is situated before the order-picking containers in the travel direction of the horizontal order-picker. According to the present invention, an operational control is provided in the operating platform, upon actuation of which the horizontal order-picker moves automatically for a predetermined distance, the length of the distance corresponding to the offset between the operating platform and one of the order-picking containers. In difference to the solution used in the USA, according to the present invention an operational control is required that has to be actuated by the driver in order to move the horizontal order-picker automatically. The travelled distance is exactly decided in this and it corresponds to the offset between the operating platform and one of the order-picking containers. The horizontal order-picker according to the present invention permits that the operator travels to a pick-up point, stops the vehicle at this pick-up point and exits the standing vehicle. Then, through the actuation the operational control, the vehicle travels automatically such that one of the order-picking containers is exactly within reach of the pick-up point. Through this, the ways of the operator between pick-up point and order-picking container can be saved. In order to continue travelling, it is only required that the operator covers the distance from pick-up point to operating platform one time.
[0010] In a practical embodiment, the movement direction is selected such that after movement, one of the order-picking containers is in a position in which the operating platform had been before the movement.
[0011] In a particularly preferred embodiment, the load section of the horizontal order-picker according to the present invention has several order-picking containers disposed one after another in the travel direction in order to permit to accommodate the goods to be commissioned. In this embodiment, the operational control has means which permit to select one of the several order-picking containers, wherein the length of the distance to be moved corresponds to the offset between the selected order-picking container and the operating platform. Thus, when leaving the vehicle, the operator can select which order-picking container is to be moved into a position that is optimum for loading.
[0012] In another preferred embodiment, the operational control triggers a movement of the horizontal order-picker after the vehicle had been braked down into standstill. In this embodiment, the driver has complete control of the vehicle until it has been brought to standstill. Only after leaving the standing vehicle, it is automatically moved through the triggering of the operational control.
[0013] A sensor is advantageously provided in the horizontal order-picker, which acquires the distance to be moved and stops the automatic movement process when an obstacle appears. Such a sensor may be radar for instance, but other sensors are also conceivable. It is completely sufficient for the invention when the sensor acquires only the region before the vehicle up to a distance about which the vehicle is to be moved. This permits to use simple sensors with a small range of reach.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0014] The present invention will be explained in more detail in the following by means of the figures.
[0015] FIG. 1 shows the process of the automatic positioning of the horizontal order-picker,
[0016] FIG. 2 shows in a schematic view selection means for the order-picking containers, and
[0017] FIG. 3 shows the commissioning process of the state of the art.
DETAILED DESCRIPTION OF THE INVENTION
[0018] While this invention may be embodied in many different forms, there are described in detail herein a specific preferred embodiment of the invention. This description is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiment illustrated.
[0019] In its upper part, FIG. 1 shows a horizontal order-picker 10 with an operating platform 12 and three order-picking containers 14 , 16 , 18 . The usual movement direction of the horizontal order-picker 10 is indicated by the arrow F. During the commissioning process, an operator advances to the pick-up point 20 . Directly within reach of the pick-up point 20 , there are racks with the goods to be commissioned (not shown). During the commissioning process, the driver leaves the operating platform 12 and goes to the pick-up point 20 and covers the distance A by doing so.
[0020] As shown in the lower part of FIG. 1 , thereafter the vehicle automatically moves about the distance B, so that no longer the operating platform 12 , but instead the order-picking container 18 is in the direct neighbourhood of the pick-up point 20 . Now, the driver can put the goods to be commissioned into the order-picking container 18 . For this purpose, he covers the distance C several times. After completion of the commissioning process, the operator goes back to the operating platform 12 along the distance D.
[0021] All in all, the driver of the commissioning process covers the distances A and D one time, and several times the distance C.
[0022] FIG. 3 shows the distances covered by the driver in conventional commissioning. In this commissioning process, the driver advances to the pick-up point 20 anew and leaves the operating platform 12 . In doing so, he covers the distance A′. In the following, the goods to be commissioned are picked up in the pick-up point 20 and stocked in the order-picking container 18 . For this purpose, the operator covers the distance B′ several times. After the last good to be commissioned had been put into the order-picking container 18 , the driver returns to the operating platform along the distance C′. In this, the distance C′ corresponds to distance D of FIG. 1 . Due to the geometry of the ways, significantly longer distances are covered by the driver in the conventional commissioning process than in the utilisation of the horizontal order-picker according to the present invention. In addition, usually the offset A′ is selected to be greater by a driver in the state of the art when he approaches the pick-up point 20 , in order to reach the order-picking containers better along the distance B′. This does also not apply with the horizontal order-picker according to the present invention, using which the distance A can also be selected to be significantly shorter.
[0023] FIG. 2 shows a preferred embodiment, in which a schematically shown operational control 22 is provided in the operating platform 12 . The operational control 22 has three switching means 24 , 26 , 28 by which the order-picking container 14 , 16 , 18 to be filled up can be selected before or when leaving the horizontal order-picker.
[0024] In the horizontal order-picker according to the present invention, a movement operation is triggered by actuating the operational control 22 only then when the vehicle is in complete standstill. Preferably, a small delay may still be provided here, which permits that the driver leaves the operating platform 12 and places himself at the pick-up point 20 .
[0025] The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.
[0026] Further, the particular features presented in the dependent claims can be combined with each other in other manners within the scope of the invention such that the invention should be recognized as also specifically directed to other embodiments having any other possible combination of the features of the dependent claims. For instance, for purposes of claim publication, any dependent claim which follows should be taken as alternatively written in a multiple dependent form from all prior claims which possess all antecedents referenced in such dependent claim if such multiple dependent format is an accepted format within the jurisdiction (e.g. each claim depending directly from claim 1 should be alternatively taken as depending from all previous claims). In jurisdictions where multiple dependent claim formats are restricted, the following dependent claims should each be also taken as alternatively written in each singly dependent claim format which creates a dependency from a prior antecedent-possessing claim other than the specific claim listed in such dependent claim below.
[0027] This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.
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A horizontal order picker with an operating platform and a load section which is provided for accommodating at least one order-picking container, wherein an operational control is provided in the operating platform, upon actuation of which the horizontal order picker moves for a predetermined distance (D) automatically, the length of the distance (D) corresponding to the offset between the operating platform and one of the order-picking containers
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FIELD OF THE INVENTION
This invention relates to a loading arrangement in a paper machine doctor, in which the doctor includes a blade carrier and a blade holder fitted to it rotatably by means of an articulated joint. Loading devices operated by a pressure medium are fitted between the blade carrier and the blade holder, to turn the blade holder in relation to the blade carrier and thus to press the doctor against the surface to be doctored.
BACKGROUND OF THE INVENTION
Generally, the blade holder of a doctor is made in several parts or to be otherwise flexible, so that the doctor blade, which is as such flexible, will lie against the surface to be doctored. In this case, however, the contact force on the actual surface of a doctor blade pressed by means of conventional loading devices varies at different points. This variation appears as a poor doctoring result and uneven wear in the doctor blade.
U.S. Pat. No. 5,279,710 discloses a paper machine doctor, in the blade holder of which there are fine-adjustment screws, in addition to the doctor blade attachment screws. The tightness of the fine-adjustment screws acts on the doctor blade and the screws can be used to try to force the doctor blade to conform to the shape of the surface being doctored. The solution disclosed is, however, complicated and only a small shaping effect can be achieved on the doctor blade with the fine-adjustment screws. In addition, the blade settings cannot be changed during operation, and vibration can cause the setting of the fine-adjustment screws to alter.
SUMMARY OF THE INVENTION
The present invention provides new kind of loading arrangement for a paper machine doctor, by means of which the shape of the doctor blade and the force it directs to the surface being doctored can be adjusted in zones during operation.
More specifically, the present invention provides a loading arrangement in a paper machine doctor, in which the doctor includes a blade carrier and a blade holder fitted to it rotatably by means of an articulated joint. Loading devices operated by a pressure medium are fitted between the blade carrier and the blade holder to turn the blade holder in relation to the blade carrier and thus to press the doctor blade against the surface to be doctored. The loading devices include at least one operating device on the loading or the return side, which operating device comprises two or more loading components set one after the other in the longitudinal direction of the doctor. An independent pressure medium connection extends to the loading components, to make the profile of the doctor blade conform to the surface to be doctored, over the length of the doctor.
In one embodiment of the invention there are 3 - 21 loading components in the operating device. Preferably, there are 5 - 9 loading components in the operating device.
The loading components are fitted to touch each other, so that they form a loading hose extending over the length of the doctor. There are operating devices on both the return side and loading side of the doctor, the constructions of which essentially correspond to each other.
Each pressure medium connection is arranged to each loading component through its outer surface. Each pressure medium connection may be formed from a flexible tube, which extends from the loading component to either end of the doctor.
The pressure medium connection is arranged by means of tubes fitted inside the loading components, and which extend through the end walls of the loading components. The tubes are arranged inside a stiff metal pipe, which is fitted tightly to the end walls of the loading components.
Each pressure medium connection may be formed from a common feed line and have control valves connected to it. The feed lines may be arranged in the axle forming part of the jointing, or in connection with it.
The loading arrangement according to the invention can be used to load the doctor blade at certain intervals with a desired force. This improves the doctoring result throughout. The loading arrangement according to the invention can also be used to even out the possible uneven wear of the doctor blade. In addition, as the contact force can be adjusted in zones, a good doctoring result can be ensured by increasing the contact force, for example, in the web feeding area. In a corresponding way, it is possible to adjust the roughening effect of the doctor blade on the roll surface.
These and other features and advantages of the invention will be more fully understood from the following detailed description of the invention taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is an axonometric view of a partial cross-section of a doctor according to the invention, seen from the end;
FIG. 2 is a sectional view of another embodiment of a doctor loading device according to the invention;
FIG. 3 is a sectional view of a variation of the embodiment of FIG. 2; and
FIG. 4 is an axonometric view of a partial cross-section of a doctor according to a second embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings in detail, FIG. 1 shows a doctor, the main principles of which are conventional, fitted in connection with a roll 10 . As only part of the blade carrier 11 of the doctor is shown, the support of the doctor cannot be seen. Blade holder 13 is attached to blade carrier 11 by means of an articulated joint 12 , in such a way that it can be turned. Blade holder 13 is turned in relation to blade carrier 11 by means of loading devices operated by a pressure medium, which in this embodiment are loading hoses 17 and 18 . Though it is preferable to use compressed air as the pressure medium, other mediums are possible. The actual doctor blade 14 , which can be changed simply while the doctor remains in place, is installed in blade holder 13 .
According to the invention, the loading devices include at least e operating device on the loading or the return side. Such an operating device consists two or more loading components 15 , set one after the other in the longitudinal direction of the doctor. In FIG. 1, the joints between the sequential loading components 15 are shown with the reference number 16 . In addition, an independent pressure medium connection extends to each loading component 15 . Thus, the profile of doctor blade 14 can conform over the length of the doctor to the surface being doctored. In the same way, the contact force of doctor blade 14 to the surface being doctored can be adjusted in zones over the length of the doctor, by arranging a different pressure in the loading components 15 .
In order to make a loading arrangement according to the invention possible, blade holder 13 must be sufficiently flexible for the effect of the loading components to be transferred to doctor blade 14 . Alternatively, blade holder 13 can comprise several pieces, which are jointed to blade carrier 11 independently of each other. Preferably, the joints 16 between the loading components 15 are according to FIG. 1 at blade holder 13 , to create clear boundaries between the zones of doctor blade 14 .
Operating devices, the constructions of which essentially correspond to each other, can be arranged on both the return side and the loading side of the doctor. Thus, the suitable adjustment of the loading pressure of loading hose 17 and of the counter-pressure of return hose 18 , will achieve precisely the desired profile of doctor blade 14 and the contact force, over the length of the doctor. The range of possible adjustments can be increased by setting the loading components 15 of the loading and return hoses 17 and 18 at different points in the longitudinal direction of doctor blade 14 . The precision of the adjustment is also affected by the size selected for the loading components.
According to the invention, there are 3 - 21 , preferably 5 - 9 loading components. Though an increase in the number of loading components will increase the adjustment precision, it will then become more difficult to arrange the pressure medium connections. On the other hand, the use of even a few loading components only in the loading hose, will bring an obvious improvement in the doctoring result. At the same time, the contact force can be adjusted as desired with sufficient precision. In addition, the loading components need not necessarily be the same size. Loading components of different sizes can be used to concentrate the adjustment zones at the end of the doctor or at the center of it or at both. The loading hose can also have its own loading component fitted to it, for example, in the web-feeding area. In practice, the loading components are fitted so that they touch each other to form a loading hose extending over the length of the doctor. The outward appearance of a loading hose of this kind differs from that of a conventional loading hose mainly only at the joints. FIGS. 2 and 3 also show one joint 16 . The use of a unified loading hose will ensure that it remains in place between the blade holder and the blade carrier. It is also easier to form pressure medium connections to a unified loading hose than to separate loading components.
The pressure medium connections to the loading components can be arranged in several different ways. FIGS. 1-3 show three ways. According to FIG. 1, each pressure medium connection is arranged in each loading component 15 from its outer surface. In this case, each pressure medium connection is formed by a flexible tube 19 . Tube 19 extends from loading component 15 to either end of the doctor. Pressure is fed to the loading components 15 preferably from both ends of the doctor, when the longest tubes required will be less than half of the total length of the loading hose. The features presented in the disclosure also suit the return hoses, unless otherwise stated.
Another way is to arrange the pressure medium connections in the inside of the loading components. This can be easily done using tubes 20 , which extend through the joints 16 of the loading components 15 , as shown in FIG. 2 . Each tube 20 is sealed separately at joint 16 . In this case, however, numerous points requiring sealing are created. Alternatively, the tubes can be arranged inside a single larger metal pipe 20 ′, which metal pipe 20 ′ is fitted tightly to the end walls of the loading components 15 , i.e. to joint 16 . The embodiment of FIG. 3 shows this alternative.
In the solutions described above, the control valves of the loading components are situated far from the doctor. Alternatively, each pressure medium connection can be formed from a common feed line and control valves connected to it. In that case, the doctor preferably has only a single feed line and a cable for the electric valves. One way is to arrange the feed line in the axles 12 ′ forming part of the articulated joint 12 , or in connection with it. In FIG. 4 each pressure medium connection is formed from a common feed line 21 and control valves 22 connected to the common feed line 21 , which is arranged in the axle 12 ′ forming part of the joint 12 , or in connection with the axle 12 ′ .
Pressure can be fed in quite a known manner to the loading components at the ends of both the loading and return hoses. Pressure is then fed to the inner loading components in one of the ways according to the invention. Different ways can be applied simultaneously in a single doctor. In practice, all of the ways described are advantageous, though differences exist between them. Though internal tubes do not hang detrimentally, they are more difficult to maintain that external tubes. In addition, in cases of damage, all the internal tubes tend to be damaged simultaneously. Correspondingly, simultaneous damage is rare in external hoses and damaged sections can be easily located and repaired.
The loading arrangement according to the invention can also be used, not only to adjust the profile of the doctor blade, but also to adjust the force of the contact with the surface being doctored. Unlike the state of the art, the doctor can be adjusted while it is operating. The properties of the loading system can be exploited, for example, to compensate for wear in the doctor blade. In normal doctor, the doctor blade wears most in the center, so that wear is least at the edges. In the same way, there is unevenness in the loading profile of the doctor blade. By increasing the pressure on the edge zones, the contact force at these points is increased. In that case, the doctor blade wears most at the edges, so that the whole doctor blade wears evenly and the contact force is even. A local increase in contact force can also be used in the web feeding area, to ensure that web feeding succeeds. In addition, the surface being doctored is usually the surface of a roll, which practically does not wear. However, the doctor blade affects the surface roughness of the roll, so that the contact force can be adjusted to affect the surface roughness locally. Thus, the loading arrangement can be used to achieve a good doctoring result, even surface roughness of the roll, and even wear in the blade.
Although the invention has been described by reference to specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the described embodiment, but that it have the full scope defined by the language of the following claims.
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A loading arrangement in a paper machine doctor includes a blade carrier, a blade holder, and loading devices to turn the blade holder in relation to the blade carrier and thus to press the doctor blade against the surface to be doctored. The loading devices include at least one operating device including longitudinally arranged loading components and a pressure medium connection extending to each of the loading components to make the profile of the doctor blade conform to the surface to be doctored.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] Fork lifters, shovel loaders or the like industrial trucks have a load support for taking up, transporting and setting down of a load. Mostly, the transporting object is disposed on pallets, which on their part can be transported with the load fork of an industrial truck, e.g.
[0004] Transporting objects having a high centre of gravity or a low weight at a small area of standing up may fall down from the pallet or the load support, respectively, particularly when the industrial truck drives over uneven ground or through curves. For this reason, it is known since a long time to use so-called load holders, which exert a push from the upside onto the transporting object, in order to prevent any falling down from the pallet or of the pallet from the load support. From DE 9418354 U1 or EP 467210 B1 a holding device has become known, in which a horizontal plate is height-adjustably arranged and can be pushed onto the transporting object by vertical lowering. When there are several transporting objects of different height on the pallet, or when there are several pallets with transporting objects of different heights on the load support, any sufficient fixing of the transporting object is not possible.
[0005] This is the reason why it has become known from DE 412989 C or WO 214206 A2 to mount several load holders side by side on one support device. Through this, it is possible to clamp fast several transporting objects of different height, which are situated side by side on the load support. However, it is not possible to sufficiently clamp fast transporting objects of different height which are situated in the fork direction with respect to each other.
[0006] From GB 2250267 A, DE 2929621 C2 it is known to make several plates individually height-adjustable, which are arranged side by side or back to back. It is a disadvantage of this solution that the height differences between the individual transporting objects have to be in narrow limits.
[0007] This invention is based on the objective to provide a device for holding a load on a load support of an industrial truck in which the transporting objects can differ significantly in their heights.
BRIEF SUMMARY OF THE INVENTION
[0008] In the device according to the invention, a support construction, adjustable in its height, is mounted above the load support on the industrial truck. With the aid of a lifting drive, the support construction can be shifted in its height. Across a plane, which approximately corresponds to the area of a pallet, for instance, it has several vertical guidances, in which plungers are vertically guided. When the plungers are not fastened, they can find support on the respective transporting object which is situated there under. If it is taken care that after this process the plungers remain in this position, a secure fixing of the transporting object is achieved. Therefore this invention further provides a clamping device, by which the plungers can be clamped fast in the guidances on arbitrary height positions. An actuation device provides for optional clamping or releasing of the plungers in the guidances.
[0009] In the invention, a greater number of plungers which are arranged in a field corresponding about to the extension of the load, and which can be lowered onto a load in such a manner that they reproduce the discontinuous surface contour of the load, provides for sufficient securing of the transporting object on the load support. All the plungers are in contact with the load and can be vertically fixed. Through this, securing of the load is provided, particularly against canting over.
[0010] Several possibilities of construction can be conceived to realise the described teachings. One form of realisation of the invention provides for this purpose that the support construction is guided in a lifting scaffold of the industrial truck and that it is driven by a lifting cylinder, a chain drive or the like. The lifting scaffold can be realised in a manner comparable to the lifting scaffold of a fork lifter. For lifting or lowering, a double-acting lifting cylinder can be provided, which is operated hydraulically or pneumatically. However, a single-acting lifting cylinder may also be provided, a braking device being necessary in this case in addition which is switched on when needed in order to fix the support construction in an arbitrary position. However, a mechanical lifting device like a spindle or chain drive, for instance, may also be provided instead of a lifting cylinder.
[0011] It is known to provide a high-lift truck with two load supports for a double-deck loading. In this, the lower load support is rigidly fixed on the lifting scaffold of the high-lift truck. By lifting the entire lifting apparatus, the transporting object can be lifted. A load sledge is guided on the lifting apparatus, on which the upper load support is fixed. In such a construction, the upper load sledge can be replaced by the support construction according to the invention, or it can be mounted on the upper load sledge.
[0012] Several realisations can be conceived for the support construction. For instance, it can have a support plate, which is provided with bores in which the plungers are accommodated. The support plate can be made of plastic material or of a composite material, for instance. Alternatively, a welding construction can be produced from standard profiles, in which case sleeves are provided instead of the bores, in which the plungers are vertically guided.
[0013] According to a further form of realisation of this invention, the plungers have a stop on the ends, which prevents any slipping of the plungers towards the downside. For instance, enlargements of the plungers on its upper ends can serve for this purpose. The plungers, which are preferably circle-shaped in section, as well as the bores assigned thereto, can be realised as pipes or also in a massive manner.
[0014] In a further form of realisation of this invention, it is provided that a clamping unit, which can be actuated by the actuation device, is horizontally guided between a release position and a clamping position on the support construction. The clamping unit has clamping means, which can be brought into clamping or frictional lateral engagement, respectively, with the plungers in the clamping position. The clamping unit, which is preferably linearly guided by the support construction, can be actuated with the aid of one single actuation cylinder, for instance, in order to bring the clamping unit optionally into the release position or the clamping position. Instead of a double-acting actuation cylinder, a single-acting one can also be conceived, a pretension spring acting in the opposite direction, preferably in the clamping direction.
[0015] Preferably, the clamping means are frictional elements or the like, which can be brought into non-positive engagement with the shafts of the plungers. Thus, an elastic ribbon can be conceived as a frictional element, for instance, which is disposed horizontally and which partly non-positively loops around the respective plunger, when the frictional unit is in it's the clamping position.
[0016] According to a further form of realisation of the invention, the clamping unit can be formed by a frame construction, which is linearly horizontally guided in the support construction. The frame construction can have several parallel spaced apart U-profiles, the bridge of which has long holes through which plungers are guided through, and the clamping means are assigned to those long holes which are made on the limbs of the U-profiles, in the form of the already mentioned elastic ribbons, e.g.
[0017] According to a further form of realisation of the invention, the actuation of the lifting drive and the actuation device are controlled by a controlling device. In order to do this, a further form of realisation provides that the controlling device controls the clamping device into the release position when the support construction is moved and that it controls it into the clamping position when the support construction is in the idle condition. By doing so, the actuation of the holding device is performed widely automatically.
[0018] A further form of realisation of the invention enables control of the holding device which is even better co-ordinated with respect to time, according to which first sensors are assigned to the plungers, which determine whether a plunger has been shifted towards the upside about a maximum path with respect to the support construction. The controlling device stops the lowering movement of the support construction, when it receives a first sensor signal. In this case, the support construction can not be lowered further, because it would otherwise damage the object to be transported. However, at very large height differences, not all the plungers are in engagement yet in this condition. Thus, the sensor signal indicates the later and possible moment of switching off, but not imperatively the time-optimised one.
[0019] According to the invention, a further possibility of control results when second sensors, connected to the controlling device, are provided on the support construction, which emit a second sensor signal when a plunger reaches a maximum lower position. The controlling device stops the lowering movement of the support construction, when all the plungers are lifted with respect to the undermost position. This sensor set-up serves to stop the lowering movement at the earliest moment as is possible. Thus, it serves for time-saving.
[0020] For instance, the sensors can be realised in that electric contacts are provided on the support construction, which co-operate with contact surfaces on the plungers. Preferably, the lower end of the plungers is enlarged, in order to have better securing and to prevent damage of the transporting object. In every case, it is advantageous when the bottom end surfaces of the plungers have a coating or the like with a high frictional value.
DETAILED DESCRIPTION OF THE INVENTION
[0021] While this invention may be embodied in many different forms, there are described in detail herein a specific preferred embodiment of the invention. This description is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiment illustrated
[0022] FIG. 1 shows the side view of an industrial truck with a device according to the invention.
[0023] FIG. 2 shows the top view of the representation after FIG. 1 .
[0024] FIG. 3 shows the front view of the industrial truck after FIG. 1 with the device according to the invention.
[0025] FIG. 4 shows detail 4 in FIG. 2 .
[0026] FIG. 5 shows a section through the representation after FIG. 4 along the line 5 - 5 .
[0027] FIG. 6 schematically shows the bottom side of the support plate according to the device of invention.
[0028] In the FIGS. 1 to 3 , an electric drawbar lifting truck 1 can be recognised, with a fork support, having three fork tines 3 (see FIG. 3 ), which are provided with sustaining rolls 20 on the front side, with respect to which the tines 3 can be hydraulically lifted, as is per se commonly known. As can be recognised, several rolling pallets 4 are received in series in the longitudinal direction on the fork tines 3 .
[0029] A lifting scaffold 2 is attached on the lifting truck 1 , on which a support plate 6 is guided to be vertically movable. A double-acting lifting cylinder 16 effects the lifting and lowering movements of the support plate 6 ( FIGS. 2 and 3 ). Other mechanical lifting devices can be conceived instead of a pneumatic or hydraulic lifting cylinder, a spindle- or chain drive, for instance. The lifting cylinder can also be single-acting, a brake device being necessary in this case, which is applied thereto in order to fix the support plate in its respective position. As the case may be, a brake device can be omitted, provided that the load holding device has sufficiently high own weight.
[0030] The support plate 6 is shown as a massive plate, which is made from plastic material or a composite material. Instead of a massive plate, a welded construction from standard profiles can also be provided.
[0031] In the support plate 6 there are bores 22 , in which the plungers 8 can move vertically. As emerges from FIG. 6 , contact elements 24 are situated on the bottom side of the support plate 6 on opposing sides of the bores, which are not drawn for all the bores, however. They are in connection with a battery 26 . All the contact element couples 24 are connected in series.
[0032] In the represented realisation example, 4×6 bores 22 are disposed in uniform distances from each other, which corresponds to a field that can be occupied by the load support or the transporting objects which can be received on the load support, respectively. Thus, 24 plungers 8 are provided. The thickness of the support plate 6 is sufficient to assure an unobjectionable guiding in the bores 22 . It is also conceivable to use additional sleeves or, at welding constructions, sleeves only for guiding, in order to assure friction-free guiding of the plungers 8 .
[0033] On the support plate 6 a clamping unit 7 is set, which is realised as a frame construction with four parallel spaced apart U-profiles 26 , which are welded together by two transversely running U-profiles 28 . On the plate 6 there are two parallel ridges 15 , through which the clamping unit 7 is linearly guided along the axis of the industrial truck. An actuation cylinder 14 is linked to the support plate 6 , which engages with its piston rod on a cross strut 28 . On the side opposite to the cylinder 14 , a spring 12 is disposed, which supports itself on the plate 6 on the cross profile 28 on the one hand, and on an abutment 13 on the other hand. Instead of the spring 12 , the actuating cylinder 14 can also be a double-acting one.
[0034] As emerges from FIGS. 4 and 5 , the bridges of the U-profiles 26 have long holes 30 , which are aligned with the bores 22 of the support plate 6 . The plungers 8 are also guided through the long holes 30 . In the region of the long holes 30 , a bow-like mounting 17 is disposed on an inner side of the limbs of the U-profiles 7 for each elastic ribbon 18 at a time. When the plunger 8 is in the position shown in FIG. 4 , it is partially looped by the elastic ribbon 11 .
[0035] In FIG. 5 , a contact element couple 24 can also be recognised. On the bottom end of the plunger 8 is attached a frictional laying-on device 10 having a larger diameter, and an electrically conductive material 19 between the frictional laying-on device 10 and the plunger 8 . When the plunger 8 is maximally moved upward, the conductive material 19 comes into engagement with the contact element couple 24 .
[0036] The device represented in FIG. 1 to 6 works as follows. The transport of loads with the aid of the lifting truck is separated into three partial functions:
1. Setting the shown load holding device onto a load on the point of gathering of the load 2. Holding the load holding device on the load during the transport 3. Lifting off the load holding device on the point of setting down the load.
[0040] On that point where the rolling pallets 4 with load 5 situated thereon are to be gathered, the operator drives the lifting truck 1 with the fork tines 3 under six rolling pallets 4 which are stored on the floor in block storage. The fork tines 3 are in their undermost position. The support plate 6 with the clamping unit 7 is in the uppermost position, in which all the plungers 8 sit closely to the bridges of the U-profiles 26 with their enlargement 9 . The plungers 8 project out of the support plate 6 towards the downside with their maximally disposable length.
4. When a lifting truck is used for double deck loading, the course of the functions should be as follows: a) The operator drives under the rolling pallets with the forks b) Pretensioning device is released c) Support plate is lowered d) Plungers come into engagement and are tensioned again e) The lower forks with the rolling pallets are lifted, together with the lifting scaffold and the support plate.
[0047] This order ensures that canting down does not occur at the lifting of the pallets already.
[0048] When the operator actuates the lifting device for the fork tines 3 , the rolling pallets 4 are lifted from the floor and lay on the fork tines 3 . At the same time, the single-acting hydraulic cylinder 14 is actuated and shifts the clamping unit 7 away from the lifting truck 1 , against the force of spring 14 . Through this, the elastic ribbons 11 move away from the plungers 8 and the plungers 8 can freely move vertically. At the same time, the double-acting hydraulic cylinder 16 moves downward the support plate 6 in the lifting scaffold 2 . The simultaneity of the three described processes is realised by means of a not shown control device, which can be realised such that no manual operating processes have to be executed by the operator.
[0049] By the lowering of the support plate 6 , the plungers 8 come to lie on the upper side of the load 5 with their frictional laying-on devices 10 . As the plungers are freely movable in the bores 22 and 30 , they push themselves upward through the support plate. The deeper the support plate 6 is lowered, the more plungers come to lay on the different height levels of the load 5 .
[0050] The described lowering process of the support plate 6 has to be ended automatically, when at least one of the plungers 8 has been pushed maximally upward through the bore 22 . Then, the metal lay-on device 19 comes into contact with the contact element couple 24 . As emerges from FIG. 6 , an electric current is caused by this, which can be displayed in the instrument 32 , for instance, and which can be used to stop the actuation of the lifting cylinder 16 . When a double-acting lifting cylinder is used for the support plate 6 , a pressure limiting valve (not shown) is preferably to be provided for the downward movement, in order to avoid any injury of persons or damage of the load.
[0051] In addition to the described stopping of the lowering process, which designates the latest possible moment, time saving can be achieved by introducing a second condition. As soon as all the plungers 8 have come to lie on the load 8 , their enlargements 9 are released from the clamping unit 7 , because the plungers 8 begin to push themselves through the bores 22 and 30 . This can be sensed according to the same principle as has been described for the contact element couples 24 and the contact layer 19 . Thus, contact surfaces can be provided on the lower side of the enlargement 9 , which co-operate with (not shown) upper contact couples on the bridges of the U-profiles 26 . The lowering movement of the support plate 6 is stopped, when the contact between these contact couples and the contact surfaces is interrupted for all the plungers.
[0052] When the lowering movement of the support plate 6 is ended, the tension of the actuation cylinder 14 is released by the controlling device. Through this, the spring 12 pushes the clamping unit 7 into the direction of the lifting truck, which has the effect that the elastic ribbons are pressed against the plungers 8 . Through this, a frictional engagement between plungers and elastic ribbon 14 is generated, which inhibits a vertical movement of the plungers 8 . Therefore, the plunger 8 lies on the load 5 with its frictional laying-on device 10 and is fixed in its vertical movement. Because plungers 8 lay on the entire height contour of the load 5 , which are not vertically movable, the load is form-locking assured against canting and through frictional engagement against slipping by the frictional laying-on device 10 .
[0053] When arrived at the point of setting down, the operator actuates the lowering movement for the fork tines 3 . By doing so, the rolling pallets 4 are set on the floor. At the same time, the following two processes are performed by the controlling device described above:
[0054] The actuation cylinder 14 is pressurised, so that the clamping unit 7 is pushed in the direction of the fork tines against the force of the spring 17 . Through this, the tension is released from the elastic ribbons 11 and the frictional engagement for the plungers 8 is released. Thus, the plungers are freely movable in their guidances again.
[0055] On the other hand, the double-acting lifting cylinder 16 moves upward the support plate 6 . As the plungers 8 are vertically freely movable, they slip through the bores 22 onto the clamping unit 7 up to their enlargement 9 . When the double-acting lifting cylinder 16 has reached its uppermost position, the tension is released from the actuation cylinder 14 and the plungers 8 are tensioned again with the aid of the elastic ribbons 11 .
[0056] In this position, the load is no more fixed, and the operator can drive back with the industrial truck.
[0057] The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.
[0058] Further, the particular features presented in the dependent claims can be combined with each other in other manners within the scope of the invention such that the invention should be recognized as also specifically directed to other embodiments having any other possible combination of the features of the dependent claims. For instance, for purposes of claim publication, any dependent claim which follows should be taken as alternatively written in a multiple dependent form from all prior claims which possess all antecedents referenced in such dependent claim if such multiple dependent format is an accepted format within the jurisdiction (e.g. each claim depending directly from claim 1 should be alternatively taken as depending from all previous claims). In jurisdictions where multiple dependent claim formats are restricted, the following dependent claims should each be also taken as alternatively written in each singly dependent claim format which creates a dependency from a prior antecedent-possessing claim other than the specific claim listed in such dependent claim below.
[0059] This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.
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Device for holding a load on a load support of an industrial truck with the following characteristics: a support construction, adjustable in its height by a lifting drive, is mounted above the load support
the support construction has several vertical guidances, distributed across a plane, in each of which one plunger ( 8 ) is vertically guided a clamping device is attached on the support construction, by means of which the plungers are fixable in the guidances in an arbitrary height position, and an actuation device for the clamping device for optional clamping or releasing the plungers in their guidances.
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TECHNICAL FIELD
[0001] The present disclosure relates to a fencing panel and method of assembly thereof. More particularly, it is concerned with a fencing panel that enable support posts to remain perpendicular while allowing enhanced contouring of crossmembers with the terrain.
BACKGROUND
[0002] Fencing panels may be used for various functions, including fencing a plot of land to keep people, vehicles, and/or animals on or off of the land. As depicted in FIG. 1A , a typical fence 100 may be comprised of multiple individual fencing panels 102 (shown as fencing panels 102 a - g ). Each fencing panel 102 may include a first support post 104 (labeled as first support posts 104 a - g ) and a second support post 106 (labeled as a second support post 106 a - g ), and a plurality of crossmembers 108 (e.g., crossmembers 108 a ) therebetween. One of the support posts 104 , 106 will have one or more hooks 110 . As depicted, two hooks 110 are arranged on each of the first support posts 104 a - g. Each fencing panel 102 a - g further includes one or more receiving loops 112 . As depicted, two receiving loops 112 are arranged on the second support post 106 of each fencing panel 102 . The hooks 110 of one panel 102 are to be arranged within the receiving loops 112 of another panel, thereby coupling the panels together. An enlarged view of this is illustrated in FIG. 1B . This configuration, however, presents many problems.
[0003] For example, due to the rigidity of the crossmembers 108 coupled to the support posts 104 , 106 , the panel 102 a - g is unable to flex with uneven terrain, thus leaving gaps between the panels 102 a - c, especially upon slopes, peaks, and troughs of land. As depicted, the hill or peak 114 of land slopes the two panels 102 c and 102 d in opposite directions, therefore not enabling the hooks 110 d to be arranged within the receiving loops 112 c. Resulting therefrom, a gap 116 is formed, where animals may be able to escape, or alternatively be caught therein and unable to be freely released. Different animals may react in different manners to being caught, such as a horse pulling back when stuck, but a cow may try to push through the panels 102 c and 102 d, thereby moving and/or breaking them, along with injuring the animal itself.
[0004] Similar issues arise at the trough or low point of land 118 . As depicted, the panels 102 f and 102 g are only partially able to connect via the hook 110 g and receiving loop 112 f due to being at various angles when conforming to the land. Such an arrangement creates a gap 120 between the two panels 102 f and 102 g. Again, animals may be able to escape through the gap 120 , or alternatively become stuck in the gap 120 , possibly causing injury or death to the animal, and damage to the fencing panels 102 f and 102 g. Current solutions are to arrange additional panels 102 in areas which such gaps 116 , 120 occur. However, such a solution is both costly (due to the extra panels 102 required to be purchased), and may prove ineffective over a period of time as the land continues to move and shift. Accordingly, a fencing panel which solves the aforementioned problems remains highly desirable.
SUMMARY OF THE INVENTION
[0005] The present disclosure introduces various illustrative embodiments for a fencing panel, and method of assembly thereof, that enable support posts to remain perpendicular while allowing enhanced contouring of crossmembers with the terrain.
[0006] It is an object of the present disclosure to provide a fencing panel that includes a first support post having a first pair of arms radially extending therefrom, each arm having a hole horizontally arranged therethrough at substantially the same location, and a second support post having a second pair of arms radially extending therefrom, each arm having a hole horizontally arranged therethrough at substantially the same location. The fencing assembly further including a first crossmember having a first end and a second end, each end having a horizontal hole therethrough, where a means for coupling the crossmember to a support post is employed at each end of the crossmember to couple the crossmember to each support post via the associated holes in the ends of the crossmember and holes in the arms of each support post.
[0007] It is another object of the present disclosure to provide a method for assembling a fencing panel, wherein the method employs a means for coupling a crossmember to a support post to couple a first end of a first crossmember to a first support post via holes in a first pair of arms radially extending from the first support post and a hole in the first end of the first crossmember, and further employs the means for coupling a crossmember to a support post to couple a second end of the first crossmember to a second support post via holes in a second pair of arms radially extending from the second support post and a hole in the second end of the first crossmember. Advantageously, such a configuration enables the support posts to remain perpendicular while allowing enhanced contouring of crossmembers with the terrain.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The following figures are included to illustrate certain aspects of the present invention, and should not be viewed as an exclusive embodiments. The subject matter disclosed is capable of considerable modification, alteration, and equivalents in form and function, as will occur to one having ordinary skill in the art and the benefit of this disclosure.
[0009] FIGS. 1A and 1B depict a plurality of prior-art fencing panels.
[0010] FIG. 2 illustrates a side view of a fencing panel, according to one or more embodiments.
[0011] FIG. 3 illustrates a top-down view of the fencing panel, according to one or more embodiments.
[0012] FIGS. 4A and 4B shows enlarged views of the fencing panel support post, according to one or more embodiments.
[0013] FIG. 5 illustrates a side-view of a fencing panel that includes an intermediate support post, according to one or more embodiments.
[0014] FIG. 6 is an enlarged angled-view of the intermediate support post, according to one or more embodiments.
[0015] FIG. 7 is a flow diagram of an illustrative method for assembling a fencing panel, according to one or more embodiments.
DETAILED DESCRIPTION
[0016] The present disclosure relates to a fencing panel and method of assembly thereof. More particularly, it is concerned with a fencing panel that enable support posts to remain perpendicular while allowing enhanced contouring of crossmembers with the terrain, thereby preventing gaps between panels from occurring.
[0017] Referring now to the drawings, wherein like reference numbers are used herein to designate like elements throughout the various views and embodiments of a unit. The figures are not necessarily drawn to scale, and in some instances the drawings have been exaggerated and/or simplified in places for illustrative purposes only. One of the ordinary skill in the art will appreciate the many possible applications and variations based on the following examples of possible embodiments. As used herein, the “present disclosure” refers to any one of the embodiments described throughout this document and does not mean that all claimed embodiments must include the referenced aspects.
[0018] FIG. 2 illustrates a side view of a fencing panel 200 , according to one or more embodiments. As depicted, the panel 200 includes a first support post 202 , a second support post 204 , and a plurality of crossmembers 206 (four shown) coupled therebetween. Each crossmember 206 includes a first end 208 and a second end 210 , both ends 208 and 210 having at least one hole (not shown) arranged horizontally therethrough. The crossmembers 206 may be, for example, 12 feet in length. While four crossmembers 206 are shown, one of skill in the art will appreciate that more or less than four crossmembers 206 may be employed, of which may be longer or shorter than 12 feet, in other embodiments and are contemplated herein without departing from the scope of the disclosure.
[0019] Described in further detail below ( FIG. 3 ), briefly, the first support post 202 includes a pair of arms 212 radially extending therefrom, wherein each arm 212 of the pair includes at least one hole 214 arranged therethrough (two holes 214 shown). The second support post 204 similarly includes a pair of arms 216 radially extending therefrom, wherein each arm 216 includes at least one hole 218 arranged therethrough. A means for coupling the crossmember to the support posts 202 , 204 is employed at each end of the crossmember 206 , thereby coupling the crossmember 206 to the support posts 202 , 204 via the associated holes in each end 208 , 210 of the crossmember and holes 214 , 218 in the arms 212 , 216 of each support post 202 , 204 .
[0020] FIG. 3 illustrates a top-down view of the fencing panel 200 , according to one or more embodiments. As depicted, the fencing panel 200 includes the first support post 202 (for visual purposes only, depicted on the left) which has a pair of arms (a first arm 212 a and a second arm 212 b ) coupled thereto. Each arm 212 a and 212 b includes a hole 214 a, 214 b arranged therethrough, wherein the holes 214 a and 214 b are arranged at substantially the same location (i.e., substantially the same distance from the first support post 202 ) in each arm 212 a and 212 b.
[0021] The fencing panel 200 further includes the second support post 204 (for visual purposes only, depicted on the right) which has a pair of arms (a first arm 216 a and a second arm 216 b ) coupled thereto. Each arm 216 a and 216 b has a hole 218 a, 218 b arranged therethrough, wherein the holes 218 a and 218 b are arranged at substantially the same location (i.e., substantially the same distance from the second support post 204 ). FIG. 3 also depicts the crossmember 206 having a first hole 302 horizontally arranged near the first end 208 and a second hole 304 horizontally arranged near the second end 210 .
[0022] In some embodiments, the arms 212 and 216 may be approximately 6 inches long, and each arm 212 a, 212 b, 216 a, 216 b may be a thickness ranging from approximately 3/16 inch to 1 inch. Moreover, for embodiments including a plurality of holes (e.g., holes 214 a, 214 b, 218 a, 218 b ) in each arm, the holes may be spaced approximately 2 inches apart. In other embodiments, the holes may be spaced equally or unequally in distance, as may be appropriate or necessary for coupling of the crossmember 206 to the arms 214 , 218 . In further embodiments, the support posts 202 , 204 may be constructed of a variety of materials, such as a metal (e.g., steel). The support posts 202 , 204 are preferably of a larger gauge, such as 11 or 12 gauge. However, in other embodiments, the support posts 202 , 204 may range from 18 gauge to 22 gauge, and, while lighter in weight, the thinner construction may result in decreased durability and strength.
[0023] A means for coupling the crossmember 206 to each support post 202 , 204 is employed at each end 208 , 210 of the crossmember 206 to couple the crossmember 206 to each support post 202 , 204 via the associated holes 302 , 304 in the ends of the crossmember and holes 214 , 218 in the arms of each support post. Such a means for coupling the crossmember 206 to each support post 202 , 204 may include, for example and without limitation, a lynch pin 306 (two depicted as 306 a and 306 b ) having a head 308 , a body 310 , and an end 312 , and a cotter pin 314 . The head 306 is generally larger in diameter than the hole (e.g. hole 214 or 302 ) which the body 310 will be arranged through, thereby securing the head 306 on one side of the arm 212 or 214 .
[0024] In exemplary operation, the first end 208 of the crossmember 206 may be coupled to the first support post 202 via the first pair of arms 212 a,b. The lynch pin body 310 a may be conveyed through the hole 214 a in the first arm 212 a, through the hole 302 in the first end 208 of the crossmember 206 , and through the hole 214 b in the second arm 212 b, wherein the end 312 a of lynch pin 306 a is secured from removal by coupling of the cotter pin 314 a thereto. In other embodiments, the means may operate to convey the lynch pin body 310 in a reverse order, while still accomplishing the goal of coupling the crossmember 206 to the first pair of arms 212 a,b.
[0025] Similarly, the means can also be employed for coupling the second end 210 of the crossmember 206 to the second support post 204 via the second pair of arms 216 , wherein a second lynch pin 306 b and second cotter pin 312 b are employed. In such an embodiment, the body 310 b of the second lynch pin 306 b is arranged through the hole 218 a of first arm 216 a, through the hole 304 at the second end 210 of the crossmember 206 , and through the hole 218 b of the second arm 216 b, whereby the lynch pin 306 b is secured from removal by coupling of the second cotter pin 314 b to the end 312 b thereof.
[0026] Advantageously, such a means for hingedly coupling the crossmember 206 to the support posts 202 , 204 enables the fencing panel to be arranged on uneven terrain, while allowing the support posts 202 to remain perpendicular, but enabling angular arrangement of the crossmembers 206 . Therefore, the crossmember 206 may run parallel to the terrain, even when at an angle. Further advantageous is the reduction or alleviation of gaps (e.g. gap 116 and gap 120 shown in FIG. 1 ) due to the support posts remaining perpendicular. Even further advantageous are discussed below, for example, in FIG. 5 .
[0027] FIGS. 4A and 4B shows enlarged views of the fencing panel support post 202 , according to one or more embodiments. In FIG. 4A , the first support post 202 is depicted, an embodiment of which includes four arms 212 , each arm 212 having three holes 214 therethrough. Also disclosed and depicted is a means 402 for securing together a plurality of fencing panels (e.g. panel 202 , FIG. 2 ). Such a means 402 may include, for example and without limitation, a chain 404 having a plurality of chain links 406 (three labeled). In some embodiments, the chain 404 is welded at one point to the support post 202 at location 408 , whereas the rest of the chain is free to be wrapped around the support post of another fencing panel, thus joining the two fencing panels together. Advantageously, such welding would prevent loss of the chain. Moreover, welding is generally animal friendly, as there are fewer (if any) sharp edges for an animal to cut themselves on.
[0028] In other embodiments, however, the means 402 may be tied, screwed, bolted, or the like to the support post 202 . Where the means 402 for securing together a plurality of fencing panels includes the chain 404 , the means 402 may further include a chain securing mechanism 410 for securing the non-welded end or portion of the chain after it has been wrapped around a support post of an additional fencing panel. The base of the support post 202 may penetrate into the ground, for example when muddy or on soft soil, in which case a further embodiments of the present disclosure may include a base 414 which resists penetration into the ground. For example the base 414 may be a “j-style” base, as known to those skilled in the art, whereby the support post 202 resists penetration into the ground via a larger surface area of the base 414 , advantageously, helping to maintain stability and desired height of the support post 202 .
[0029] Referring now to FIG. 4B , illustrated is an enlarged portion of the support post 202 , arm 212 having holes 214 , and chain securing mechanism 410 . The chain securing mechanism may be coupled securely to the support post 202 in any variety of ways known to those skilled in the art, one of which including being welded to the support post 202 and/or the arm 212 . The chain securing mechanism 410 , as depicted, operates to secure the chain via a groove 412 for interlocking with at least one of the chain links 406 ( FIG. 4A ). Because the chain securing mechanism precludes the chain 404 from moving freely therethrough, the chain is secured at a desired length, thus also securing together the panels it is attached to and secured around.
[0030] Advantageously, using a chain as a means for securing together a plurality of fencing panel enables some flexing of the panels and movement with the terrain, while still preventing gaps between the panels. Notably, while the chain 404 and chain securing mechanism 410 are described with respect to the first support post 202 , embodiments contemplated herein include where they are arranged on either or both of the support post 202 or 204 .
[0031] FIG. 5 illustrates a side-view of a fencing panel 500 that includes an intermediate support post 502 , according to one or more embodiments. The fencing panel 500 is similar to the fencing panel 200 of FIGS. 3-5 , and includes a first support 202 , as depicted, having four pairs of arms 212 (one labeled), each arm 212 having at least one hole 214 (two holes 214 depicted) therethrough. The fencing panel 500 also includes a second support post 204 , as depicted, having three pairs of arms 216 (one labeled), each arm 216 having at least one hole 214 (two depicted) therethrough. However, the fencing panel 500 further includes the intermediate support post 502 arranged between the first support post 202 and second support post 204 .
[0032] The intermediate support post 502 includes a third pair of arms 506 (three depicted) and a fourth pair of arms 508 (three depicted). In some embodiments, as depicted, the third and fourth pair of arms 506 , 508 are radially extending in opposing directions. Each arm of the third pair of arms 506 includes at least one hole 510 (two depicted) therethrough, the holes 510 of each arm being at substantially the same distance from the intermediate support post 502 . Similarly, each arm of the fourth pair of arms 508 also includes at least one hole 512 (two depicted) therethrough, the holes 512 of each arm being at substantially the same distance from the intermediate support post 502 .
[0033] The fencing panel 500 further includes a first crossmember 514 having a first end 516 and a second end 518 , and a second crossmember 520 having a first end 522 and a second end 524 . The first and second crossmembers 514 , 516 , accordingly, are similar to the crossmember 206 , wherein the end of each crossmember includes a hole (not shown) at each end, thereby enabling coupling of the crossmember to a support post (e.g., support posts 202 or 204 ) or the intermediate support post 502 . Thus, as depicted, the first crossmember 514 is coupled near the first end 516 between the arms 212 of the first support post 202 and near the second end 218 to the third pair of arms 506 of the intermediate post 502 , and the second crossmember 516 is coupled at its first end 522 between the fourth pair of arms 508 of the intermediate post 502 and at its second end 524 between the arms 216 of the second support post 204 .
[0034] Such couplings of the ends of the crossmembers to the arms occurs by a means for coupling the crossmembers to the support posts. Such a means may include, for example and without limitation, a lynch pin which is arranged through the end of the crossmember and the arms, and precluded from removal by attachment of a cotter pin, similar to that described above in FIG. 3 . Advantageously, inclusion of the intermediate support post 502 further enables flexibility of the fencing panel 500 over uneven terrain, while still enabling the first and second support posts 202 , 204 to remain perpendicular. For example, as depicted, the terrain includes a low point or a dip 504 . With the intermediate support post 502 being hingedly coupled between the first support post 202 and the second support post 204 , the intermediate support post 502 is capable of substantially fencing the dip 504 with the first and second crossmembers 514 , 520 , thereby precluding animals from entering or exiting therethrough.
[0035] It will be appreciated by those skilled in the art that while a single intermediate post 502 is depicted, other embodiments contemplated herein may include a plurality of intermediate posts coupled to each other and arranged between the support posts 202 , 204 , without departing from the scope of the disclosure.
[0036] FIG. 6 is an enlarged angled-view of the intermediate support post 502 , according to one or more embodiments. In some embodiments, the intermediate support post 502 may be hollow throughout. In other embodiments, the intermediate support post 502 may include only a bottom portion 602 which is hollow, thereby enabling an extension leg 604 to be inserted or removed therefrom. The bottom portion 602 may include a hole 606 , and the extension leg 604 may also include one or more holes 608 (three depicted) therethrough, thus enabling a means for securing the bottom portion to the extension leg at a desired height via the holes 606 and 608 . In other embodiments, the extension leg 604 may include a plurality of holes 608 at various heights, thus enabling a variety of corresponding height selections for the intermediate post 502 .
[0037] In some embodiments, for example and without limitation, the means for securing the bottom portion 602 to the extension leg 604 at a desired height may include a lynch pin 610 and cotter pin 612 , similar to those previously described, wherein the lynch pin is arranged through the holes 606 and 608 of the bottom portion 602 and extension leg 604 , accordingly.
[0038] In other embodiments, the extension leg 604 may include a base portion 614 which resists penetration into the ground, such as by including a larger surface area in contact with the ground, for example, via “j-style” configuration as known to those skilled in the art.
[0039] In even further embodiments, the third pair of arms 506 and the fourth pair of arms 508 are hingedly coupled to the intermediate support post 502 via a securing mechanism, for example, a lynch pin 616 and cotter pin 618 . Advantageously, such a securing means enables axial movement of the arms 506 and 508 , for example, in the direction labeled A (or, alternatively, in a direction opposite of A) thereby enabling further arrangement of the fencing panel 500 to better conform with the terrain and prevent animal pass through.
[0040] While inclusion of the extension leg 604 brings the benefits described above, gaps may still be left beneath the crossmembers (e.g. crossmembers 514 and 520 ) which a user may want to be fenced in. Briefly, referring back to FIG. 5 , such gaps are illustrated at areas 526 and 528 . However, further embodiments of the fencing panel 500 may prevent such gaps 526 , 528 by further including a third crossmember 530 coupled between one of the support posts (as depicted, the first support post 202 ) and the extension leg 604 . The third crossmember 530 includes a first end 532 and a second end 534 , each of which includes a hole therethrough.
[0041] As depicted, the first end 532 of the third crossmember 530 is coupled to the lowest set of arms 212 of the first support post 202 . Such may be accomplished via similar means as previously discussed for coupling a crossmember to one of the support posts, for example, by employing a lynch pin and cotter pin ( FIG. 3 ). However, the second end 534 of the third crossmember 530 is not coupled to the intermediate support post 502 , but is coupled to the extension leg 604 via the hole in the second end 534 of the third crossmember 530 and one of the holes 608 in the extension leg. Such an embodiment greatly narrows the gap 526 , and thus reduces or precludes animals from passing therethrough.
[0042] FIG. 7 is a flow diagram of an illustrative method 700 for assembling a fencing panel, according to one or more embodiments. At block 702 , the method 700 employs a means for coupling a crossmember to a support post to couple a first end of a first crossmember to a first support post via holes in a first pair of arms radially extending from the first support post and a hole in the first end of the first crossmember. At block 704 , the method 700 further employs the means for coupling a crossmember to a support post to couple a second end of the first crossmember to a second support post via holes in a second pair of arms radially extending from the second support post and a hole in the second end of the first crossmember. Advantageously, such a configuration enables the support posts to remain perpendicular while allowing enhanced contouring of crossmembers with the terrain. In some embodiments, for example and without limitation, the means for coupling a crossmember to a support post includes a lynch pin and cotter pin.
[0043] In other embodiments, a means for securing together a plurality of fencing panels is additionally employed, the means being coupled to one of the support posts. For example, such a means may include a chain having a plurality of chain links, where one end of the chain is welded to one of the support posts. Advantageously, such would prevent loss of the chain. Moreover, such a method of welding is animal safe, as there are fewer (if any) sharp edges for an animal to cut themselves on. Even further, with the welded end acting as an anchor, the non-welded end may be wrapped around another fencing panel, and secured to the first fencing panel at a certain length via a means for securing together a plurality of fencing panels, such as interlocking a link of the chain within a groove of a chain securing mechanism coupled to the same support post as the chain.
[0044] In further embodiments, an intermediate support post is included between the first and second support posts. The intermediate support post includes a third and fourth set of arms, the arms radially extending therefrom in opposite directions in some embodiments. Each arm of the third and fourth sets of arms includes one or more holes arranged therethrough, the holes of each arm for a pair of arms being arranged at substantially the same location or distance from the intermediate support post.
[0045] In some embodiments that include the intermediate support post, the first crossmember is not coupled between the first and second support post, but is coupled between the first support post and the intermediate support post. Thus, the first end of the first crossmember is still coupled to the first support post via the first pair of arms, but the second end of the first crossmember is coupled to the intermediate support post via the holes in the third pair of arms of the intermediate support post and the holes in the second end of the first crossmember. Moreover, the means for coupling a crossmember to a support post may be employed to couple a first end of a second crossmember to the intermediate support post via holes in a fourth pair of arms and a hole in the first end of the second crossmember. Additionally, the means for coupling a crossmember to a support post may be employed to couple the second end of the second crossmember to the second post via the holds in the second pair of arms (of the second post) and a hole in the second end of the second crossmember.
[0046] Advantageously, such a configuration may further enable the support posts of the panel to remain perpendicular, while allowing the crossmembers to better remain parallel with the terrain, thereby preventing gaps and animals from moving through such gaps. It will be appreciated by those skilled in the art that while a single intermediate post is described above, further embodiments contemplated herein may include a plurality of intermediate posts arranged between the first and second support posts without departing from the scope of the disclosure.
[0047] Providing further flexibility and ability to contour to the terrain, further embodiments of the method 700 may include extending an extension leg from within a bottom portion of the intermediate support post towards the ground and employing a means for securing the bottom portion to the extension leg at a desired height via corresponding holes in the bottom portion and extension leg. Advantageously, such may provide support for all support posts, but the intermediate support post in particular, thereby reducing the stress on all portions of the fencing panel.
[0048] Even further embodiments may include employing a second means for coupling the first crossmember to the first pair of arms and the third pair of arms, thereby substantially precluding hinged movement of the first crossmember, but still enabling hinged movement of the second crossmember. In other words, the portion of the fencing panel between the first support post and the intermediate support post would be essentially immobilized, however, the portion of the fencing panel between the intermediate support post and the second support post would continue to be hingedly movable. Such may advantageous to assist stability of the fencing panel on certain terrains.
[0049] Although the disclosure has been described and illustrated with respect to exemplary objects thereof, it will be understood by those skilled in the art that various other changes, omissions, and additions may be made therein and thereto without departing from the scope of the present disclosure.
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A dynamically adjustable fencing system that includes a first support post having a first pair of arms extending therefrom, a second support post having a second pair of arms extending therefrom, and a crossmember pivotally coupled at a crossmember first end to the first support post via the first pair of arms, and further pivotally coupled at a crossmember second end to the second support post via the second pair of arms, thereby enabling dynamic crossmember adjustability of the crossmember.
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This application is a national stage completion of PCT/EP2003/011453 filed Oct. 16, 2003 which claims priority from German Application Serial No. 102 49 048.1 filed Oct. 22, 2002.
FIELD OF THE INVENTION
The invention relates to a switching device.
BACKGROUND OF THE INVENTION
Modern and multi-step vehicle transmission in industrial vehicles have a multi-step main transmission part, an auxiliary-section transmission part and/or one multi-step splitter transmission part. With a splitter transmission the gear steps of the main transmission can be further split in their ratio so that lower ratio ranges result in successive gears. With an auxiliary-section transmission the total ratio of the main transmission, can be increased by it being possible to use all gear steps of the main transmission together with each gear step of the auxiliary-section transmission and in at least one gear step of the auxiliary-section transmission, to step up or down the otherwise direct ratio of the gear steps of the main transmission.
Such a vehicle transmission has been disclosed, for example, in DE 44 22 900 A1. These vehicle transmissions are mostly manually switched in the main transmission part while the switchings in the splitter transmission part and in the auxiliary-section transmission part result by a pneumatic or hydraulic actuator after a corresponding switching has been triggered by the driver. An automated switching device for vehicle transmissions of the kind mentioned above has also been disclosed such as described in EP 0 541 035 B1. Here are combined side-by-side in a control unit actuators of which one actuator operates the splitter transmission part, the main transmission part and the auxiliary-section transmission part. Each one of said actuators engages the ratio steps via a switching rod upon the respective switching devices. Each transmission part having to be operated by a separate actuator with appertaining valves, sensors and switching rods is a disadvantage here. This involves a great multiplicity of parts and the costs and heavy weight related therewith.
The problem on which the invention is based is to show a switching device for a vehicle transmission which simplifies the actuation of the auxiliary-section transmission part.
SUMMARY OF THE INVENTION
A switching device for a multi-step vehicle transmission having one main transmission part and at least one auxiliary-section transmission part comprises switching means for actuating switching elements in the main transmission part and switching means for actuating switching elements in the auxiliary-section transmission part. According to the invention, the switching means for actuating the switching elements in the main transmission part also actuate the switching elements in the auxiliary-section transmission part. In one advantageous development, the switching means for actuating the switching elements in the main transmission part comprise a single selector shaft. In one embodiment, the switching means for actuating the switching elements in the main transmission part comprise one pneumatic, hydraulic or electric actuator for carrying out a switch command and, in one advantageous embodiment, the switching means for actuating the switching elements in the main transmission part also comprise one pneumatic, hydraulic or electric actuator for carrying out a selection command. The respective actuator is preferably controlled by automation, based on a command processed in a control device according to preset rules. In one preferred embodiment, the switching means have a clearance where one element of the switching means, such as a selector finger that actuates the switching elements, especially switching rods, is movable on the selector shaft in direction to a switching operation during a selection procedure for choosing the desired switching element. The motion of the selector finger goes here in the same direction as during a switching operation but, unlike this, represents part of a selection operation. Thereby actuators, which are to perform the actual switching motions, contribute in a certain range to the selection motion. One development shows that on the clearance, one switching element of the auxiliary-section transmission part abuts on one side and one switching element of the main transmission part on the other side. In this clearance, the selector finger changes, during its movement, e.g., from a switching rod, which serves for switching the main transmission part over to a switching rod with which the auxiliary-section transmission is switched. The switching elements are preferably synchronized switching elements. In another and also advantageous development, the switching elements comprise one dog clutch engagement without synchronizing elements. In case of one dog clutch engagement without synchronizing elements, the switching elements close to the clearance are preferably switching elements for the highest and lowest ratio steps of the main transmission part. In one advantageous embodiment, the selector finger also cannot be situated upon a selector shaft, but can be directly actuated by actuators belonging to the switching means being for the purpose directly connected therewith.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of example, with reference to the accompanying drawings in which:
FIG. 1 is a diagrammatic view of the switching device;
FIG. 2 is a diagrammatic view of the switching elements of a synchronized switching; and
FIG. 3 is a diagrammatic view of the switching elements of a dog clutch engagement.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a switching device 2 of a vehicle transmission 4 with one main transmission part 6 , one splitter transmission part 8 and one auxiliary-section transmission part 10 . One actuator 12 operates a selector shaft 14 or a selector finger 38 axially along the arrow direction 16 . By the second actuator 18 , the selector shaft 14 can be swung around its axis of rotation along the arrow direction 20 . With the actuators 12 and 18 are connected connecting lines 22 , 24 , 26 and 28 by way of which the actuators 12 and 18 are controlled. These can be electric lines, but also feedlines, for a control medium in the form of a fluid for a hydraulic or pneumatic adjustment. Here is described one pneumatic control with air, such as often exist in industrial vehicles, conditioned by the vehicle and, together with the brake control, is also used for switching the transmission. In the splitter transmission part is shown one selector fork 30 which engages in a switching element (not shown here) in the splitter transmission part 8 and divides two steps of the splitter transmission to subdivide one gear step in the main transmission part 6 . The selector fork 30 is displaced by an actuator 34 , via a selector rod 32 , axially along the arrow direction 36 whereby the different steps of the splitter transmission part 8 can be switched. The actuators 12 , 18 and 34 are connected with one control device 37 where switch signals are generated according to preset rules.
The selector shaft 14 has the selector finger 38 which in FIG. 1 is placed in a clearance 40 between a selector rod 42 and a selector rod 44 . In this position, the actuator 12 can freely move the selector shaft 14 and therewith the sector finger 38 axially along the arrow direction 16 without one of the selector rods 42 or 44 being moved. A selector fork 46 , which engages in a sliding sleeve (not shown here) in the auxiliary-section transmission part 10 , is fixedly connected with the selector rod 44 . One selector fork 50 , provided for switching two gear steps in the main transmission part 6 , is fixedly connected with the selector rod 42 . These two gear steps constitute the first forward gear and the reverse gear of the main transmission part 6 . Upon the side of the selector rod 42 , opposite to the clearance 40 , one other selector rod 52 is provided in which the selector finger 38 can likewise engage. The selector rod 52 is connected with a selector fork 54 which engages the second and third forward gears in the main transmission part 6 .
In FIG. 2 , the switching sequence of a switch in the main transmission part 6 and auxiliary-section transmission part 10 is described. In this alternative, the auxiliary-section transmission part 10 is provided with one synchronizer unit. According to FIG. 1 , the selector finger 38 is shown in a central position in this diagrammatic view, which it assumes when air from a central air reservoir (not shown here), abuts on the actuators 12 and 18 on all inlets 22 , 24 , 26 and 28 during a pneumatic switching. In a reverse switching from the fourth gear to the third gear of the vehicle transmission 4 , the vehicle clutch is first opened and air abuts on the central air supply. In the vehicle transmission shown here, three forward gears and one reverse gear are provided in the main transmission part 6 so that the first three forward gears are conducted with the slow position GPL of the auxiliary-section transmission part 10 and the fourth forward gear corresponds to the position of the first forward gear in the main transmission part 6 with the quick position GPS of the auxiliary-section transmission part 10 .
The selector rod 44 is shown here in the slow position GPL of the auxiliary-section transmission part 10 .
In the position for the fourth gear as initial position for the reverse switching to be described next, the selector finger 38 is in the area of the selector rod 42 in a position offset to the left relative to the position shown in FIG. 2 so that the selector rod 42 has engaged the first gear in the main transmission part 6 . To that end, the connecting line 24 is aerated on the actuator 12 . The connecting lines 26 and 28 are simultaneously aerated on the actuator 18 in order to hold the selector finger in this position corresponding to the arrow direction 20 . The connecting line 22 is additionally aerated whereby the selector finger 38 assumes the position shown in FIG. 2 , and is in neutral position. Thereupon the vehicle clutch is closed. By de-aerating the connecting line 28 in the drawing plane of FIG. 2 , the selector finger 38 is moved upward until it cannot continue its way in this direction since it strikes against the selector rod 44 . By additional de-aeration of the connecting line 22 that follows in the drawing plane of FIG. 4 , the selector finger 38 moves to the left in the clearance 40 between the selector rod 44 and the selector rod 42 until, in the position GPS, the movement of the selector finger in direction to the aperture being maintained by the actuator 18 can engage in an aperture in the selector rod 44 , and the obstacle to continuation of the upward movement of the selector finger 38 in the drawing plane is eliminated when the aperture is reached. Thereupon the connecting line 22 is again aerated and the selector finger 38 moves the selector rod 44 first until reaching the position N. The connecting line 24 is then de-aerated and the selector finger moves the selector rod 38 fully until reaching the position GPL. The auxiliary-section transmission part is thus switched to the slow ratio position while the main transmission part 6 is in the neutral position from now on. The path between the positions GPS and GPL to be covered for the selector finger corresponds to the path which the selector finger has to cover in one of the selector rods 42 and 52 between the two respectively introduced switching positions. The removal from the neutral position of an engaged switching position on the selector rods 42 and 52 thus corresponds to the removal from the neutral position N of the engaged switching position GPS or GPL on the selector rod 44 . For the final switching in the main transmission part 6 , the connecting line 22 is now de-aerated in order to prevent movement of the selector finger 38 and a locking in the first place. The added aeration of the connecting line 28 results in that the selector finger 38 is downwardly moved in the drawing plane of FIG. 2 until it cannot continue on its way in this direction for its strikes against the selector rod 42 . By an aeration of the connecting lines 22 and 24 that follows in the drawing plane of FIG. 2 , the selector finger 38 moves to the left until it can engage in the aperture in the selector rod 42 in the position N; the movement of the selector finger in direction to this aperture being maintained by the actuator 18 and the obstacle to continuation of the downward movement of the selector finger 38 in the drawing plane is eliminated when reaching the aperture. The connecting line 26 is de-aerated whereby the selector finger 38 can engage in the aperture in the selector rod 52 . In this position, the selector finger 38 remains first until the engine rotational speed required for switching in the main transmission part 6 has been reached. As soon as the desired rotational speed has been reached, the connecting line 22 is first also de-aerated and, in the drawing plane of FIG. 2 , the selector finger 38 moves the selector rod 52 to the left whereby the third gear is engaged. Finally, the central air supply is switched off.
Likewise with the aid of FIG. 2 , the switching sequence of one other switching in the main transmission part 6 and auxiliary-section transmission part 10 is now described. In this alternative, the auxiliary-section transmission part 10 is also provided with one synchronization unit. In an upshift from the third gear to the fourth gear of the vehicle transmission 4 , the vehicle clutch is first opened and air abuts on the central air supply. As already mentioned in the vehicle transmission shown here, three forward gears and one reverse gear in the main transmission part 6 are provided so that the first forward gears are conducted with the slow position GPL of the auxiliary-section transmission part 10 and the fourth forward gear corresponds to the quick position GPS of the auxiliary-section transmission part 10 . In the position for the third gear as an initial position for the upshift to be now described, the selector finger 38 is in the area of the selector rod 52 in a position offset to the left and downward compared to the position shown in FIG. 2 so that the selector rod 52 has engaged the third gear in the main transmission part 6 . To that end, the connecting line 24 is aerated on the actuator 12 . The connecting line 28 is also aerated on the actuator 18 . The connecting line 22 is then additionally aerated whereby the selector finger 38 assumes first a position downwardly offset relative to the position shown in FIG. 2 and is in neutral position. Thereupon the vehicle clutch is closed. By de-aerating the connecting line 28 and aerating the connecting line 26 , the selector finger 38 is downwardly moved in the drawing plane of FIG. 2 until it cannot proceed on its way in this direction, since it strikes against the selector rod 44 . By virtue of the further aeration that follows of the connecting line 24 , the selector finger 38 , in the drawing plane of FIG. 2 , moves to the right in the clearance 40 between the selector rod 44 and the selector rod 42 until it can engage in the position GPL in an aperture in the selector rod 44 ; the movement of the selector finger in direction to this aperture being maintained by the actuator 18 and the obstacle to continuation of the upward movement of the selector finger 38 in the drawing plane being removed again when the aperture is reached. Thereupon the connecting line 24 is again aerated and the selector finger 38 moves the selector rod 44 first until reaching the position N. The connecting line 22 is then de-aerated and the selector finger 38 moves the entire selector rod 44 until reaching the position GPS. The auxiliary-section transmission part 10 is thus switched to the high ratio position while the main transmission part 6 is still in the neutral position. For final switching in the main transmission part 6 , the connecting lines 22 and 24 are now de-aerated in order first to prevent a movement of the selector finger 38 and a locking. The added aeration of the connecting line 28 results in that the selector finger 38 is downwardly moved in the drawing plane of FIG. 2 until it cannot pursue its way in this direction, since it strikes against the selector rod 42 . By an aeration that follows of the connecting lines 22 and 24 , the selector finger 38 moves to the right in the clearance 40 in the drawing plane of FIG. 2 , until it can engage in the position N in the aperture in the selector rod 42 ; the movement of the selector finger in direction to the aperture is maintained by the actuator 18 and the obstacle to continuation of the downward movement of the selector finger 38 in the drawing plane when reaching the aperture being eliminated. In this position, the selector finger 38 remains first until the engine rotational speed required for switching in the main transmission part 6 is reached. As soon as the desired rotational speed is reached, the connecting line 22 is de-aerated and the selector finger 38 moves the selector rod 42 to the left in the drawing plane of FIG. 2 whereby the fourth gear is engaged as first gear in the main transmission part 6 .
In the two switching operations so far described, the auxiliary-section transmission part 10 is reversed while the main transmission part 6 is in neutral, i.e., no gear is engaged in the main transmission part 6 while the engine of the vehicle is adjusted to the relevant connecting rotational speed. The switching in the main transmission part 6 is then carried out as the last part of the entire switching. When a dog clutch engagement is used in the auxiliary-section transmission part 10 , the rotational speed for switching in the auxiliary-section transmission part 10 is adjusted by synchronization of the engine. Therefore in this case, the switching in the auxiliary-section transmission part 10 in this case has to be carried out as the last switching and the switching in the main transmission part 6 is already finished. In order that the clearance 40 for movement of the selector finger 38 can also be reached while the selector rod 42 is in a switching position, the gears of the main transmission part 6 , which are switched by the selector rod 42 in this alternative, have to include the lowest and the highest ratios of the main transmission part 6 . Only then can the selector rod 44 be pulled away from the switching position with the selector finger for adjusting the auxiliary-section transmission part 10 and be reversed from the highest gear of the slow ratio of the auxiliary-section transmission part 10 to the lowest gear of the quick ratio of the auxiliary-section transmission part 10 and vice versa.
In FIG. 3 , the first and the third gear of the main transmission part 6 are located on the selector rod 42 while the second gear and the reverse gear are located on the selector rod 52 . With the aid of FIG. 3 is described the sequence of a switching in the main transmission part 6 and auxiliary-section transmission part 10 . In this alternative, the auxiliary-section transmission part 10 is provided with a dog clutch engagement. According to FIG. 1 , the selector finger 38 is shown in a central position in this diagrammatic graph, which is assumed (shown here) abuts on the actuators 12 and 18 on all inlets 22 , 24 , 26 and 28 during a pneumatic switching.
The selector rod 44 is shown here in the quick position GPS of the auxiliary-section transmission. This is reversed from the position in FIG. 2 , but serves to optimize the switching sequence. The positions of the selector rods have to be arranged differently depending on the structure of the auxiliary-section transmission. In an arrangement of the positions according to FIG. 2 , the switching sequence, described below, has to be accordingly adapted.
In a reverse switch from the fourth gear to the third gear of the vehicle transmission 4 , the clutch is first opened and air abuts on the central air supply. As already shown, relative to the other alternative, in the main transmission part 6 of the vehicle transmission (shown here), three forward gears and one reverse gear are provided so that the first three forward gears are conducted with the slow position GPL of the auxiliary-section transmission part 10 and the fourth forward gear corresponds to the position of the first forward gear in the main transmission part 6 combined with the quick position GPS of the auxiliary-section transmission part 10 . In the position for the fourth gear as initial position for the reverse switch to be next described, the selector finger 38 is in the area of the selector rod 42 in a position offset to the right contrary to the position, shown in FIG. 3 , 50 that the selector rod 42 has engaged the first gear in the main transmission part 6 . To that end, the connecting line 22 is aerated on the actuator 12 . The connecting lines 26 and 28 are also simultaneously aerated on the actuator 18 in order to keep the selector finger 38 in this position 4 . accord to the arrow directions 20 . The connecting line 22 is then de-aerated. Due to the de-aeration of the connecting line 28 in the drawing plane of FIG. 3 , the selector finger 38 is moved upward until it can engage in the aperture in the selector rod 44 in the position GPS. Thereupon the connecting lines 22 and 24 are again aerated and the selector finger 38 moves the selector rod 44 until reaching the position N. The auxiliary-section transmission part 10 is thus 4 . switched to the neutral position while the main transmission part 6 remains in the first gear. The connecting lines 22 and 24 are de-aerated. By additional aeration of the connecting line 28 , the selector finger 38 moves downwards in the drawing plane of FIG. 3 until it cannot continue on its way in this direction, since it strikes against the selector rod 42 . By an additional aeration that follows of the connecting line 22 in the drawing plane of FIG. 3 , the selector finger 38 moves to the right the clearance 40 between the selector rod 44 and the selector rod 42 until it can engage in the position for the first gear in the aperture in the selector rod 42 ; the movement of the selector finger 38 in direction to the aperture being maintained by the actuator 18 and the obstacle to continuing the downward movement of the selector finger 38 in the drawing plane when reaching the aperture being eliminated. After reaching the rotational speed needed for switching the main transmission part 6 , the connecting line 22 is de-aerated and the connecting line 24 aerated and, in the drawing plane, the selector rod 42 switches to the left until the switching position for the third gear is reached in the main transmission part 6 . Thereupon the vehicle clutch is closed. For final switching in the auxiliary-section transmission part 10 , the connecting lines 22 and 24 are now de-aerated in order to prevent movement of the selector finger 38 in the first place. By de-aeration of the connecting line 28 , the selector finger 38 is moved upward in the drawing plane of FIG. 3 until it cannot continue on its way in this direction for having stricken against the selector rod 44 . By simultaneous aeration that follows of the connecting lines 22 and 24 , the selector finger 38 , in the drawing plane of FIG. 3 , moves to the right in the clearance 40 between the selector rod 44 and the selector rod 42 until it can engage in the position N in the aperture in the selector rod 44 ; the movement of the selector finger 38 in direction to this aperture being maintained by the actuator 18 and the obstacle to continuation of the upward movement of the selector finger 38 in the drawing plane being eliminated when the aperture is reached. The selector finger 38 remains in this position first until reaching the engine rotational speed required for switching in the auxiliary-section transmission part 10 . As soon as the desired rotational speed has been reached, the connecting line 22 is de-aerated and the selector finger 38 moves the selector rod 44 until the position GPL is reached. The connecting line 24 is de-aerated. The additional aeration of the connecting line 28 results in that the selector finger 38 is moved downwards in the drawing plane of FIG. 3 until, in the position of the switched third gear of the main transmission part 6 , it can engage in the aperture in the selector rod 42 . Finally the central air supply is switched off.
The switching sequence of another switching in the main transmission part 6 and auxiliary-section transmission part 10 is now described, likewise with reference to FIG. 3 . In this alternative, the auxiliary-section transmission part 10 is also provided with a dog clutch engagement. In an upshift from the third gear to the fourth gear of the vehicle transmission 4 , the clutch is first opened and air abuts on the central air supply. In the position for the third gear as starting position for the upshift to be described, the selector finger 38 is in the area of the selector rod 42 in a position offset to the left, unlike the position shown in FIG. 3 , so that the selector rod 42 has engaged the third gear in the main transmission part 6 . For the purpose, the connecting line 24 on the actuator 12 is aerated. The connecting lines 26 and 28 on the actuator 18 are also simultaneously aerated in order to keep the selector finger 38 in this position, according to the arrow direction 20 . The connecting line 24 is additionally de-aerated. By the de-aeration of the connecting line 28 , the selector finger 38 is moved upwards in the drawing plane of FIG. 3 until it can engage in the position GPL in an aperture in the selector rod 44 . Thereupon the connecting lines 22 and 24 are again aerated and the selector finger 38 moves the selector rod 44 until reaching the position N. The auxiliary-section transmission part 10 is thus switched to the neutral position while the main transmission part 6 remains in the position for the third gear. The connecting lines 22 and 24 are de-aerated. By additional aeration of the connecting line 28 , the selector finger 38 moves downwardly in the drawing plane of FIG. 3 until it cannot proceed on its way in this direction by striking against the selector rod 42 . By an additional aeration that follows of the connecting line 24 in the drawing plane of FIG. 3 , the selector finger 38 moves to the left in the clearance 40 between the selector rod 44 and the selector rod 42 until it can engage in the position for the third gear in the aperture in the selector rod 42 , the movement of the selector finger 38 in direction to the aperture being maintained by the actuator 18 and the obstacle to the continuation of the downward movement of the selector finger 38 in the drawing plane being eliminated. After reaching the rotational speed needed for switching in the main transmission part 6 , the connecting line 24 is de-aerated and the connecting line 22 aerated and the selector rod 42 , in the drawing plane, switches to the right until reaching the switching position for the first gear in the main transmission part 6 . Thereupon the vehicle clutch is closed. For the final switching in the auxiliary-section transmission part 10 , the connecting lines 22 and 24 are now de-aerated in order next to prevent a movement of the selector finger 38 . By de-aerating the connecting line 28 , the selector finger 38 is moved upwards in the drawing plane of FIG. 3 until it cannot continue on its way in this direction since it strikes against the selector rod 44 . By a simultaneous aeration that follows of the connecting lines 22 and 24 , the selector finger 38 , in the drawing plane of FIG. 3 , moves to the left in the clearance 40 between the selector rod 44 and the selector rod 42 until, in the position N, it can engage in the aperture in the selector rod 44 , the movement of the selector finger in direction to the aperture is maintained by the actuator 18 and the obstacle to continuation, in the drawing plane, of the upward movement of the selector finger 38 until reaching the aperture being eliminated. In this position, the selector finger 38 remains mainly until reaching the engine rotational speed required for switching in the auxiliary-section transmission part 10 . As soon as the desired rotational speed has been reached, the connecting line 24 is de-aerated and the selector finger 38 moves the selector rod 44 until reaching the position GPS. The connecting line 22 is de-aerated. The additional aeration of the connecting line 28 results in that the selector finger 38 , in the drawing plane of FIG. 3 , is moved downwards until it can engage in the position of the switched first gear of the main transmission part 6 in the aperture in the selector rod 42 . The central air supply is finally switched off.
By the design described, it is possible for switching the auxiliary-section transmission part 10 to eliminate a separate actuator with appertaining control and control valves, the same as the mechanical transmission needed between this actuator and the selector fork in the auxiliary-section transmission part 10 . This operates with special advantage when a transmission originally laid out for four gear steps in the main transmission part 6 drops one of the gear steps whereby a selector rod can be eliminated. Thereby the number of gears of the vehicle transmission is certainly reduced but, in the switching expenses, can thereby be saved.
REFERENCE NUMERALS
2 switching device
4 vehicle transmission
6 main transmission part
8 splitter transmission part
10 auxiliary-section transmission part
12 actuator
14 selector shaft
16 arrow direction
18 actuator
20 arrow direction
22 connecting line
24 connecting line
26 connecting line
28 connecting line
30 selector fork
32 selector rod
34 actuator
36 arrow direction
37 control device
38 selector finger
40 clearance
42 selector rod
44 selector rod
46 selector fork
50 selector fork
52 selector rod
54 selector fork
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A switching device ( 2 ) for a multi-step vehicle transmission ( 4 ) having one main transmission part ( 6 ) and an auxiliary-section transmission part ( 10 ) comprising the switching mechanisms ( 12, 14, 18, 38 ) for actuating switching elements ( 44, 50, 52, 54 ) in the main transmission part ( 6 ) and switching mechanisms ( 12, 14, 18, 38 ) for actuating switching elements ( 42, 46 ) in the auxiliary-section transmission part ( 10 ). The switching mechanisms ( 12, 14, 18, 38 ) for actuating the switching elements ( 44, 50, 52, 54 ) in the main transmission part ( 6 ) also actuate the switching elements ( 42, 46 ) in the auxiliary-section transmission part ( 10 ).
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 10/667,040 filed on Sep. 22, 2003, which is a continuation of application Ser. No. 09/882,536 filed on Jun. 14, 2001 and claims priority under 35 U.S.C. 119 of Danish application nos. PA 2000 00932 and PA 2001 00372 filed on Jun. 16, 2000 and Mar. 7, 2001 respectively, and U.S. provisional application Nos. 60/214,470 and 60/275,790 filed on Jun. 27, 2000 and Mar. 14, 2001 respectively. The benefit of application Ser. No. 09/882,536 filed on Jun. 14, 2001 in the U.S. is claimed under 35 U.S.C. 120, the contents of which are fully incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to syringes by which a dose can be set by rotating a dose setting member and by which an injection button elevates from an end of the syringe a distance proportional to the set dose and wherein the set dose can be injected by pressing home the injection button to its not elevated position.
[0003] An almost classic pen of this type is described in EP 327 910.
[0004] By setting a dose on this pen a tubular member forming an injection button is screwed up along a threaded piston rod a distance corresponding to the distance said piston rod must be moved to inject the set dose. The tubular member simply forms a nut which is during the dose setting screwed away form a stop and which is during the injection pressed back to abutment with said stop and the force exerted on the button is directly transmitted to the a piston closing one end of an ampoule in the syringe which ampoule contains the medicament to be injected. When the piston is pressed into the ampoule the medicament is pressed out through a needle mounted through a closure at the other end of the ampoule. By time it has been wanted to store larger amount in the ampoules, typically 3 ml instead of 1.5 ml. As it has not been appropriate to make the syringe longer the ampoule is instead given a larger diameter, i.e. the area of the piston facing the medicament in the ampoule has been doubled and consequently the force which has to be exerted on the piston to provide the same pressure as previously inside the ampoule has been doubled. Further the distance the piston has to be moved to inject one unit of the medicament has been halved.
[0005] This development is not quite favourable, as especially users having reduced finger strength have their difficulties in pressing the injection button, a problem that is further increased when still thinner needles are used to reduce the pain by injection. Also with quite small movements of the button it is difficult to feel whether the button is moved at all and by injection of one unit from a 3 ml ampoule the piston and consequently the injection button has to be moved only about 0.1 mm.
[0006] Consequently a wish for a gearing between the injection button and the piston has occurred so that the button has a larger stroke than has the piston. By such a gearing the movement of the injection button is made larger and the force, which has to be exerted on the injection button, is correspondingly reduced.
[0007] In EP 608 343 a gearing is obtained by the fact that a dose setting element is screwed up along a spindle having a thread with a high pitch. When said dose setting element is pressed back in its axial direction the thread will induce a rotation of said dose setting element, which rotation is via a coupling transmitted to a driver nut with a fine pitch which driver nut will force a threaded not rotatable piston rod forward.
[0008] A similar gearing is provided in WO 99/38554 wherein the thread with the high pitch is cut in the outer surface of a dose setting drum and is engaged by a mating thread on the inner side of the cylindrical housing. However, by this kind of gearing relative large surfaces are sliding over each other so that most of the transformed force is lost due to friction between the sliding surfaces. Therefore a traditional gearing using mutual engaging gear wheels and racks is preferred.
[0009] From WO 96/26754 is known an injection device wherein two integrated gear wheels engages a rack fixed in the housing and a rack inside a plunger, respectively. When the plunger is moved axially in the housing the rack inside this plunger can drive the first gear wheel to make the other integral gear wheel move along the fixed rack in the housing. Thereby the gear wheel is moved in the direction of the plunger movement but a shorter distance than is this plunger and this axial movement of the integrated gear wheels is via a housing encompassing said gear wheels transmitted to a piston rod which presses the piston of an ampoule further into this ampoule. However, the rack inside the plunger is one of a number axial racks provided inside said plunger. These racks alternates with untoothed recesses, which allow axial movement of the plunger without the first gear wheel being in engagement with a rack in this plunger. This arrangement is provided to allow the plunger to be moved in a direction out of the housing when a dose is set. When the plunger is rotated to set a dose it is moved outward a distance corresponding to one unit during the part of the rotation where the first gear wheel passes the untoothed recess, thereafter the first gear wheel engages one of the racks so the set unit can be injected, or the rotation can be continued to make the first gear wheel pass the next recess during which passing the set dose is increased by one more unit and so on until a dose with the wanted number of units is set.
[0010] A disadvantage by this construction is that the teeth of the racks and gearwheels alternating have to be brought in and out of engagement with each other with the inherit danger of clashing. As only a few racks separated by intermediary untoothed recess can be placed along the inner surface of the plunger only few increments can be made during a 360 degree rotation.
SUMMARY OF THE INVENTION
[0011] It is an objective of the invention to provide an injection device, which combines the advantages of the devices according to the prior art without adopting their disadvantages and to provide a device wherein is established a direct gearing, i.e. a gearing by which more transformations of rotational movement to linear movement and linear movement to rotational movement are avoided, between the injection button and the piston rod.
[0012] This can be obtained by an injection device comprising a housing wherein a piston rod threaded with a first pitch is non rotatable but longitudinally displaceable guided, a nut engaging the thread of the piston rod which nut can be screwed along the threaded piston rod away from a defined position in the housing to set a dose and can be pressed back to said defined position carrying the piston rod with it when the set dose is injected, a dose setting drum which can be screwed outward in the housing along a thread with a second pitch to lift an injection button with it up from the proximal end of the housing, which injection device is according to the invention characterised in that a gearbox is provided which provides a gearing between the axial movements of the injection button and the nut relative to the housing which gearing has a gearing ratio corresponding to the ratio of said second and first pitch.
[0013] In a preferred embodiment the gearing between the movements of the injection button and the nut is obtained by the gearbox comprising at least one gear wheel carried by a connector which projects from the gear box longitudinally displaceable but non rotatable relative to said gearbox and is integral with the nut, a first rack integral with a first element of the gearbox, which element is rotational but not longitudinally displaceable relative to the housing, and second element carrying a second rack projecting from said gearbox longitudinally displaceable but non rotatable relative to said first element and being coupled to the injection button to follow longitudinal movements of said button, the at least one gear wheel engaging the first and the second rack, respectively, and being dimensioned to provide a gearing by which a longitudinal movement of the second rack is transformed to a longitudinal movement of the connector with a gearing ratio for the mentioned longitudinal movements of the second rack and the connector relative to the housing, which gearing ratio corresponds to the ratio of said second to said first pitch.
[0014] In such a device only the forces necessary to drive the dose setting drum are transformed by a thread with a high pitch whereas the forces necessary to move the piston by injection is transmitted to said piston through a conventional gear with constantly engaging gears and racks.
[0015] The piston rod is provided with a stop for the movement of the nut along the thread of said piston rod. This way a dose setting limiter is provided in the classic way, which involves no additional members to prevent setting of a dose exceeding the amount of liquid left in the ampoule.
[0016] In the following the invention is described in further details with references to the drawing, wherein
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 schematically shows a sectional view of an injection device according to the invention, and
[0018] FIG. 2 shows schematically a sectional view of the gear box along the line I-I in FIG. 1 ,
[0019] FIG. 3 shows a longitudinal sectional view in the dose setting part of another embodiment of an injection device according to the invention,
[0020] FIG. 4 shows a longitudinal sectional view perpendicular to the view in FIG. 3 , and
[0021] FIG. 5 shows an exploded picture of the of the device shown in FIGS. 3 and 4 .
DETAILED DESCRIPTION
[0022] In the device shown in FIG. 1 an elongated cylindrical housing 1 has a partitioning wall 2 which divides the housing in a compartment containing a dose setting mechanism and a compartment 3 designed for the accommodation of a not shown ampoule. A threaded piston rod 4 has a not round cross section by which it fits through a central opening in the wall 2 so that the piston rod 4 can be displaced longitudinally through the central opening in the wall 2 but not rotated relative to this wall.
[0023] Concentrically with the housing 1 the wall 2 carries on its side turning away from the compartment 3 a tubular element 5 which is at a part of it adjacent to the wall 2 provided with an outer thread 6 and which has at its free end a circumferential recess 7 . A ring shaped coupling element 8 on a gear box 9 engages the recess 7 . By this coupling the gearbox is fixed in the housing 1 in a way that allows the gearbox 9 to rotate in the housing but not to be axially displaced relative to said housing.
[0024] In the gearbox 9 a gear wheel assembly comprising two integral gear wheels is journaled on a shaft 11 , which runs perpendicular to the longitudinal axis of the device between two axial connection bars 12 . The connection bars 12 project from the gear box towards the partition wall 2 and are connected to a nut 13 which adjacent to the wall 2 engages the thread of the piston rod 4 . The gear wheel assembly comprises a gear wheel 14 with a large diameter engaging the teeth of a rack 15 which is guided in the gear box to be displaced in the longitudinal direction of the device, and a gear wheel 16 with a small diameter engaging a rack 10 in FIG. 2 extending in the longitudinal direction of the device on the inner wall of the gearbox 9 . The gear wheel 16 with the small diameter may be divided into two gear wheels placed on each side of the of the gear wheel 14 , and the rack on the inner wall of the gearbox 9 may have a longitudinal recess without any teeth to make room for the gear wheel 14 .
[0025] A tubular dose setting drum 17 fitting into the housing 2 is at an end provided with an internal thread mating and engaging the outer thread 6 of the tubular element 5 and has at its other end a part with enlarged diameter forming a dose setting button 18 . Due to the engagement with the thread 6 the dose setting drum 17 may be screwed in and out of the housing to show a number on a not shown helical scale on its outer surface in a not shown window in the housing 1 .
[0026] A bottom 19 in a deep cup shaped element, which has a tubular part 20 fitting into the dose setting drum 17 and encompassing the gearbox 9 , forms an injection button. Coupling means between the dose setting drum 17 and the cup shaped element ensures that rotation of the dose setting drum 17 is transmitted to the cup shaped element. Further the inner wall of the tubular part 20 has longitudinal recesses 22 engaged by protrusions 23 on the gearbox 9 so that rotation of the dose setting drum 17 via the cup shaped element is transmitted to the gearbox 9 .
[0027] At the edge of the open end of the cup shaped element a rosette of V-shaped teeth are provided, which teeth engage a corresponding rosette of V-shaped teeth 24 on a ring 25 which is pressed against the edge of the cup shaped element by a spring 26 which is compressed between a not toothed side of the ring 25 and a round going shoulder 27 on the inner wall of the dose setting drum 17 at an inner end of the inner thread of this drum. The ring is provided with an inner recess, which is engaged by a longitudinal rib 28 on the tubular element 5 so that the ring 25 can be displaced in the axial direction of the device but cannot be rotated relative to the housing 1 . Thereby a click coupling is established which makes a click noise when the V-shaped teeth at the edge of the cup shaped element by rotation of this element rides over the V-shaped teeth of the ring 25 .
[0028] A head 29 on the projecting end of the rack 15 is with a play fixed at the bottom of the cup shaped element between the bottom 19 forming the injection button and an inner wall 30 near this bottom. The rack is fixed in a position with its head pressed against the wall 30 by a spring 31 between the bottom 19 and the head 29 .
[0029] To set a dose the dose setting button 18 is rotated to screw the dose-setting drum 17 up along the thread 6 . Due to the coupling 21 the cup shaped element will follow the rotation of the dose-setting drum 17 and will be lifted with this drum up from the end of the housing 1 . By the rotation of the cup shaped element the V-shaped teeth 24 at the edge of its open end will ride over the V-shaped teeth of the non rotatable ring 25 to make a click sound for each unit the dose is changed. A too high set dose can be reduced by rotating the dose setting button 18 in the opposite direction of the direction for increasing the dose. When the dose setting drum is screwed up along the thread 6 on the tubular element 5 the ring 25 will follow the dose setting drum in its axial movement as the spring 26 is supported on the shoulder 27 . The spring will keep the V-shaped teeth of the ring 25 and the cup shaped element in engagement and maintain in engagement the coupling 21 , which may comprise A-shaped protrusions 32 on the cup shaped element engaging A-shaped recesses in an inner ring 33 in the dose setting button 18 .
[0030] The rotation of the dose setting button 18 and the cup shaped element is further transmitted to the gearbox 9 through the protrusions 23 on this gearbox engaging the longitudinal recesses 22 in the inner wall of the tubular part 20 of said cup shaped element. The rotation of the gearbox 25 is through the connection bars 12 transmitted to the nut 13 , which is this way screwed up along the thread of the piston rod 4 and lifted away from its abutment with the wall 2 when a dose it set. As the dose is set by moving the nut 13 on the very piston rod which operates the piston in the not shown ampoule in the compartment 3 a dose setting limiter, which ensures that the size of the set dose does not exceed the amount of medicament left in the ampoule, can easily be established by providing the piston rod 4 with a stop 35 which limits the movement of the nut 13 up along the piston rod 4 .
[0031] Due to the confinement of the head 29 in the space between the bottom 19 and the wall 30 of the cup shaped element, the rack 15 is drawn with the injection button outward. Also the axial movement of the nut 13 relative to the housing 1 will be transmitted to the gear wheel assembly through the connection bars 12 and this movement will through the gear-box induce an outward movement of the rack 15 . This induced outward movement have to be the same as the outward movement induced by outward movement of the injection button. This is obtained by dimensioning the gear wheels of the gearbox 9 so that the gear ratio for the movements of the connection bars 12 and the rack 15 relative to the housing corresponds to the ratio of the pitches for the thread on the piston rod and for the thread 6 for the longitudinal movement of the dose setting drum 17 .
[0032] To inject a set dose the injection button is pressed by pressing on the bottom 19 . In the initial phase of the pressing the spring 31 is compressed where after the pressing force is directly transmitted to the head 29 of the rack 15 and this way to the rack 15 itself. Through the gear box 9 the force is transformed and is transmitted through the connection bars 12 to the nut 13 which will press the piston rod 4 into the compartment 3 until the dose-setting drum 17 abuts the wall 2 .
[0033] During the initial phase of the movement of the injection button the A-shaped protrusions 32 on the cup shaped element will be drawn out of their engagement with the A-shaped recesses in the ring 33 . The dose-setting drum 17 can now rotate relative to the injection button and will do so when the A-shaped protrusions 32 press against a shoulder 34 at the bottom of the dose setting button 18 . Only a force sufficient to make the dose setting drum rotate to screw itself downward along the thread 6 is necessary as the force necessary to make the injection is transmitted to the piston rod 4 through the gearbox 9 . A helical reset spring 36 concentric with the dose setting drum can be mounted at the lower end of this drum and can have one end anchored in the dose setting drum 17 and the other end anchored in the wall 2 . During setting of a dose this spring may be tighter coiled so that on the dose setting drum it exerts a torque approximately corresponding to the torque necessary to overcome the friction in the movement of the dose setting drum along the thread 6 so that the force which the user have to exert on the injection button is only the force necessary to drive the piston rod into an ampoule to inject the set dose.
[0034] It shall be noticed that use of only one size gear wheel which engages as well the rack 15 , which is movable relative to the gear box 9 , as the rack 10 , which is unmovable relative to the gear box, provides a gearing ratio of 2:1 for the longitudinal movement relative to the syringe housing 1 for the movable rack 15 and the connector 12 , which carries the shaft 11 of the gear wheel.
[0035] FIGS. 3 and 4 shows a preferred embodiment wherein only one size gear wheel is used and wherein elements corresponding to elements in FIGS. 1 and 2 are given the same references as these elements with a prefixed “1”.
[0036] For manufacturing reasons minor changes are made. So the partitioning wall 102 and the tubular element 105 are made as two parts which are by the assembling of the device connected to each other to make the assembled parts act as one integral part. The same way the dose setting drum 117 and the dose setting button 118 are made as two parts, which are fixed firmly together.
[0037] A circumferential recess 107 is provided as an outer recess at the free end of the tubular part 105 and a ring shaped coupling element is provided as an inner bead 108 on the gear-box element 109 which bead engages the recess 107 to provide a rotatable but not axially displaceable connection between the tubular part 105 and the gearbox.
[0038] A tubular element 120 having ridges 122 which engages recesses 123 on the gearbox is at its upper end closed by a button 119 from which a force provided by pressing this button is transmitted to the tubular element 120 .
[0039] The gearbox is formed by two shells, which together form a cylinder fitting into the tubular element where the shells are guided by the engagement between the ridges 122 and the recesses 123 . Racks 110 and 115 are provided along edges of the shells facing each other. One shell forming the gearbox part 109 is provided with the inner bead 108 , which engages the circumferential recess 107 at the end of the central tubular part 105 and carries the rack 110 . The other shell is axially displaceable in the tubular element 120 and forms the rack 115 . At its outer end projecting from the gearbox the shell carrying the rack 115 is provided with a flange 140 which is positioned in a cut out 141 in the end of the tubular element 120 carrying the button 119 so that this button and the tubular element 120 can be moved so far inward in the device that the engagement of the teeth 132 and 133 can be released before the button 119 abuts the flange 140 .
[0040] A tubular connection element 112 connects the threaded piston rod 104 with the gearbox. At its end engaging the piston rod 104 the connection element has a nut 113 with an internal thread mating the external thread of the piston rod. At its end engaging the gear box the connection element is provided with two pins 111 projecting perpendicular to the longitudinal axis of the connection element 112 at each side of this element. Each pin 111 carries a gear wheel 114 which is placed between and engages the two racks 110 and 115 . This way the connection element 112 will be rotated with the gear box but can be displaced axially relative to said gear box when the racks 110 and 115 are moved relative to each other. In practice it will be the rack 115 , which is moved relative to the gearbox element 109 and the housing and will by the shown construction result in a movement of the connection element 112 relative to housing a distance which is half the distance which the rack 115 is moved. A ring 125 which is at its periphery provided with a rosette of teeth 124 and has a central bore fitting over the central tube in the housing 101 so that this ring 125 can be axially displaced along said central tube 105 , but internal ridges 128 in the central bore of the ring 125 engages longitudinal recesses 137 in the central tube to make the ring non rotatable in the housing so that a rosette of teeth at the edge of the tubular element 120 can click over the teeth 124 of the ring when said tubular element is rotated together with the dose setting drum 117 . A spring 126 working between the ring 125 and an internal shoulder 127 provided in the dose setting drum 117 makes the ring follow the tubular element 120 when this element with the dose setting drum is moved longitudinally in the housing. To make the dose setting drum easy rotatable, especially when said dose setting drum is pressed inward in the housing, a roller bearing having an outer ring 142 supported by the shoulder 127 and an inner ring 143 supporting a pressure bushing 144 which supports the spring 126 . By the provision of this smooth running support only very small axial forces are needed to rotate the dose setting drum 117 back to its zero position when a set dose is injected. This solution replaces the provision of a reset spring as the spring 36 in FIG. 1 . The bearing is shown as a radial bearing but can be replaced by an axial bearing
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A medication dispensing device with a housing and a member wherein the member is moveable in a distal direction is useful in delivering medication to a patient. A fluid container can be used with the device and often has a moveable piston at one end and an outlet at the other. The member receives a force from a user and drives the piston in the distal direction to expel medication. A intermediate system is disposed between the member and the piston including a gear set that has a pinion in meshed engagement with a rack. The system allows the member to move a greater distance than the piston moves thereby increasing the force on the piston.
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BACKGROUND OF THE INVENTION AND RELATED ART STATEMENT
The present invention relates to a connecting device for connecting one plate with the other plate, which is formed of a support column in a plate or rectangular shape formed at a lower surface of a base flange, and elastically deformable engaging members are attached to both sides of the support column. Each engaging member is enlarged or protruded outwardly in a middle portion in an axial or longitudinal direction of the support column. An upper side of the base flange is fixed to one plate, and the support column and the engaging members are forcibly inserted into a circular connecting hole formed in the other plate, so that the one and the other plates are connected together. In particular, the connecting device is improved in durability when it is used repeatedly, and the insertion force and removing force are reduced when it is fixed and removed, so that working ability is improved.
Conventionally, as a connecting device for connecting two plates together, a connecting device disclosed in Japanese Patent Publication (KOKAI) No. 3-113108 has been known. As shown in FIGS. 13(A)-13(D), a support column d in a plate or rectangular shape is formed to project from a lower surface of a circular shape base flange a, on which a connecting flange c is attached through a neck b, and elastically deformable engaging members e are attached to both sides of the support column d. Each engaging member e is integrally formed to project from the lower surface of the base flange a, and tips or lower ends of the engaging members e are integrally joined with the lower end of the support column d. The engaging member e has a circular arc shape in a lateral cross section, and a middle portion in a longitudinal or axial direction of the support column, which is enlarged laterally. In the drawings, f is an elastically deformable flange for preventing wobbling of the connecting device, and g is a depression formed in the neck b and opened at an upper portion of the connecting flange c for reducing a material of the connecting device.
As shown in FIG. 13(D), the connecting device is fixed by inserting the connecting flange c and the neck b into a hole h 1 formed of two circular openings and disposed in one plate P 1 , and also inserting the support column d and the engaging members e into a round engaging hole h 2 formed in the other plate P 2 . An area around the engaging hole h 2 is held between the enlarged portions of the engaging members e and the flange f for preventing wobbling formed at the lower side of the base flange a. Thus, the plates P 1 and P 2 are connected together.
However, as shown in FIG. 13(C), the engaging members e are formed separately around the support column d to respectively cover areas from the different side edges of the support column d to the middle portions of the support column d in the width direction. Thus, the engaging members e can abut against the inner surface of the engaging hole h 2 substantially equally. In this case, if the projecting distances (enlarged amount) or elasticity of the engaging members e are increased to form good fixing force, a force required to forcibly insert the connecting device into the engaging hole h 2 becomes large to decrease the working ability. On the other hand, if the projecting distances or elasticity of the engaging members e are reduced with reference to the working ability, a sufficient fixing force is not obtained.
In the past few years, in case two plates are connected to and disconnected from each other, the connecting devices are recovered and used again. In this case, if the projecting distances (enlarged amount) or elasticity of the engaging members e are increased, the working ability for forcibly inserting and removing the connecting device decreases. Also, the enlarged portions of the engaging members e are ground at the edge of the engaging hole h 2 by repeated insertion and removal of the connecting device, so that the initial ability or effect of the connecting device may not be obtained.
Further, in case the connecting devices are integrally formed of plastic by an injection molding, the plastic at the neck b with large thickness contracts significantly, so that molding defect, such as depression at the upper center portion of the connecting flange c, is liable to occur. In this connecting device, the depression g is formed in the neck b to face upwardly from the connecting flange c to form the thickness of the neck b as in the other portions, so that molding defect due to contraction of the plastic is avoided. However, a mold having a thickness reducing pin for forming the depression g has to be formed separately from a mold for forming a main portion of the connecting device in view of the mold disassembling or separating direction. Thus, it requires a complicated molding steps by using a three-phase or three-separation mold, which causes an increase of the cost of the connecting device.
The present invention has been made in view of the above circumstances.
An object of the invention is to provide a connecting device for connecting two plates, which can surely provide good fixing force, and good working ability in fixing and removal of the connecting device.
Another object of the invention is to provide a connecting device as stated above, wherein the ability of the connecting device is not degraded even if the connecting device is fixed and removed repeatedly.
A further object of the invention is to provide a connecting device as stated above, which can be easily manufactured by two-phase or two-separation mold.
Further objects and advantages of the invention will be apparent from the following description of the invention.
SUMMARY OF THE INVENTION
In order to attain the above objects, in a connecting device of the invention, a support column in a plate shape is formed at a lower side of a base flange to project outwardly therefrom, and elastically deformable engaging members are formed at both sides of the support column and project from the lower surface of the base flange. Tips or lower ends of the engaging members are joined together with a tip or lower end portion of the support column, and each engaging member has a circular arc shape in a lateral cross section. A middle portion of the engaging member in the axial or longitudinal direction of the support column is projected or enlarged laterally outwardly. One plate is fixed to an upper side of the base flange, and the support column and the engaging members are forcibly inserted into a circular connecting hole formed in the other plate so that a peripheral area of the connecting hole is held between the enlarged portions of the engaging members and a lower surface of the base flange. Thus, the one and the other plates are connected together.
In the invention, the width of a base end of the support column adjacent to the base flange is identical to the inner diameter of the connecting hole. One side edge of the support column is cut diagonally from the middle portion to the lower end portion thereof, and the other side edge of the support column is cut diagonally from near the base end to the lower end portion. Each of the engaging members disposed on each side of the support column is formed to cover from near the one side edge of the support column to a middle of the support column in the width direction.
In accordance with the connecting device of the invention, even if the projecting distances (enlarged amount) or elasticity of the engaging members are relatively increased in view of the fixing force to the engaging hole formed at the other plate, insertion and removal of the connecting device can be performed with good working ability without increasing the insertion force to the engaging hole and the removal force from the engaging hole. Further, it is possible to establish a good fixing force.
Namely, in case the connecting device of the invention is fixed to the engaging hole formed in the other plate, the support column and the engaging members are forcibly inserted into the engaging hole. The engaging members pass through the engaging hole by elastically deforming the engaging members inwardly, and then the engaging members are elastically recovered. As a result, the periphery of the engaging hole is held between the enlarged portions of the engaging members and the base flange. In this case, in the connecting device of the invention, since each of the engaging members is formed to cover from the one side edge of the support column to a middle of the support column in the width direction, the counter forces of the engaging members generated when the engaging members are elastically deformed inwardly appear biasedly at the one side edge of the support column and act on the support column in the engaging hole to move in a direction to the other side edge. In this case, since the other side edge of the support column is cut diagonally from near the base end to the lower end, the support column and the engaging members are moved in the engaging hole to the other side edge. Accordingly, the counter forces of the engaging members are absorbed, and the engaging members and the support column can be easily inserted into the engaging hole.
Further, since the length of the base end of the support column is formed to be identical with the inner diameter of the engaging hole, in case the engaging members and the support column are entirely inserted into the engaging hole and the engaging members are elastically restored, the engaging device of the invention is held in a predetermined position in the engaging hole while aligning the centers of the support column and the engaging hole together. Both engaging members effectively act on the periphery of the engaging hole to firmly fix the engaging device. Also, the connecting device operates in the same way when the engaging members and the support column are removed from the engaging hole.
Accordingly, in the invention, the engaging device can be inserted and removed in good working ability. Also, it is possible to obtain a good fixing force.
Further, when the support column and the engaging members are inserted into or removed from the engaging hole, the support column and the engaging members are moved to the other side edge of the support column to thereby absorb counter forces formed at the engaging members. Therefore, it is surely prevented that when the connecting device is removed, the surfaces of the enlarged portions of the engaging members and the side edges of the support column are pushed on the inner edge of the engaging hole and are ground. Even if the connecting device is inserted and removed repeatedly, the fixing ability is not lowered. Thus, the connecting device can be reused properly.
In the connecting device of the invention, as means for fixing one plate on the upper side of the base flange, a fixing flange is formed through a neck on the upper side of the base flange. The fixing flange and the neck are inserted into a hole formed of two circles located in the one plate, so that the connecting device is fixed to the one plate. In this case, in order to prevent formation of the injection defect due to resin contraction, preferably, a depression or a through hole extending along the radial direction of the neck is formed to form the thickness of the neck as in the other portions. As a result, formation of the injection defect due to the resin contraction is surely prevented, and it is possible to easily form the connecting device by a two-phase or two-separation mold.
As stated above, the depression or through hole formed in the neck is arranged along the radial direction of the neck, so that a thickness reducing pin for forming the depression or the through hole may be formed in one side of the two-separation mold separating in the radial direction of the connecting device. It is not required to form a third portion of a mold, which is required in a case where a thickness reducing depression is formed along the axial direction of the neck, as in the conventional connecting device. The connecting device of the invention can be easily formed by the two-separation mold.
Also, in the connecting device, a wobbling prevention flange, which is elastically deformable, may be formed under the base flange to cover the support column and the engaging members, similar to the conventional connecting device. Thus, when the support column and the engaging members are forcibly inserted into the engaging hole formed in the other plate and are fixed there at, the wobbling prevention flange abuts against the other plate in the condition that the wobbling prevention flange elastically deforms to prevent wobbling between the connecting device and the plate.
Further, in the connecting device of the invention, a side edge of the engaging member located near the other side edge and at the axial middle portion, which becomes the largest portion in the enlarged portion of the engaging member, may be partly projected in the width direction to thereby further partly enlarge the enlarged portion of the engaging member. As a result, it is possible to elongate a contact portion between the inner periphery of the engaging hole and the engaging member at the time of engagement to thereby stably fix the connecting device to the plate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of one embodiment of a connecting device of the invention;
FIG. 2 is a front view of the connecting device;
FIG. 3 is a side view of the connecting device;
FIG. 4 is a rear view of the connecting device;
FIG. 5 is a bottom view of the connecting device;
FIG. 6 is a sectional view of the connecting device taken along line 6--6 in FIG. 2;
FIG. 7 is a sectional view of the connecting device taken along line 7--7 in FIG. 2;
FIG. 8 is a sectional view of the connecting device taken along line 8--8 in FIG. 2;
FIG. 9 is a perspective view for explaining a method of connecting two plates by the connecting device of the invention;
FIGS. 10(A) and 10(B) are partially sectional side views for explaining the operation when the plates are connected by the connecting device, wherein FIG. 10(A) shows a condition at a time of completion of the connection, and FIG. 10(B) shows a condition at a time of forcible insertion of the connecting device;
FIGS. 11(A) and 11(B) are bottom views for explaining the operation when the plates are connected by the connecting device, wherein FIG. 11(A) shows a condition at a time of completion of the connection, and FIG. 11(B) shows a condition at a time of forcible insertion of the connecting device;
FIG. 12 is a side view of a different embodiment of the connecting device of the invention; and
FIG. 13(A) is a front view of a conventional connecting device;
FIG. 13(B) is a side view of a conventional connecting device;
FIG. 13(C) is a sectional view taken along line 13(C)--13(C) in FIG. 13(A); and
FIG. 13(D) is a perspective view for explaining a method of connecting two plates by the conventional connecting device.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1-11 show one embodiment of a connecting device of the invention. In the connecting device, a hole fixing portion 2 is formed on an upper side of a base flange 1 with a circular plate shape, and an engaging hole fixing portion 3 is formed on a lower side of the base flange 1.
In the fixing portion 2, a neck 4 which has a columnar shape with a short axial length is fixed on an upper central portion of the base flange 1, and a fixing flange 5 with a disc shape, which has a diameter smaller than that of the base flange 1, is integrally formed on an upper end of the neck 4. Also, in the neck 4, a depression 6 for reducing the thickness is formed along a radial direction of the neck 4, by which the thickness of the neck 4 is regulated to be substantially the same as in the other portions.
Also, the fixing portion 3 is formed of a support column 7 projecting from a lower center portion of the base flange 1, and engaging members 8 formed at both sides of the support column 7 and projecting downwardly from the lower portion of the base flange 1. The tips or lower ends of the engaging members 8 are joined integrally with the tip or lower end of the support column 7, and the engaging member 8 has a circular arc shape in lateral section.
As clearly shown in FIGS. 2 and 4, each of the engaging members 8 is projected or enlarged laterally outwardly at a portion slightly above a middle in the axial direction of the support column 7, and an enlarged portion 8a is gradually inclined inwardly toward the lower end. The fixing portion 3, as a whole, is laterally enlarged at the portion slightly above the middle of the support column 7 to have a largest diameter portion, and is gradually tapered toward the tip thereof.
There are hollow portions 9a between the engaging members 8 and the support column 7, so that when the engaging members 8 are pushed inwardly, the engaging members 8 can be elastically deformed inwardly. Also, as shown in FIG. 8, each of the engaging members 8 is formed to cover from near one side edge 7a of the support column 7 to a middle portion of the support column 7 in the width direction thereof. A thin slit 9 is formed between the one side edge 7a of the support column 7 and the engaging member 8, respectively, and at the other side edge 7b of the support column, the hollow portions 9a, each being formed between the support column 7 and the engaging member 8, are made relatively large and open outwardly. Also, a groove or cutout 10 extending from the base end to the enlarged portion 8a is formed on an outer surface of each engaging member 8 near the one side edge 7a to thereby partially form a thin wall portion. By the cutouts 10, as shown in FIG. 8, the engaging members 8 can elastically deform easily inwardly at the one side edge 7a (shown by arrows).
Also, as shown in FIGS. 3 and 6, the width at the base end of the support column 7 is made identical to an inner diameter of an engaging hole h 2 (FIG. 9) for fixing the fixing portion 3. The one side edge 7a of the support column 7 is cut diagonally from the middle to the tip or the lower end thereof, and the other side edge 7b is cut diagonally from near the base end to the lower end, so that the both side edges have different shapes. Namely, one dot chain lines 7c in FIGS. 3 and 6 show a symmetrical shape relative to the one side edge 7a, and the other side edge 7b has a shape cut linearly and diagonally from near the base end to the lower end.
Incidentally, numeral 11 is a wobbling prevention flange, which is elastically deformable and is formed below the base flange 1 integrally with the support column 7 and the engaging members 8 to surround or cover the same. When the connecting device is fixed to the engaging hole h 2 by forcibly inserting the fixing portion 3 to the engaging hole h 2 , the wobbling prevention flange 11 abuts against a plate P 2 having the engaging hole h 2 in the condition that the wobbling prevention flange 11 is elastically deformed, so that wobbling between the connecting device and the plate P 2 is prevented. As shown in FIG. 6, the base flange 1 has a shape slightly bent upwardly in a middle thereof and is elastically deformable. When the fixing portion 2 is fixed to a hole h 1 (FIG. 9) with two circular portions, the base flange 1 abuts against a plate P 1 having the hole h 1 in the condition that the base flange 1 is elastically deformed, so that wobbling or mis-alignment between the connecting device and the plate P 1 is prevented.
When the two plates are connected together by using the connecting device of the invention, as shown in FIG. 9, the neck 4 and the flange 5 are inserted into a large diameter portion of the hole h 1 and are moved to a small diameter portion of the hole h 1 , so that the connecting device is fixed to the plate P 1 . Also, the support column 7 and the engaging members 8 are forcibly inserted into the engaging hole h 2 to fix to the other plate P 2 . As a result, the plates P 1 , P 2 are connected together by the connecting device of the invention. In this case, as explained above, the base flange 1 abuts against the plate P 1 in the condition that the base flange 1 is elastically deformed to thereby prevent wobbling or misalignment between the connecting device and the plate P 2 . Also, the wobbling prevention flange 11 abuts against the plate P 2 in the condition that the wobbling prevention flange 11 is elastically deformed to thereby prevent wobbling between the connecting device and the plate P 2 . Therefore, the plates P 1 , P 2 are surely connected and fixed together without wobbling.
In the connecting device of the invention, even if the widths or the sizes of the enlarged portions of the engaging members 8, or the counter elastic force of the engaging members 8 are relatively increased with reference to the fixing force of the connecting device to the hole h 2 of the plate P 2 , it is possible to perform insertion and removal operations of the connecting device with good working ability without increasing the insertion force to and the removal force from the engaging hole h 2 . Further, it is possible to obtain a good fixing force.
Namely, the function is explained with reference to FIGS. 10 and 11. In case the connecting device of the invention is fixed to the engaging hole h 2 of the plate P 2 , the support column 7 and the engaging members 8 are forcibly inserted into the engaging hole h 2 . As a result, the engaging members 8 are once elastically deformed inwardly to allow the enlarged portions 8a to pass through the engaging hole h 2 , and then the engaging members 8 are recovered to the original shapes. As shown in FIGS. 10(A) and 11(A), the connecting device holds the periphery of the engaging hole h 2 between the enlarged portions 8a of the engaging members 8 and the flange 1 in the condition the wobbling prevention flange 11 is placed therebetween. In this case, since both engaging members 8 are formed to extend from the one side edge 7a to cover the middle portion of the support column 7 in the width direction thereof, the counter forces when the engaging members 8 are inwardly deformed appear biasedly at the one side edge 7a, as shown by arrows in FIG. 11(B), which act on the support column 7 in the engaging hole h 2 to move in the direction of the other side edge 7b.
At this time, in the connecting device of the invention, since the other side edge 7b of the support column 7 is cut diagonally from a portion near the base end to the lower end, the support column 7 and the engaging members 8 move in the engaging hole h 2 toward the other side edge 7b (refer to t in FIGS. 10(A), 10(B), 11A(A), 11(B)). As a result, the counter force or bent force of the engaging members 8 is absorbed, so that the support column 7 and the engaging members 8 can be inserted easily to the engaging hole h 2 . Since the base end of the support column 7 has a diameter as in the inner diameter of the engaging hole h 2 as explained before, the engaging members 8 and the support column 7 can be completely entered in the engaging hole h.sub.. In the condition that the shapes of the engaging members 8 resiliently return to the original shapes as shown in FIGS. 10(A) and 11(A), the connecting device of the invention is set on the predetermined position, wherein the center of the connecting device accords with the center of the engaging hole h 2 . In this position, the engaging members 8 properly act on the periphery of the engaging hole h 2 , so that the connecting device is securely fixed to the plate. When the support column 7 and the engaging members 8 are removed from the engaging hole h 2 , the connecting device moves or operates reversely as explained above.
Accordingly, in the connecting device of the invention, the insertion and removal operations can be performed with good working ability. Moreover, a good fixing force can be obtained.
Further, as explained above, when the support column 7 and the engaging members 8 are inserted in or removed from the engaging hole h 2 , the support column 7 and the engaging members 8 are moved toward the other edge 7b, so that the bending force or counter force of the engaging members 8 is absorbed. Therefore, it is surely prevented that when the connecting device is fixed or removed, the enlarged portions 8a of the engaging members 8 and the edges 7a, 7b of the support column 7 are urged strongly onto the edge of the engaging hole h 2 and are thus ground. Even if the insertion and removal are repeated, the effect of the connecting device is not degraded or reduced. Therefore, it is possible to reuse the connecting device.
Also, in the connecting device of the invention, in order to prevent formation of molding defect at the neck 4 due to resin contraction, the dent 6 is formed to extend in the radial direction of the neck 4 to have the thickness substantially the same as those in the other portions. Therefore, it is possible to effectively prevent formation of the molding defect due to resin contraction. Moreover, the molding can be made easily by a two-separation mold.
Namely, since the dent 6 in the neck 4 is formed to extend in the radial direction of the neck 4, as stated above, the thickness reducing pin for forming the dent 6 may be formed in one part of the two-separation mold dividing along the radial direction. In the invention, a third part of a mold is not required as in a case for forming a thickness reducing dent extending in an axial direction of the neck like a conventional connecting device. The connecting device of the invention can be easily formed by the two-phase or two-separation mold.
As explained above, in the connecting device of the invention, good fixing force can be surely obtained, and working ability for fixing or removing the device is excellent. Also, the quality of the connecting device is not degraded even if fixing and removing of the connecting device is repeated, and the connecting device can be formed easily by the two-separation mold.
FIG. 12 shows the other embodiment of the connection device of the invention. In this connecting device, a side 8b, close to the edge 7b, of the enlarged portion 8a is expanded in the width direction. Since the side or expanding portion 8b shown in a diagonal hatching in FIG. 12 is formed, the contacting length between the inner periphery of the engaging hole h 2 and the engaging members at the time of fixing can be prolonged. Thus, the connecting device can be firmly and stably fixed to the engaging hole h 2 . In this case, after the connecting device is molded, when the connecting device is taken out from the mold, the expanding portion 8b comes to an undercut or located partly behind a part of the mold. However, since the portion behind a part of the mold is only a small part of the enlarged portion 8a and is deformable, the connecting device can be taken out easily from the mold without trouble.
Since the structure and operation of the above embodiment are the same as in the embodiment shown in FIGS. 1-11, the identical numerals are assigned to the identical portions, and the explanation thereof is omitted.
Two embodiments of the invention have been explained herein before, but the invention need not be limited to the above embodiments. For example, the fixing portion formed on the upper side of the base flange may be changed in accordance with the plate to be fixed, and also, a through hole may be formed instead of the depression 6. Further, it is possible to eliminate the depression or wobbling prevention flange 11. Still further, the shape of the base flange and other structure may be changed without changing the scope of the invention.
As explained above, in the connecting device of the invention, good fixing force can be surely obtained, and the working ability at the time of fixing and removal is excellent. Also, the effect is not degraded even if the fixing and removal of the connecting device are repeated, so that the connecting device can be reused. Further, the connecting device can be formed easily by the two-separation mold.
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A connecting device of the invention is used to connect two members together. The connecting device is formed of a base flange, a support column extending downwardly from the base flange, and elastically deformable engaging members formed at both lateral sides of the support column and projecting from the base flange. The support column has first and second side edges, and the lateral sides extending between the first and second side edges. The distance between the first and second side edges is greater than that between the lateral sides. The first side edge is cut diagonally from a longitudinal middle portion of the support column to a lower end portion of the support column, and the second side edge is cut diagonally from near a top of the support column to the lower end portion. The engaging members have lower ends terminating at and joining with the lower end portion. Each engaging member has a circular arc shape in a lateral cross section and extends from near the first side edge to cover a middle of the width at one lateral side, and an enlarged portion extending laterally outwardly from the support column at the longitudinal middle portion of the support column. The connecting device can be used repeatedly for connecting the two members together.
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This claims the benefit of German patent application DE 10 2006 023 151.1, filed May 16, 2006 and of German patent application DE 10 2007 017 630.0, filed Apr. 12, 2007, and hereby incorporated by reference herein.
The present invention relates to a method for the high-precision measurement of coordinates of at least one structure on a substrate placed on a stage moveable in X/Y coordinate directions in an interferometric-optical measuring system. The structure on the substrate is imaged onto a detector via a measurement objective having its optical axis aligned in the Z coordinate direction.
BACKGROUND
A measuring device as used for measuring structures on substrates (wafers or masks) has been described in detail in the paper entitled “Pattern Placement Metrology for Mask Making” held by Dr. Carola Blasing at the Semicon Education Program Convention in Geneva on Mar. 31, 1998. The description given there is the basis of a coordinate measuring device. Since the present invention can be advantageously used with such a measuring device and will be primarily described with reference to such a measuring device, without prejudice to its general applicability, this measuring device will be described in the following with reference to annexed FIG. 1 . The well-known measuring device 1 is for measuring structures 31 and their coordinates on a sample 30 , such as masks and wafers. In the context of the present application, the terms “sample”, “substrate” and the general term “object” are to be regarded as synonymous. In the production of semiconductor chips arranged on wafers with ever increasing integration the structural widths of the individual structures 31 become ever smaller. As a consequence the requirements as to the specification of coordinate measuring devices used as measuring and inspection systems for measuring the edges and the positions of structures 31 and for measuring structural widths and overlay data become ever more stringent. Optical sampling techniques in the form similar to a microscope and in combination with a laser distance measuring system are still favored. The advantage of optical measuring devices is that they are substantially less complicated in structure and easier to operate when compared to systems with different sampling, such as X-ray or electron beam sampling, and their greater stability with respect to the position measurement.
The actual measuring system in this measuring device 1 is arranged on a vibration-damped granite block 23 . The masks or wafers are placed on a measuring stage 26 by an automatic handling system. This measuring stage 26 is supported on the surface of granite block 23 by air bearings 27 , 28 . Measuring stage 26 is motor driven and displaceable in two dimensions (X and Y coordinate directions). The corresponding driving elements are not shown. Planar mirrors 9 are mounted on two mutually vertical sides of measuring stage 26 . A laser interferometer system 29 comprising a plurality of interferometers is used to track and determine the position of measuring stage 26 .
The illumination and imaging of the structures to be measured is carried out by a high-resolution microscope optics with incident light and/or transmitted light in the spectral range of the near UV (without prejudice to its general applicability). A CCD camera serves as a detector. Measuring signals are obtained from the pixels of the CCD detector array positioned within a measuring window. An intensity profile of the measured structure is derived therefrom by means of image processing, for example, for determining the edge position of the structure or the intersection point of two structures intersecting each other. Usually the positions of such structural elements are determined relative to a reference point on the substrate (mask or wafer) or relative to optical axis 20 . Together with the interferometrically measured position of measuring stage 26 this results in the coordinates of structure 31 . The structures on the wafers or masks used for exposure only allow extremely small tolerances. Thus, to inspect these structures, extremely high measuring accuracies (currently in the order of nanometers) are required. A method and a measuring device for determining the position of such structures is known from German Patent Application Publication DE 100 47 211 A1 and related U.S. Pat. No. 6,920,249, which is hereby incorporated by reference herein. For details of the above position determination explicit reference is made to these documents.
In the example of a measuring device 1 illustrated in FIG. 1 , measuring stage 26 is formed as a frame so that sample 30 can also be illuminated with transmitted light from below. Above sample 30 is the incident-light, illumination and imaging device 2 , which is arranged about an optical axis 20 . (Auto)focusing is possible along optical axis 20 in the Z coordinate direction. Illumination and imaging means 2 comprises a beam splitting module 32 , the above detector 34 , an alignment means 33 , and a plurality of illumination devices 35 (such as for the autofocus, an overview illumination, and the actual sample illumination). The objective displaceable in the Z coordinate direction is indicated at 21 .
A transmitted-light illumination means with a height adjustable condenser 17 and a light source 7 is also inserted in granite block 23 , having its light received via an enlarged coupling-in optics 3 with a numerical intake aperture which is as large as possible. In this way as much light as possible is received from light source 7 . The light thus received is coupled-in in the coupling-in optics 3 into a light guide 4 such as a fiber-optic bundle. A coupling-out optics 5 which is preferably formed as an achromatic objective couples the light into condenser 17 . The illumination light can also be coupled-in from light source 7 via a mirror assembly.
In order to achieve the required nanometer accuracy of the structural measurement it is essential to minimize as far as possible interfering influences from the environment, such as changes in the ambient air or vibrations. For this purpose the measuring device can be accommodated in a climate chamber which controls the temperature and humidity in the chamber with great accuracy (<0.01° C. or <1% relative humidity). To eliminate vibrations, as mentioned above, measuring device 1 is supported on a granite block with vibration dampers 24 , 25 .
The accuracy of determining the position of the structures is highly dependent on the stability and accuracy of the laser interferometer systems used for determining the stage position in X and Y coordinate directions. Since the laser beams of the interferometer propagate in the ambient air of the measuring device, the wavelength depends on the refractive index of this ambient air. This refractive index changes with changes in the temperature, humidity and air pressure. Despite the control of temperature and humidity in the climate chamber, the remaining variations of the wavelength are too strong for the required measuring accuracy. A so-called etalon is therefore used to compensate for measuring value changes due to changes in the refractive index of the ambient air. In such an etalon a measuring beam covers a fixed metric distance so that changes in the corresponding measured optical length can only be caused by changes in the measuring index of the ambient air. This is how the influence of a change in the refractive index can be largely compensated with the etalon measurement by continuously determining the current value of the wavelength and taking it into account for the interferometric measurement.
To achieve the highest accuracy, the laser distance measuring system is usually operated according to the heterodyne principle, which uses the possibility of splitting the laser beam into the two linearly polarized components (herein, the small frequency difference of the two Zeemann lines is used). The two components are split up in the interferometer, are used as measuring and reference beams, and again superimposed in the interferometer and made to interfere with each other. The laser distance measuring system used has a resolution of 0.309 nm per integer value (laser click) of the laser distance measuring system, at a wavelength λ Laser of the Laser of 632.8 nm.
To describe the accuracy of the measuring device described, usually the threefold standard deviation (3σ) of the measured average value of a coordinate is used. In a normal distribution of measuring values, statistically 99% of the measuring values are within a 3σ range about the average value. Indications as to repeatability are made by measuring a grid of points in the X and Y coordinate directions, wherein for each direction, after repeated measuring of all points, an average and a maximum 3σ value can be indicated. As a typical example, crossed chromium structures having a width of 1 μm of a 15×15 grid (pitch of the grid points: 10 mm) are measured on a quartz substrate. The measurement 2× (X and Y) 225points is repeated 20 times (20 passes). After a so-called multipoint correction, which allows all points of a pass to be commonly rotated and shifted, a repeatability (maximum value 3σ of the deviation of all 3σ values of the 450 points) of 1.5 to 2 nm is achieved. Without the multipoint correction, the values are between 2 and 6 nm.
A further improvement of the repeatability and therefore of the measuring accuracy of the measuring device described is desirable. Special attention has been paid in the present invention to the laser interferometer used for coordinate measurement of the measuring stage or for determining changes in the coordinates of this measuring stage. It is noted that the present invention is not limited to interferometers in the context of the measuring device described but can generally be used in laser-interferometric measurements.
From U.S. Pat. No. 5,469,260 an apparatus is known for measuring the position of a one or two dimensionally traversable stage by means of laser interferometry. For this purpose a stationary mirror is attached, for example, on the stationary optical system while the moveable stage carries a mirror along with it. In the well-known manner a laser beam is split in such a way that one part is incident on the stationary mirror while the other part is incident on the mirror which is carried along, and reflected on it. The reflected partial beams are made to interfere with each other wherein, by displacing the interference rings, a relative displacement of the mirror carried along with respect to the stationary mirror can be derived and the amount of this displacement can be determined.
As an example of the above measuring system, the position measurement of a wafer support stage during exposure of a wafer through a mask and an optical projection system (stepper) are discussed in the present document. Herein the position of the support stage relative to the stationary optical projection system is measured by means of interferometry. To measure the X and Y coordinates of the stage in a plane two interferometer systems are therefore necessary.
SUMMARY OF THE INVENTION
There are strong indications that a significant error component of the LMS IPRO, manufactured by Vistec Semiconductor System GmbH of Wetzlar, Germany, is caused by the interferometer error. This error is caused by the Agilent interferometer system. It has a sinusoidal form and can be observed to change with the stage position at a period length of λ Laser /4(=632.8 nm/4=158.2 nm) and λ Laser /2, depending on the passage through the interferometer during which the error is produced. Since the reflection angle can vary slightly due to the mirrors on the stage body and the moveability of the stage body itself, and therefore the places of incidence of the laser beams in the interferometer as well as the superposition of measuring and reference beam are changed, so the amplitude and phase of the interferometer error also changes. While the change in the refractive index measured by the etalon correctly takes the associated position change into account, also over longer distances, it cannot compensate the interferometer error itself.
The correction of this error is therefore not precisely possible since it changes not only as a function of the measuring place on the mask but also over time. This is why the usual method of interferometer correction has reached its limits. The optimum consideration of this error should take the place and time of the measurement into account. This is ideally realized if a measuring logarithm is implemented, which simultaneously determines and calculates out the interferometer correction during each position measurement. I would like to present such an algorithm here. It is integrated in the existing method so that the measuring time should only be minimally affected.
An object of the present invention is to increase the measuring accuracy of a measuring system for the determination of positions of structures on a substrate and, at the same time, to eliminate the influence of the laser interferometer error on the measuring accuracy.
According to the present invention this object is solved by a method, in which first the stage moveable in the X/Y coordinate direction is traversed in such a way that a structure on a substrate is positioned in at least one predefined measuring window of the detector. Then a relative movement in the Z coordinate direction is carried out at least once, during which a plurality of images of the structure are taken by the detector in synchronism to the relative movement in the Z coordinate direction, and the position of the stage in the X and Y coordinate directions is determined also in synchronism to the imaging. Then the stage is traversed at least once by a distance in the plane defined by the X and Y coordinates, wherein the measuring window is also displaced by this distance. A relative movement in the opposite Z coordinated direction is produced at least once, wherein a plurality of images of the structure are taken by the detector in synchronism to the relative movement in the Z coordinate direction, wherein the position of the stage is determined in the X and Y coordinate directions also in synchronism to the imaging. Finally at least one actual position of the structure is determined from the Z position recorded in synchronism to the recorded images of the structure during the relative movement in the Z coordinate direction and opposite direction, and from the position of the stage determined in association to each image.
The position of the stage during imaging is determined by means of at least one laser interferometer, wherein the light of the laser interferometer has a wavelength of λ Laser .
Prior to the measuring operation, a suitable value is determined for the distance by which the stage is traversed in the plane defined by the X and Y coordinate directions.
The distance by which the stage is traversed in a plane defined by the X and Y coordinate directions corresponds to an integer multiple of a ¼ of the wavelength λ Laser of the laser interferometer.
The distance by which the stage is traversed in the plane defined by the X and Y coordinate directions is composed by a component in the X coordinate direction and a component in the Y coordinate direction, wherein the two components can differ in magnitude.
The relative movement in the Z coordinate direction and in the opposite direction and the associated synchronous recording of a plurality of images of the structure is carried out in such a way that the stage is traversed in the plane defined by the X and Y coordinate directions immediately prior to the reversal of the Z direction.
At least one first predefined measuring window for measuring a coordinate is associated with the detector. A plurality of windows may be associated with it, wherein a further measuring window can be rotated, for example, by 90° with respect to the first measuring window. The measuring windows are quadrangles. The quadrangles can differ in size.
The traversing distance for the relative movement of the measuring objective is in the range of the depth of focus of each measuring objective to be used in the Z direction. The relative movement of the measuring objective in the Z direction comprises several tenths of nm up to a few micrometers.
According to a preferred embodiment, the relative movement in the Z coordinate direction is carried out once. Also, the stage is traversed by a distance in the plane defined by the X and Y coordinate directions once. Subsequently, the relative movement in the opposite Z coordinate direction is carried out once.
According to the method for high-precision measuring of coordinates on a substrate, it is particularly advantageous for the positioning of a structure to be carried out in at least one measuring window prior to the actual measuring process. Typically, the relative movement is carried out in the Z coordinate direction, wherein a plurality of images of the structure on the substrate are recorded by means of a CCD camera during the relative movement in the Z coordinate direction. The movement in the Z direction is primarily to determine the focus position with high-precision and in synchronism (coincidentally) with the other measuring values. It is also possible to carry out measurement without a relative Z movement. This does not, however, limit the claim with respect to the interferometer error. In parallel to the imaging (and the Z position measurement), the position of the stage during imaging is recorded with at least one laser interferometer. Subsequently the stage is traversed by a distance if possible displaced by half of the interferometer error period. To avoid another location of the structure being positioned in the measuring window, the measuring window is displaced accordingly. In the concrete case, at λ Laser /4 (a period of 158 nm), there is a displacement of 80 nm, at λ Laser /2, a displacement of 160 nm. Depending on each error situation, other values are also conceivable. This value can have been dynamically determined beforehand. This is, again, followed by the creation of a relative movement in the opposite Z coordinate direction, wherein a plurality of images of the structure on the substrate are again recorded by means of a CCD camera during the relative movement in the opposite Z coordinate direction. In effect, the interferometrically determined stage position, the recorded images of the two positions of the measuring windows and each synchronously recorded Z position during traversal in the Z direction and in the opposite direction are used for determining the position of the edges of the structure and the structure width.
According to a further embodiment, the stage is not only traversed by a single distance, but successively by two or more distances, each time accompanied by the recording of data.
According to a further embodiment, the traversal in the Z coordinate direction is only carried out until the focusing point is reached. At this Z position, the image measuring device is fixed. The recording of a sufficient amount of measuring data at this location if followed by a displacement in the coordinate measuring direction, and the measurement of further measuring data sets is carried out at this Z position. The structures can be elements, such as lines, spaces, dots, holes, hammerheads etc.
The structure on the substrate is for example formed as a cross. A plurality of crosses are applied on a testing mask as the substrate, wherein the crosses have a physical size of 4μm. The above-mentioned climate chamber is a chamber sealed as far as possible with respect to external atmospheric influences, such as temperature and moisture, with a regulating apparatus for maintaining constant the above mentioned parameters. Further parameters which change the refractive index are the composition of the atmosphere in the climate chamber and the pressure of this atmosphere. Usually, air is chosen as the atmosphere to have its temperature and moisture regulated. Without limiting the general applicability, an air flow will be referred to in the following.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the invention and their advantages will be described in more detail in the following with respect to the accompanying drawings, in which:
FIG. 1 schematically shows a coordinate measuring device, in which the position measuring method according to the present invention can be advantageously used;
FIG. 2A shows the repeatability of the X coordinate direction in a measuring system according to FIG. 1 , wherein the coordinate positions of a 15×15 grid are indicated for nine measuring passes, wherein for better detection of the repeatability, the average value of all nine measuring passes is subtracted from all positions at each grid position;
FIG. 2B shows the repeatability of the Y coordinate direction in a measuring system according to FIG. 1 , wherein the coordinate positions of a 15×15 grid are indicated for nine measuring passes, wherein for better detection of the repeatability, the average value of all nine measuring passes is subtracted from all positions at each grid position;
FIG. 3 shows the comparison of the interferometer error predetermined in the simulation with the error detected by means of the Fourier analysis of the measuring positions;
FIG. 4 shows a camera image of a cross structure, wherein two measuring windows are provided for determining the individual coordinates in the X coordinate direction and Y coordinate direction;
FIG. 5 shows the displacement of the structure by a predetermined distance and a corresponding displacement of the measuring window associated with the camera;
FIG. 6A shows an intensity profile of the structure recorded with the measuring window of the camera; the abscissa is the position in the camera image, the ordinate is the intensity;
FIG. 6B shows an intensity profile of a different image during the scan in the Z coordinate direction of a structure, which was imaged with a measuring window of the camera; the abscissa is the position in the camera image, the ordinate is the intensity;
FIG. 6C shows another intensity profile of the structure, which was imaged with a measuring window; the abscissa is the position in the camera image, the ordinate is the intensity;
FIG. 7 shows the contrast value of the different images of the profiles as a function of the Z value, wherein the plurality of the profiles have been recorded during the scan in the Z coordinate direction and the opposite direction;
FIG. 8 shows the position of the left and right edges as a function of the position in the Z coordinate direction, wherein the ordinate is the deviation of the measured stage positions from the setpoint position;
FIG. 9A shows the deviation of the measuring values of the position measurement from the setpoint value in the X coordinate direction, due to the interferometer error;
FIG. 9B shows the Fourier transform of the position spectrum shown in FIG. 9A , wherein the peak is caused by the interferometer error λ Laser /4;
FIG. 10A shows the fluctuation of the measuring values of the position measurement in the Y direction from the setpoint value, due to the interferometer error and a camera characteristic;
FIG. 10B shows the Fourier transform of the position spectrum shown in FIG. 10A , wherein the peak, again, corresponds to λ Laser /4 and the peak is caused by the differing gain of even and odd camera lines;
FIG. 11 shows the sinusoidal interferometer error curve, which is introduced into the measuring result up to the full amplitude of 1 nm;
FIG. 12 shows a schematic view of the effect of the Dual Scan;
FIG. 13 shows the measured data without drift correction, wherein the data is recorded by displacement in steps of 20 nm; and
FIG. 14 shows the comparison of the measuring results obtained with the new “Dual Scan” method by an LMS IPRO3, with the measuring results obtained the previous method “Normal Mode”.
DETAILED DESCRIPTION
A coordinate measuring device of the type shown in FIG. 1 has already been explained in detail in the introductory portion of the description.
The repeatability or reproducibility of such a coordinate measuring device is usually determined in the factory by measuring a measurement grid of 15 by 15 points (measuring area 6 inches, 152×152 mm). The value of the threefold standard deviation (3σ) is typically determined after 20 measurements for the coordinates obtained in the X and Y coordinate directions. The maximum value of this threefold standard deviation represents the repeatability and therefore the machine performance.
If the measurements are made locally on a defined mask position, i.e. in this case the X/Y measuring stage is not traversed, this is an indication for short-term reproducibility (here 20*100 measurements*4 sec=2.2 hours). This measurement gives an indication on the repeatability within a short period of time (so-called needle test).
The result of this measurement, more precisely of each value of the maximum threefold standard deviation (repeatability) are plotted in FIGS. 2A and 2B for the X or Y direction, respectively, against the measuring runs. The first measuring run is indicated as .NA0, the second as .NA1 etc. The position value is indicated in each graphical representation. 100 measuring values are taken per measuring run. The result is a repeatability of 1.4 nm in the X coordinate direction and 1.1 nm in the Y coordinate direction in a range of 2.8 nm in the X direction or 2.3 nm in the Y direction, respectively, wherein the range represents the difference between the maximum and minimum values and therefore a measure for the noise band.
When the short term reproducibility is determined (in the factory) of position X, Y (20fold measurement of a 15×15 dot grid at a grid pitch of 10 mm on a semiconductor mask), a clear dependence of the measured reproducibility can be observed (typical is 1.5 nm with a 3-fold standard deviation for the maximum value of all 450(15×15×2) individual points after correction of the drift) from the air pressure variation during the measuring time (typically 8hours)). A reason herefore can be seen in the interferometer error, which has a sinusoidal form (or an overlay of sinusoidal waves) and overlays with the stage position. The deviation varies primarily with the period length of λ/4(=632.8 nm/4=158.2 nm; λ=measuring wavelength of the interferometer system) and/or λ/2. As the air pressure changes, the density of the air also changes, and therefore the refractive index and, in turn, the measuring wavelength of the laser distance measuring system assumed to be constant, so that the short term reproducibility correlates with the variation of the air pressure. Test measurements show that the interferometer error is constant neither temporally in the long term nor spatially, and that therefore the measuring wavelength cannot be determined precisely enough and corrected by a single determination of the error proportion for the necessary measurement time (several hours) and the measuring places (140 mm×140 mm).
FIG. 3 shows the comparison of the interferometer error predetermined in the simulation with the error obtained by the Fourier analysis. The Fourier analysis (not FFT) currently appears to be the most precise mathematical method for determining the local 4/λ frequency. The abscissa 40 is the position of the measuring stage 26 . The ordinate 41 is the interferometer error in μm. Herein, the interference is characterized by: The error is described by:
F ( x ) = a s f s ( x ) + a c f c ( x ) with f s ( x ) = sin ( kx ) f c ( x ) = cos ( kx ) k = 8 π λ
The amplitudes a s and a c for f s and f c are given by:
a s = 2 x end - x start ∫ x start x end p ( x ) f s ( x ) ⅆ x a c = 2 x end - x start ∫ x start x end p ( x ) f c ( x ) ⅆ x
Herein, p (x) is the function which results from the interpolation of the edge positions as a function of the stage position. Herein the predetermined interferometer error 42 and the interferometer error 43 determined by measurement are indicated.
The position of a structure is determined by measuring and averaging two different positions of the structure displaced with respect to each other by a portion of the period of the interferometer error or proportions thereof and by having the measurements succeed each other directly. Herein, the measuring window(s) of the measuring camera is/are also displaced in a corresponding manner with the position displacement by the X/Y stage 27 so that the two measuring results should theoretically provide the same position. The prior and well proven process of measuring the position by stopping the table 26 (via an electronic feedback stopping control in the X and Y positions) with position control and passing the focus position is maintained. After first passing the focus position (in the Z coordinate direction) the stage and the measuring window of the camera are displaced corresponding to the period of the interferometer error, and on the second or reverse pass of the focus position (in the opposite Z coordinate direction) the position is determined a second time. This also results in the measuring time being minimized.
FIG. 4 shows the arrangement of a first measuring window 50 and a second measuring window 51 with respect to a cross structure 52 imaged by the camera frame. Each profile of the structure in measuring window 50 , 51 is calculated from the pixels of each measuring window 50 , 51 . As already described above, the measuring window(s) 50 , 51 is/are positioned on structure 52 to be measured, and subsequently the focus is changed by a relative movement in the Z direction (a relative movement of measuring objective 17 in the Z coordinate direction or in the direction of optical axis 20 ). The data from measuring window(s) 50 , 51 are read out at different focus positions. From the read out data, that position in the Z coordinate direction is determined which provides optimum focus. While in FIG. 4 a cross structure is shown, this should not be construed as a limitation. A variety of structures can be measured with the method according to the present invention. Possible structures are lines, spaces, dots, holes, hammerheads etc.
FIG. 5 shows shift 55 of structure 52 by a predetermined distance and a corresponding shift 57 of measuring window 56 associated with the camera. First structure 52 is measured with measuring window 56 of the camera or detector. To do this, a plurality of images of structure 52 on the substrate are taken during the relative movement in the Z coordinate direction by means of the CCD camera. In parallel, the position of the stage is also determined, which is carried out by a laser interferometer using light at a particular wavelength ο. Once the plurality of images are recorded, the stage is traversed by a distance corresponding to wavelength λ of the light used in the laser interferometer. The measuring window is shifted in a corresponding manner so that the same place on a structure is again positioned in each measuring window 56 . Subsequently, a relative movement in the opposite Z coordinate direction is carried out wherein, again, a plurality of images of the structure on the substrate are taken by means of the CCD camera. Shift 55 is composed of a component in the X coordinate direction and a component in the Y coordinate direction. It is conceivable that the shift is first carried out in the X coordinate direction and subsequently in the Y coordinate direction.
The different intensity profiles of a structure are shown in FIGS. 6A , 6 B and 6 C. The individual images from which the intensity profiles are obtained have been imaged at different Z positions of the measuring objective. Herein, abscissa 60 is the image position and ordinate 61 is the measured intensity in any suitable units. As repeatedly mentioned, several camera images are taken concurrently with the determination of the associated stage positions in the X coordinate direction and Y coordinate direction from the laser interferometer data and the focus values, or the values in the Z coordinate direction. As shown in FIG. 4 , at least one measuring window is positioned above the structure to be measured. During the relative movement in the Z coordinate direction, 50 images are taken during the relative movement. The number of profiles results from the product of the number of images and the number of measuring windows. If a relative movement is carried out in the opposite Z coordinate direction, the number of the recorded images is doubled. FIG. 6A shows for example an intensity profile 62 of the 19 th recorded image. FIG. 6B shows intensity profile 63 of the 29 th recorded image during the movement in the Z coordinate direction. FIG. 6C shows intensity profile 64 of the structure of the 39 th recorded image during the relative movement in the Z coordinate direction. A difference in the signal magnitude and the signal form as a function of the position of the image just recorded during the movement in the Z coordinate direction can be clearly seen from a comparison of the individual images of FIGS. 6A , 6 B and 6 C. The signal magnitude or the slope of the profile edge is a measure for the contrast and therefore the focus or the focus position.
FIG. 7 shows the contrast values of 100 profiles resulting from passing the “true” focus point twice. This is why abscissa 70 is the position of the focus or the position of the measuring objective in the Z coordinate direction. Ordinate 71 is the contrast value of the measured intensity profiles of the structure. The contrast of the individual profiles is shown as a function of the value in the Z coordinate direction. The individual measuring points are fitted to a curve, so that maxima result for each of the curves. The first curve 72 is fitted to those intensity profiles which result from the measured intensity profiles resulting from the movement of the measuring objective in the Z coordinate direction. The second curve 73 is fitted to those intensity profiles which result from the measured intensity profiles resulting from the movement of the measuring objective in the opposite Z coordinate direction. One of the maxima is indicated by a broken line 74 and therefore represents the best focus.
In FIG. 8 , each position of the left and right edges of a structure are indicated as a function of the position in the Z coordinate direction. Abscissa 80 is the focus position. Ordinate 81 is the deviation of the edge position from the setpoint value in μm. One measuring window 52 was used for each determination of the position of the left and right edges (see illustration in FIG. 4 ). Each position of the edge with respect to each position in the Z coordinate direction can be calculated from the individual profiles as shown, for example, in FIGS. 6A , 6 B and 6 C. The structure just measured in the image of the camera can thus be obtained from the average value of the two edges. This image position and the position data determined from the measurement with the laser interferometer are added. The graphic representation of this addition can be seen from FIG. 8 . The position of the two edges of a structure, and consequently the position of the structure itself in a coordinate direction can be obtained from the intersection point with broken line 82 (representing the point of the optimum focus).
FIG. 9A shows the deviation from the setpoint value of the position measurement in the X coordinate direction which is due to the interferometer error. The abscissa 90 is the X position in nm. Ordinate 91 is the measured X position in μm. The data are recorded by equidistant position shifting with a concurrent shift of the measuring window for the X coordinate direction. In the measured position area of about 2.5 μm the signals show a drift of about 1 nm. This is due to non-linearities of the measuring structure on the order of μm (e.g. of the mirror body) and the general machine drift (on the order of nm, since the machine is never completely still). The signals shown in FIG. 9A also show a periodicity which can be associated with certain frequencies or wavelengths. FIG. 9B shows the Fourier transform of the measured position spectrum, which is shown in FIG. 9A . Abscissa 92 shows the wave numbers resulting from the Fourier transformation of 256 points, and ordinate 93 is subdivided in any suitable unit. A clear peak 94 can be seen in FIG. 9B , which corresponds to a wavelength of about 158 nm. This peak 94 corresponds to about a quarter of the measuring wavelength of the laser light used in the interferometer (in one embodiment the wavelength of the light is 633 nm). This behavior is also predicted by theory.
FIG. 10A shows the position measurement of a structure on the substrate in the Y coordinate direction. Abscissa 100 is again the Y position on which the measurement is currently carried out with the measuring window. Ordinate 102 is the measured Y position of the structure in μm. The data are also recorded by equidistant position shifting with a concurrent shift of the measuring window in the Y coordinate direction. In the measured position area of about 2.5 μm, the signals, again, show a drift of about 1 nm. FIG. 10B shows the Fourier transform of the measured position data, which are shown in FIG. 10A . Abscissa 102 is in nm, and ordinate 103 is subdivided in any suitable units. The Fourier transform shown in FIG. 10B also shows a peak 104 corresponding to about a quarter of the measuring wavelength, and also a peak corresponding to the period of 90 nm. The 90 nm peak 105 arises due to non-linearities of the camera which operates with two analog amplifiers which cannot be trimmed over the whole of the amplification range. The lines of pixels are therefore alternately and differently read out with two amplifiers. The pixel width of the CCD sensor used here is 45 nm. This is averaged out in the X coordinate direction, while in the Y coordinate direction, this period cannot be averaged out. Errors with half of the measuring wavelength occur as well as errors at a quarter of the measuring wavelength as shown in FIGS. 9B and 10B . Since the occurring interferometer errors are constant neither temporally (in the period of hours) nor spatially (on the order of mm), they cannot be corrected just once. This means that they have to be determined or compensated for with the measuring method “in situ” in the position measurement.
The measuring method used must be explained for better understanding of the invention. The measuring value is obtained from a comparison of the actual measuring distance with a fixed reference distance. The measuring light is therefore split up into a measuring and a reference beam. It has to be considered that there is not only a change in the measuring distance, but that the laser wavelength itself is changed due to the dependence on pressure (temperature, air composition) of the refractive index. This variation is determined by a further interferometric measurement both prior to and during the actual position measurement. This etalon correction varies in the amount of several hundreds of nm and, due to the measuring structure, it depends primarily on air pressure fluctuations, since the temperature and humidity or the gas composition can be maintained almost constant by means of the climate chamber. The etalon correction affects both the correction of the measuring value and the determination of the position reached on the structure itself. The latter occurs because when the measuring position is reached by the stage, the etalon correction causes the structure to be measured to have the same position relative to the measurement camera up to a deviation of a few nm. As a result, the 90 nm error due to the CCD camera has a relatively small error proportion. The interferometer errors due to the laser, however, depending on the magnitude of the air pressure fluctuations and depending on each “position” on the approximately sinusoidal interferometer error curve, are introduced into the measuring result up to their full amplitude.
FIG. 11 schematically shows the effects of air pressure fluctuations on the resulting interferometer error. Abscissa 110 is the position in nm. Ordinate 111 is the interferometer error in nm. The sinusoidal curve represents the error proportion of the interferometer measuring system in a small area (300 nm) of the substrate. The solid arrows mark different air pressure ranges, passed through during a reproducibility measurement (e.g. 20measurements each in the “same” position); the longer the arrow the greater the pressure fluctuation. The vertical, broken-line arrows mark the magnitude of the associated error. FIG. 11 shows that the probability of measuring the whole of the error budget rises with the air pressure variation (see indications 1 - 4 in FIG. 11 ). When the sample is in an unfavorable position with respect to the distance measuring system, however, the entire error budget can be exhausted even with small pressure fluctuations (see indication 3 ). The error can also be of different magnitude, even with equal pressure fluctuations (see indications 2 A or 2 B), depending on the area of the sinusoidal curve in which the measuring values are located. From a certain magnitude (see indication 4 ) the error budget is exhausted, except if the error amplitude itself is position dependent. This is true to a small extent because of the different reflection and material properties of the optical components.
The determination of the position of a structure on the substrate is carried out in the method according to the present invention by measuring and averaging two positions shifted with respect to each other by a portion of the period of the interferometer error or interferometer error percentages and having the measurement in direct temporal sequence. Herein, the measuring window of the CCD camera is shifted together with the position shift, so that the two measuring results should theoretically provide the same position. The prior and well-proven measuring process of the position by stopping the X/Y stage via an electronic feedback stopping control in the X and Y directions, with position control of passing the focus position and synchronous imaging is maintained. Upon first passing the focus position, the X/Y stage and the measuring window of the CCD camera are shifted corresponding to the period of the interferometer error, and during the second, or reverse, pass of the focus position (traversal in the reverse Z coordinate direction) the position of the structure is determined a second time.
FIG. 12 shows a schematic representation of the operation of the so-called Dual Scan (traversing the measuring objective in the Z coordinate direction and subsequently in the opposite Z coordinate direction). Abscissa 120 is the position λ in nm. Ordinate 121 is the interferometer error in nm. Each position of a structure on the substrate is measured twice. The second measuring place is shifted by half of the period of the error curve (here 158/2 nm=79 nm). The two arrow points of each solid-line double arrow mark these two points. Averaging the two measurements compensates for the measuring error due to the interferometer. Herein, the point on the error curve on which the first measurement is carried out is immaterial. The second measurement is shifted in such a way that there is always a compensation. Another advantage is that two measurements are taken. The positional measuring accuracy is correspondingly increased, in particular also the accuracy of the CD measurement. If error portions with different wavelength are mixed (see FIG. 13 ) there is only a partial compensation.
FIG. 13 shows the measured data without drift correction, wherein the data are recorded by shifting the measuring structure in steps of 20 nm. Abscissa 130 is the position in nm. Ordinate 131 is the position error in μm. The double arrows mark two measurements with a shift of 80 and 120 nm. The broken-line, vertical arrows 132 mark the effect of the compensation.
Measuring results obtained by the method according to the present invention, the so-called Dual Scan, are presented on an LMS IPRO3. The results are compared with the measuring results of the prior method (Normal Mode) (see FIG. 14 ). Abscissa 140 is the time in hours. First ordinate 141 is the position deviation in nm. Second ordinate 142 is the change in air pressure in mbar. All data are evaluations of a 15×15 grid of crosses measuring 4 μm on testing masks. For each 10 subsequent measuring results, the maximum 3 sigma value for the positions in the 15×15 grid, the mean 3 sigma value for the positions in the 15×15 grid and the fluctuation range of the barometric pressure during the measurement of the 10 passes is indicated. The evaluation was done “on the fly”, i.e. 10 subsequent loops were evaluated in one go. This means that first the first 10 loops, then loop 1 to 11, then loop 2 to 12, were evaluated etc. So 11 measuring values are obtained from 20 loops, for example, as shown in FIG. 14 . The data were measured “concurrently” with Dual Scan and Normal Mode (two sites in one job, with site1=Dual Scan and site2=Normal Mode). There is therefore only one curve for the fluctuation range of the barometric pressure. The measurements with Dual Scan were carried out with 50 images for each scan and a shift of the X/Y stage of 80 nm between the two scans. The measurements in the Normal Mode were carried out with 50 images. The air pressure fluctuations were quite small at 1.6 mbar. At least in the Y direction a dependence on the air pressure could still be seen. The air pressure dependence was substantially smaller with Dual Scan.
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A method for the high-precision measurement of coordinates of at least one structure on a substrate. A stage traversable in X/Y coordinate directions is provided, which is placed in an interferometric-optical measuring system. The structure on the substrate is imaged on at least one detector ( 34 ) via a measuring objective ( 21 ) having its optical axis ( 20 ) aligned in the Z coordinate direction. The structure is imaged with the so-called Dual Scan. Systematic errors can thereby be eliminated.
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BACKGROUND OF THE INVENTION
The present invention relates to a fuel injection timing control unit for an electronic controlled fuel injection apparatus mounted on an internal combustion engine, and more particularly to a fuel injection timing control unit which enables a fuel injection timing to be adjustable.
In the electronic controlled fuel injection systems, there have been known three different types. One of the types is such an electronic controlled fuel injection system as a fuel is injected at the same time to all the cylinders of an engine. Another of the types is such an electronic controlled fuel injection system as a fuel is injected to a group of cylinders. The other of the types is such an electronic controlled fuel injection system as a fuel is separately injected to each of the cylinders in the condition that the fuel injection timing is synchronized with the induction stroke of each cylinder. According to the foregoing three types of an electronic controlled fuel injection systems, all the timing of injecting a fuel into a cylinder or cylinders is fixed. As the fuel injection timing is fixed, this impairs the response to an operator's demand that the acceleration of a vehicle is necessitated, in the transitional engine running condition. For example, in the engine running condition that a quick acceleration of a vehicle is necessitated. To obviate the foregoing drawback, the following two countermeasures are proposed. The first is, fuel is injected into the cylinders in the condition that the fuel injection timing is not synchronized with the induction stroke of the cylinders. The second is, an additional amount of a fuel is injected to the cylinders when the quick acceleration of a vehicle is necessitated. These countermeasures necessitate a complicated control. Further, the additional amount of a fuel to be injected is limited in order to reduce the amount of the exhaust gas, especially the components of HO and CO, discharged into the atmosphere. Hence, it is desirable to reduce the additional amount of injected fuel to be as little as possible.
SUMMARY OF THE INVENTION
The present invention was made in view of the foregoing background and to overcome the foregoing drawbacks. It is an object of this invention to provide a fuel injection timing control unit which enables a fuel injection timing to be adjustable, for an electronic controlled fuel injection apparatus mounted on an internal combustion engine.
To attain the above objects, a fuel injection timing control unit according to the present invention includes a means for detecting an engine speed, a means for measuring an amount of air introduced into the internal combustion engine, a means for detecting at least one parameter which indicates a driving condition of the engine, a first calculating means for calculating a fundamental duration of a fuel injection pulse from the amount of introduced air and the engine speed, a second calculating means for calculating an actual duration of the fuel injection pulse by compensating the fundamental duration of the fuel injection pulse calculated by the first calculating means, said compensating occurring due to said detected at least one parameter, a third calculating means for calculating a desired injection pulse commencement timing from the engine speed, the third calculating means means adopting the injection pulse duration as a parameter, a means for dividing a map of the desired injection pulse timing into multiple zones, a means for determining which zone the desired injection pulse commencement timing falls, and a means for setting a boundary value of the zone where the desired injection pulse commencement timing is contained, as an actual injection pulse commencement timing.
According to the fuel injection timing control unit of the present invention, it is not necessary to complicate the control unit and employ a large capacity memory in order to obtain an adjustable fuel injection timing.
The above objects, features and advantages of the present invention will become more apparent from the following description of the preferred embodiment taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a unit according to the present invention;
FIG. 2 is a partial cross-sectional view of an automobile equipped with a fuel injection timing control unit according to the present invention;
FIG. 3 is a circuit diagram of the electronic control unit illustrated in FIG. 2;
FIG. 4 is a graph illustrating a relation between a desired commencement time of a fuel injection pulse and an engine speed;
FIG. 5 is a graph illustrating a valve timing of an intake valve and an exhaust valve;
FIG. 6 is a flow chart illustrating operations of the fuel injection timing according to the present invention; and
FIG. 7 is a flow chart illustrating operations for injecting fuel according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is described in detail with reference to the accompanying drawings which illustrate an embodiment of the present invention.
FIG. 1 discloses a block diagram which is incorporated into the present invention. Means for detecting the volume of an intake air, for example, an air flow meter 3, is provided. Rotation angle sensors 9 and 11 are provided and are designed to detect the engine speed. The output signals of the air flow meter 3, the rotation angle sensors 9 and 11 are inputted to a first calculating means 400 for calculating a fundamental duration of a fuel injection pulse. The output signal of the means 400 is inputted to a second calculating means 402 for calculating an actual duration of a fuel injection pulse. A throttle sensor 5 is provided and is designed to detect an opening of a throttle valve 4. Further, an engine coolant temperature sensor 6 is provided and is designed to detect an engine coolant temperature. The output signals of the throttle sensor 5 and the engine coolant temperature sensor 6, are inputted to the second calculating means 402. In the second calculating means 402, the fundamental duration of a fuel injection pulse detected by the first calculating means 400 is compensated by the parameters (the throttle opening, the engine coolant temperature and so forth) detected by the sensors 5 and 6, thereby calculating an actual duration of the fuel injection pulse. The output signal of the means 402 is inputted to a means 404 for calculating a commencement time of a desired fuel injection pulse. The output signals of the rotation angle sensors 9 and 11 are inputted to the means 404. The output signal of the means 404 which designates a commencement time of a desired fuel injection pulse, is inputted to a determination means 406 for determining a zone where a desired fuel injection is positioned. The output signal of the means 406 is inputted to a means 408 which determines the boundary value of the zone and adopts the boundary value as the commencement time of a desired fuel injection pulse. The output signal of the means 408 is outputted to an electromagnetic fuel injection valve 13.
Referring next to FIG. 2, a partial cross-sectional view of an internal combustion engine equipped with the fuel injection timing control unit according to the present invention, is disclosed. An air flow meter 3 is provided in an intake passage 2 and is designed to calculate the amount of air introduced into an air-cleaner (not shown in drawings). The air flow meter 3, containing a potentiometer therein, generates an analog output signal which is proportional to the amount of introduced air. A throttle sensor 5 is secured to an intake manifold 12. The throttle sensor 5 detects the opening of the throttle valve 4, and generates an idling signal when the throttle valve 4 is fully closed and generates a full load signal when a full load is applied to an engine 1. The engine coolant temperature sensor 6 is mounted on a cylinder block of the engine 1 and detects the temperature of the engine coolant which is contained in an engine coolant jacket. The engine coolant temperature sensor 6 generates an analog output signal which is proportional to the engine coolant temperature. In an ignition distributor (not shown in drawings), there are provided a clock pulse generating rotation member 7 and a cylinder discriminating rotation member 8. The members 7 and 8 generate a pulse signal when the crank angle is 360° or 30°. The rotation angle sensors 9 and 11 are provided in order to detect the rotation angles of the rotation angle members 7 and 8, respectively. The rotation angle sensors 9 and 11 generate output pulse signals. The output pulse signals of the rotation angle sensors 9 and 11 are employed as a fundamental timing signal of the fuel injection, a fundamental timing signal of an engine ignition, a signal for demanding an interrupted calculation of the fuel injection, and a signal for demanding an interrupted calculation of the ignition timing. The electromagnetic fuel injection valve 13 is mounted on the intake manifold 12, and injects pressurized fuel, which is supplied from a fuel gallery 20, into the intake passage 2. A control valve 14 is designed to control the amount of the air which bypasses the throttle valve 4. When the engine coolant temperature is low, the air is introduced into the intake passage 2 and into the electromagnetic fuel injection valve 13. A part of the bypassed air is supplied to the electromagnetic fuel injection valve 13 to expedite the generation of vaporized fuel. The control valve 14 is communicated with the intake passage 2 through a pipe 15 which opens at the upstream intake passage of the throttle valve 4. Further, the control valve 14 is communicated through a pipe 16, which opens in a surge tank 18 provided in the downstream intake passage of the throttle valve 4. The control valve 14 is communicated through a pipe 17, which opens in an air injection adaptor 19 at one end thereof, provided adjacent to the electromagnetic injection valve 13. The numerals 23 and 24 designate an intake valve and an exhaust valve, respectively.
The output signals from the air flow meter 3, the engine coolant temperature sensor 6, the rotation angle sensors 9 and 11, and the throttle sensor 5, are inputted into an electronic control unit (hereinafter referred to as ECU) 10. After these output signals are calculated by the ECU 10, the output of the ECU 10 is fed into the fuel injection valve 13 and into the control valve 14.
FIG. 3 indicates that the ECU 10 functions as a digital computer and comprises a multiplexer 101, an analog-digital converter (hereinafter referred to as A/D) 102, a timing signal generating circuit 103, a rotation number generating circuit 104, input ports 105, a central processing unit (hereinafter referred to as CPU) 106 which carries out the arithmetic and logic processing means, a clock generating circuit 107, a random-access memory (hereinafter referred to as RAM) 108 which temporarily stores the calculated data of the CPU 106, a read-only memory (hereinafter referred to as ROM) 109 which stores a predetermined control program and arithmetic constants therein, output ports 110, and actuation circuits 111 and 112.
The analog output signals of the air flow meter 3 and the engine coolant temperature sensor 6 are fed through the multiplexer 101 into the A/D 102. The multiplexer 101 is selectively controlled by the CPU 106. The A/D 102 converts the analog output signals of the air flow meter 3 and of the engine coolant temperature sensor 6 into the digital signals, by employing the clock signal (CLK) of the clock generating circuit 107. After the analog signals are converted by the A/D 102 to the digital signals, the A/D 102 feeds an interruption signal to the CPU 106. In the interruption routine, the latest data of the air flow meter 3 and of the engine coolant temperature sensor 6 are memorized in a predetermined area in the RAM 108, where the data can be read at an equal speed. The output pulse signals of the rotation angle sensors 9 and 11 are fed into the timing signal generating circuit 103, which generates an interruption signal and a fundamental timing signal. Further, the output pulse signal of the rotation angle sensor 11 is fed through the rotation number generating circuit 104 into the predetermined positions of the input ports 105. The rotation number generating circuit 104 receives the clock signal from the clock generating circuit 107, and generates a digital signal which is in inversely proportional to the engine speed. The output signal of the throttle sensor 5 is fed directly into a predetermined position of the input ports 105. The latest data of the engine speed RPM and of the engine coolant temperature are memorized in the predetermined area of the RAM 108, if necessary in the main routine, the sub routine, and the interruption routine. In the ROM 109, there are memorized programs of the main routine, the routine for calculating the commencement time of a fuel injection pulse, and a routine for carrying out a fuel injection, data, and constants which are employed in the programs. The CPU 106 controls the injection valve 13 and the actuation circuits 111 and 112 through output ports 110.
The commencement time of a fuel injection pulse is determined by the following procedure:
In FIG. 4, the abscissa represents an engine speed RPMe, and the ordinate represents a desired commencement time θ s of a fuel injection pulse. The reference TDC in FIG. 4, designates θ a top dead center. The zone in the ordinate, whose value is more than TDC, is a zone where a spark timing is delayed. The zone whose value is less than TDC in the ordinate, is a zone where a spark timing is advanced. In FIG. 4, a group of lines, which are defined by the following relation, are shown in the condition that a fuel injection pulse duration Ti (i=1, 2, . . . ) m sec are employed as a parameter.
θ.sub.s =180-θ.sub.e -6·10.sup.-3 ·RPMe(Ti+A+B) (1)
where,
θ e : a predetermined crank angle (° CA) at the point when a desired fuel injection is completely introduced.
A: a time period (m sec) taken from the completed time of a full injection pulse to a time when a fuel injection valve is actually closed.
B: a time period (m sec) taken a time when vaporized fuel is injected by a fuel injection valve to a time when the fuel is intaken into a combustion chamber of an engine.
The values of θ e and B are constants determined by an engine. The constant A is determined by a fuel injection valve, based upon the results of experimentations or simulations. θ 1 , θ 2 , . . . θ n (For example, n=3) indicated on the ordinate in FIG. 4, are arbitrary timings when the actual fuel injection pulse is commenced. The whole zone θ s of a desired injection pulse commencement time is divided into three zones, θ 1 -θ 2 , θ 2 -θ 3 , and more than θ 3 . A desired injection pulse commencement time θ s , which is calculated by the value of the engine speed RPMe and the injection pulse duration Ti, is determined.
In this embodiment, three points θ 1 -θ 3 are selected as the actual commencement time, but the optimum number of such points may be selected, according to an engine. When a desired injection pulse commencement time θ s is positioned on a point less than θ limit (θ=1), θ 1 , is selected as the actual commencement time. When the engine is in the idling condition, θ idle is selected as the actual commencement time. According to the present embodiment, a desired fuel injection pulse timing is divided into three zones, which are θ 1 -θ 2 , θ 2 -θ 3 , and θ 3 -θ idle. The boundary values of the zones are θ 1 , θ 2 , θ 3 , and θ idle. When the desired injection pulse commencement timing θ s is positioned in one of the zones, the value of the boundary point which is located on an advanced portion within the specific zone, is selected. θ 1 (=θ limit) and θ idle are limit values. When the commencement time θ s is positioned on a delayed zone, θ 3 is selected as a desired commencement time of a fuel injection pulse. If the commencement time θ s is between θ 2 and θ 3 , θ 2 is adopted as the commencement time. Further, if the commencement time θ is between θ 1 and θ 2 , θ 1 is adopted as the commencement time. The data of θ 1 -θ 3 are memorized in the RAM 108. Thus, the commencement time θ s is compared with θ 1 -θ 3 , and one of θ 1 -θ 3 is selected as the actual commencement time. For example, when the fuel injection pulse duration is Tin, the desired fuel injection pulse commencement time of a point "a" corresponding to the engine speed RPM a, is θa. The θ a is positioned on a delayed zone, in comparison with the point θ 3 whose value is TDC. In this case, the actual fuel injection pulse commencement is done at the timing, θ 3 .
FIG. 5 is a graph illustrating a valve timing of an intake valve and an exhaust valve. TDC designates a top dead center (0°CA). BDC designates a bottom dead center (180°CA). The reference INO designates a timing when the intake valve commences to open. The reference INC is a timing when the intake valve commences to close. The reference EXO is a timing when the exhaust valve commences to open. The reference EXC is a timing when the exhaust valve commences to close, θidle shown in FIG. 4 is positioned at the outside of the overlapped time when both of the intake valve and the exhaust valve are opened, as shown in FIG. 5. According to the present embodiment, θ idle is positioned at 60°CA.
FIG. 6 is a flow chart illustrating operation of the fuel injection timing according to the present embodiment. Step 201 commences to calculate the interruption program, upon the receipt of the output signal of the timing signal generating circuit 103 shown in FIG. 3. In step 202, the amount Q of the introduced air to the air flow meter 3 is read. In step 203, the engine speed RPMe, which is detected by the rotation angle sensor, is read. This read data is memorized in the predetermined area of the RAM 109 by the CPU 106.
In step 204, the CPU 106 calculates a fundamental duration T B of a fuel injection pulse, based on the data of the Q and the RPMe, by employing the map memorized in the ROM 109. In step 205, the engine coolant temperature detected by the engine coolant temperature sensor 6 is read and is memorized in the predetermined zone of the RAM 108. In step 206, the throttle opening detected by the throttle sensor 5, is read and is memorized in the predetermined zone of the RAM 108.
In step 207, the CPU 106 compensates or adjusts the the fundamental duration T B of the fuel injection pulse, according to the detected parameters of engine coolant temperature and throttle opening and calculates an actual duration of the fuel injection pulse. Further, the injection pulse duration, which is fed into the fuel injection valve 13, is memorized in the predetermined zone of the RAM 108. In step 208, the engine speed RPMe and the injection pulse duration T i are read from the RAM 108. The desired injection pulse commencement time θ s is calculated by the above-described relation (1), the time θ s is memorized in the predetermined zone of the RAM 108. In step 209, the routine ends.
FIG. 7 is a flow chart illustrating operations for injecting a fuel according to the present embodiment. This flow chart is an interruption routine. In step 301, the interruption routine is commenced. In step 302, it is determined whether the engine is in the idling condition or not. If the engine is in the idling condition, the program proceeds to step 303. In step 303, θ idle is set to be as the desired injection pulse commencement time θ s . Contrary to this, if the engine is not in the idling condition, the program proceeds to step 304. In step 304, θ s is compared with θ n (n=1,2, . . . ). If θ s is equal to θ 2 or more than θ 2 (for example, n=2), the program proceeds to step 305. In step 305, θ 2 is set as θ s . Contrary to this, if θ s is less than θ n (for example, θ 2 ), the program proceeds to step 306. In step 306, θ s is compared with θ limit. If θ s is more than θ limit, the program proceeds to step 307. In step 307, θ n-1 is set as θ s (for example, θ 3 ). If θ s is equal to or less than θ limit, the program proceeds to step 308. In step 308, θ limit is set as θ s . Thus, the injection pulse commencement time is set, and the program proceeds from steps 303, 305, 307 and 308 to step 309. In step 309, the injection pulse duration T i is set in a down counter, and the operation of the injection valve 13 is commenced. The program proceeds to step 310. In step 310, the fuel injection is made until the counted value of the down counter equals zero. When the counted value equals zero, the program proceeds to step 311. In step 311, the fuel injection by the injection valve 13 is stopped. In step 312, the interruption routine is completed.
Thus, according to the present invention, the injection pulse commencement time is not fixed and is adjusted by the driving condition.
While the present invention has been described in its preferred embodiments, it is to be understood that the invention is not limited thereto, and may be otherwise embodied within the scope of the following claims.
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This invention relates to a fuel injection timing control unit for an electronic controlled fuel injection apparatus mounted on an internal combustion engine. The fuel injection timing of a fuel injection valve is first calculated and subsequently adjusted or modified due to an amount of throttle opening or an engine speed, thereby improving the engine response when a rapid acceleration of a vehicle is necessary.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from U.S. Provisional Application No. 60/952,768 filed on Jul. 30, 2007 in the United States Patent Office, the disclosure of which is incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an optical probe and more particularly, to a method for manufacturing a probe which uses optical fibers arranged in parallel which can be easily bent by application of a heat source to improve the performance and reduce the diameter of the optical probe.
[0004] 2. Description of the Related Art
[0005] Industry has been working on varying angles of light incident to various materials to obtain information about optical properties of materials at different depths from surfaces for sensing or diagnostic purposes. For Example, Early Cervical Cancer Detection is based on looking at light interactions at different depths of epithelial layer of tissue. Generally, different incident angles of light illumination and collection are employed to look at different depths in tissue. Numerous automated diagnostic methods have been developed which allow faster, more effective patient management and potentially further reduce mortality. Accordingly, in much of the related technology specific focus is on the epithelial layer of tissue which is 300 to 500 microns thick where it is believed that cancer can be detected at the very onset. U.S. Pat. No. 7,202,947 is an example of this work. Earlier related patents on the same topic include U.S. Pat. Nos. 5,991,653 and 5,697,373.
[0006] Many diagnostic techniques which use varying incident angles of light require the use of a probe, In some cases, the diameter of the probe must be small enough to fit into areas that are obstructed, difficult to access or when employed for medical purposes, it must be small enough to fit into areas where if the size is not adequately small enough, the prove may potentially give the patient discomfort or increase the potential for harm. Typical optical probes found in industry are relatively large in diameter because the fiber must be bent mechanically to achieve the required incident angle. This bend must be of sufficient radius to prevent the optical fiber from breaking. Additionally, the surface atypical probes are often stainless steel or some other metal material and highly reflective. One method used to reduce the reflection of the stainless steel surface is to use blackened or anti-reflective tapes or coatings. However, these tapes or coatings are generally not suitable for use in clinical use or other high purity environments. Additionally, probes used in the related art have had a significant spacing between fibers. This separation distance can make it hard to capture adequate light in fibers with a high angle of incidence to the probe tip because these fibers have an angled facet which presents significant optical losses between the fiber and the adjacent medium.
SUMMARY OF THE INVENTION
[0007] Accordingly, the present invention has been made to solve the above-mentioned problems occurring in the related art, and an aspect of the present invention is to provide a method for manufacturing a medical optical probe which uses an optical fibers arranged in parallel Which can be easily bent by application of heat by a heat source to improve the performance of the medical probe
[0008] Additional advantages, aspects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention.
[0009] In an aspect of the present invention, an optical probe comprising arranging a plurality of optical fibers substantially in parallel and at least one of the plurality of fibers contains a bent portion. The bent portion of the fiber is towards the end of the probe.
[0010] In another aspect of the present invention, the plural optical fibers are fixed in resin in the optical probe.
[0011] In another aspect of the present invention, the plural optical fibers are fixed on a substrate in the resin, parallel inside an outer case, wherein said plural optical fibers are fixed in V-groves in the substrate.
[0012] In another aspect of the present invention, wherein the resin is a low-reflective epoxy.
[0013] In another aspect of the present invention, wherein said bent portion is bent by heating up the bent portion by a heat source. The heat source may apply heat ranging from 300 to 1400 degrees centigrade.
[0014] In another aspect of the present invention, the bent portion is bent by first bending an optical probe in room temperature and then applying the heat source to the bent region.
[0015] In another aspect of the present invention, the bent portion is bent by first applying the heat source to the bent region and then applying force to the optical probe.
[0016] In another aspect of the present invention, the bent portion is bent at angle of 0 to 45 degrees.
[0017] In another aspect of the present invention, the bent portion is bent at a predetermined angle by using a bending device.
[0018] In another aspect of the present invention, the outer casing of said optical probe contains angled portions towards the end the optical probe.
[0019] In another aspect of the present invention, the angled portions of said optical fibers have less than 200 μm sparing from one of a plurality of optical fibers and straight portions of said optical fibers have a 200 to 400 μm spacing from one of a plurality of optical fibers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The above and other objects, features and advantages of the present invention will be apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0021] FIGS. 1 a and 1 b illustrate a method to bend a portion of an optical fiber according to an exemplary embodiment of the present invention;
[0022] FIG. 2 illustrates an optical probe which contains optical fibers according to an exemplary embodiment of the present invention;
[0023] FIG. 3 illustrates an optical probe which contains optical fibers according to another exemplary embodiment of the present invention;
[0024] FIG. 4 illustrates a trimmed probe age present at the end of the optical probe according to an exemplary embodiment of the present invention;
[0025] FIGS. 5 a and 5 b illustrate a method to bend a portion of an optical fiber according to another exemplary embodiment of the present invention;
[0026] FIGS. 6 and 7 illustrate a device and the use of the device to precisely bend an optical fiber according to an exemplary embodiment of the present invention;
[0027] FIG. 8 illustrates another device that can be used to precisely bend an optical fiber according to another exemplary embodiment of the present invention.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0028] Advantages and features of the present invention and methods of accomplishing the same may be understood more readily by reference to the following detailed description of the exemplary embodiments and the accompanying drawings. The present invention may, however, be embodied in many different forms and should not be construed as being limited to the exemplary embodiments set forth herein. Rather, these exemplary embodiments are provided so that this disclosure will be thorough and complete and will fully convey the concept of the invention to those skilled in the art, and the present invention will only be defined by the appended claims. Like reference numerals refer to like elements throughout the specification.
[0029] FIGS. 1 a and 1 b are views illustrating an optical fiber according to an exemplary embodiment of the present invention. In FIG. 1 a, the optical fiber 1 typically has a diameter d of 125 μm. One of ordinary skill in the art would comprehend that concepts of the present invention can be implemented with varying diameters d. In this exemplary embodiment, a heat source 2 applies heat 3 to region 4 of the optical fiber 1 . Region 4 is preferably towards the end of the optical fiber 1 . The heat source 2 may include a CO 2 LASER, electric heater, infrared furnace and a flame. The temperature of the heat 3 being applied to the fibers in section 4 of the optical fiber 1 is typically at least 300 degrees centigrade. However, it is preferred that a temperature from 300 degrees to 1400 degrees centigrade is applied, The temperature of the heat 3 that is applied varies on the glass composition of the fiber 1 . The specific temperature of the heat is not critical to the invention; rather it must simply be sufficient to create a permanent bend in the fiber 1 .
[0030] FIG. 1 a illustrates that the heat source 2 applies heat 3 at a temperature of 1400 degrees centigrade to region 4 of the optical fiber 1 . If only heat 3 and no other physical three is applied on the optical fiber 1 , there is no change in the shape of the optical fiber 1 . In such a scenario, the optical fiber 1 at region 4 merely heats up and cools off. Therefore, the optical fiber 1 retains its shape pre-application of heat 3 from heat source 2 and post-application of heat 3 from heat source 2 .
[0031] As stated above, mere application of heat 3 by a heat source 2 does not lead to the change of shape of the optical fiber 1 . Therefore, to cause a bend in the optical fiber 1 in region 4 to which the heat 3 is being applied, a downward force 5 is applied towards the far end of the optical fiber 1 .
[0032] FIG. 1 b, illustrates the result of the application of the force 5 which causes a bend in the optical fiber 1 at region 4 . After, the optical fiber 1 is bent to an angle α of a desired amount, the application of the heat 3 by the heat source 2 is halted. As the optical fiber 1 cools, it retains its bent shape. Accordingly, an optical fiber 1 can be reshaped without having to use any other form of support or utensils to preserve that shape. Thereafter, the optical fiber 1 has a straight portion 21 and an angled portion 22 .
[0033] FIG. 2 , illustrates an optical probe 100 using multiple optical fibers 1 bent according to an exemplary embodiment of the present invention. Four optical fibers 1 are arranged substantively in parallel to form the optical probe 100 . One of the optical fibers 1 contains an angled portion 22 . Some of these optical fibers 1 are used for light illumination while some of them are used for detecting light. These optical fibers 1 are fixed in a resin 102 inside an outer case 103 . In the exemplary embodiment illustrated in FIG. 2 , the outer case 103 is a stainless steel pipe, Furthermore, any curable resin may be used for the resin 102 , but low reflection material is preferable. One of ordinary skill in the art would comprehend that materials with similar properties can be used to function as the resin 102 .
[0034] Additionally, the outer surface of the optical probe 100 may use non-reflective epoxies rather than a metal probe face (not illustrated). Therefore, noise generated by multi reflection between the probe surface and tissue may be reduced.
[0035] Further, optical fibers 1 can also be fixed within a substrate in the resin 102 . FIG. 3 illustrates according to another exemplary embodiment of the present invention, four optical fibers 1 fixed on a substrate 104 with four V-grooves 105 . One of the optical fibers 1 which has been bent applying any of the methods provided in the exemplary embodiments of the present invention, contains a straight portion 21 and an angled portion 22 . The straight portion 21 is aligned in a corresponding V-Groove 105 , while the angled portion 22 juts out. The presence of these V-Grooves 105 allows for precise fiber arrangement. Once of ordinary skill in the art would comprehend that the substrate 104 may contain an unlimited amount of V-Grooves 105 and the substrate 104 is not limited to the shape illustrated in FIG. 3 . Furthermore, in this exemplary embodiment, in sections of the optical probe 100 which contains angled portions 22 of optical fibers 1 , there is a 200 μm spacing between the optical fibers 1 , while portions of the optical probe 100 with straight portions of fiber 1 have a 200 to 400 μm spacing between the optical fibers 1 . Due to the lessened spacing between the optical fibers 1 , the desired bend is achieved over a wide spectrum of diameters including a relatively smaller relative diameter of 3 mm. This allows for prevention of “beam” type stresses or breaking forces being applied to the fiber.
[0036] FIG. 4 is an illustration of a side view trimmed probe edge 31 present at one end of optical probe 100 according to an exemplary embodiment of the present invention. As discussed above one of the optical fibers 1 has the bent region 4 and therefore the angled portion 22 towards the end of the optical probe 100 . As illustrated in FIG. 4 , the outer casing 103 contains a trimmed probe edge 31 towards the end of the optical probe 100 . As the optical probe 100 is round, the trimmed probe edge 31 goes all the way around as well. The trimmed probe edge 31 is at a sharp angle which aids in reducing reflective profile of a stainless steel tube edge.
[0037] FIGS. 5 a and 5 b , illustrate another exemplary embodiment of the present invention. In FIG. 5 a , the optical fiber 1 is bent in room temperature by application of forces 15 and 15 ′ at the respective ends. Thereafter, a heat source 2 applies heat 3 to a region 4 of the optical fiber 1 . The region 4 is preferable closer to one end of the optical probe 1 . Region 4 of the optical fiber 1 which is exposed to heat 3 from the heart source 2 become soft and the region 4 bends in accordance with angles depending on forces 15 and 15 ′ that are applied to the respective ends. FIG. 5 b illustrates the result of the application of the respective threes 15 and 15 ′, as well as heat 3 from the heat source 2 , resulting in a bend with approximately an angle α of 30 degrees being created.
[0038] However, the application of the present inventions as presented in the exemplary embodiments of FIGS. 1 and 5 does not necessarily lead to an accurate selection of the angle of the bend of the optical fiber 1 . As the optical fiber 1 is used for sensitive diagnosis, any changes in shape must be extremely precise. For this purpose, FIG. 6 illustrates a plate which can be used to precisely bend the optical probe at a particular angle α according to another exemplary embodiment of the present invention.
[0039] FIG. 6 displays a plate 6 which contains a mechanism to precisely choose an angle of the bend in the optical fiber 1 . The plate 6 contains a guide 7 with a fixed portion 8 and a movable portion 9 . The fixed portion and the movable portion are connected at a pivot point 10 . The plate displays varying angles to which a user can move the outside edge of the movable portion 9 . Accordingly, in an exemplary embodiment if a user wants a 30 degree angle of bend, the user moves the outside edge to 30 degrees and locks the movable portion at that angle through a locking mechanism (not illustrated). Furthermore, the fixed portion 7 contains latches 11 or another locking mechanism to secure the optical fiber 1 to the guide 7 .
[0040] FIG. 7 illustrates the plate 6 of FIG. 6 being utilized to bend the optical fiber 1 so that the optical fiber 1 has a bend angle α of 30 degrees. An optical fiber 1 is placed on the plate 6 and secured on the fixed portion 8 of the guide 7 using latches 11 , A user previously sets the moving portion 9 to be at an angle α of thirty degrees. Thereafter, a heat source 2 applies heat 3 at a region 4 of the optical fiber 1 which straddles the pivot point 10 . Due to the heat 3 , the optical fiber 1 at region 4 softens and when a force 5 is applied downwards, a bend is created in the optical fiber 1 at region 4 . A force 5 is continually applied till the angled portion 22 of the optical fiber 1 is completely flat against the movable portion 9 of the guide 7 . Thereafter, as soon as the fiber 1 is no longer exposed to the heat source 2 , the optical fiber 1 begins to cool off. As the optical fiber 1 cook off, it retains its shape autonomously, therefore preserving the bent shape of the optical fiber 1 at exactly thirty degrees.
[0041] FIG. 8 illustrates another mechanism to precisely bend an optical fiber 1 according to an exemplary embodiment of the present invention. In this exemplary embodiment, the optical fiber 1 is first bent in room temperature and then a heat source 2 applies heat 3 to a region 4 of the optical fiber 1 to cause a bending of the optical fiber 1 at region 4 . The forces that are applied to bend the optical fiber 1 in room temperature are applied by Force Applying Devices (FADs) 12 and 13 . FAD 12 may either be fixed or movable in the vertical direction. FAD 13 may further be fixed or movable in the horizontal direction. FADs 12 and 13 can not only apply the forces to cause a bend but may also independently hold the optical fiber 1 . Previous calculations allow the user to arrange the positions of the FADs 12 and 13 depending on a desired angle α and on the position of the optical fiber 1 where the user desires the bend (therefore, the region 4 ) to occur.
[0042] One of ordinary skill in the art would comprehend that the structure can be slightly altered to implement the principles of the present invention to produce similar results.
[0043] In another exemplary embodiment of the present invention in which the heat source 2 of FIGS. 1 and 5 - 8 is a flame, the flame is formed by a combination of C x H y O z and Oxygen. The x, y and z in C x H y O x each represent respective integer values including zero.
[0044] As described above, according to the exemplary embodiment of the present invention, a medical probe with a narrow width, made of non-reflective material, is bent accurately, thus the performance of the medical probe in clinical studies can be improved.
[0045] Although exemplary embodiments of the present invention have been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. The foregoing embodiments are merely exemplary and are not to be construed as limiting the present invention. Therefore, the scope of the present invention should be defined by the accompanying claims and their legal equivalents.
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A method for manufacturing an optical probe which uses optical fibers arranged in parallel which can be easily bent by application of a heat source to improve the performance of the optical probe. The bend may be created by application of heat by a heat source and then forcing a change in the shape of the optical probe. Alternatively, an optical probe may be bent in room temperature and then by applying heat from a heat source, a bend can be created in the optical probe.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] This invention relates to systems and methods for detecting and correcting image quality defects, such as banding defects, in image marking devices, such as, for example, xerographic marking devices, using feedback and/or feedforward control.
[0003] 2. Description of Related Art
[0004] A common image quality defect introduced by the copying or printing process is banding. Banding generally refers to periodic, linear structures on an image caused by a one-dimensional density variation in either the cross-process (fast scan) direction or process (slow scan) direction. FIG. 1 shows an image taken from an image marking device, such as, for example, a xerographic printer that illustrates an extreme case of banding due to photoreceptor and magnetic roll runout. A typical density variation of this image in the process direction is shown in FIG. 2 .
[0005] Banding defects can result due to many xerographic subsystem defects such as, for example, development nip gap variation caused by developer roll runout and/or photoreceptor drum runout, coating variations on either the developer rolls or the photoreceptor, non-uniform photoreceptor wear and/or charging, and developer material variations.
[0006] One approach to mitigate banding defects is by specifying tight tolerances in subsystem design. One problem with this “passive” approach is that stringent image quality specifications increasingly lead to subsystem components with tighter and tighter tolerances, which, in turn, are more costly to manufacture. Another potential problem is scalability. That is, the subsystem design for one product in a family may not be appropriate for a different product in the same family, thus leading to costly and time consuming redesign. Furthermore, specifying tight tolerances in subsystem design has limited robustness properties. For example, using developer rolls with a tight tolerance on runout will not help with banding due to photoreceptor wear.
SUMMARY OF THE INVENTION
[0007] Given the above discussed limitations of current “passive” approaches to correct banding, it is desirable to employ an “active” approach to mitigate banding defects.
[0008] This invention provides systems and methods that control image quality defects, such as banding defects, in xerographic image marking devices using feedback and/or feedforward control.
[0009] This invention further provides systems and methods that can actively detect and correct image quality defects, such as banding defects, in xerographic image marking devices using closed-loop feedback and/or feedforward control techniques.
[0010] In various exemplary embodiments of the systems and methods according to this invention, banding defects are determined and corrected using a feedback and/or feedforward control approach.
[0011] In various exemplary embodiments of the systems and methods according to this invention, banding defect is controlled by determining a one-dimensional density variation in an image using an optical sensor, and reducing or eliminating the one-dimensional density variation using one or more subsystem actuators in accordance with a feedback and/or feedforward control routine or application.
[0012] In various exemplary embodiments of the systems and methods according to this invention, using a closed-loop feedback and/or feedforward control approach enables the use of components with relaxed tolerances, which would reduce unit machine cost (UMC). Furthermore, using a feedback and/or feedforward control approach would allow controller design to be easily scaled from one product to the next. Moreover, feedback and/or feedforward control is inherently robust to subsystem variations, such as developer material variations and roll runout.
[0013] These and other features and advantages of this invention are described in, or are apparent from, the following detailed description of various exemplary embodiments of the systems and methods according to this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Various exemplary embodiments of the systems and methods of this invention will be described in detail, with reference to the following figures, wherein:
[0015] FIG. 1 shows an example of a banding defect due to photoreceptor and magnetic roll runout;
[0016] FIG. 2 illustrates a typical density variation in the process direction in uniform banding;
[0017] FIG. 3 schematically illustrates an exemplary image marking device developer housing and sensors that can be used to implement a feedback and/or feedforward loop control architecture for controlling banding defects in an image;
[0018] FIG. 4 illustrates an exemplary embodiment of a feedback and/or feedforward loop control architecture for controlling banding defects in an image;
[0019] FIG. 5 illustrates another exemplary embodiment of a feedback and/or feedforward loop control architecture for controlling banding defects in an image;
[0020] FIG. 6 is a flowchart of an exemplary embodiment of a method of establishing the parameters of the feedback and/or feedforward control loop for controlling banding defects;
[0021] FIG. 7 schematically illustrates an exemplary simplified runout model for the image marking device of FIG. 3 employing the feedback and/or feedforward control loop strategies for controlling banding defects;
[0022] FIG. 8 illustrates a simulated optical sensor response for the case where the development voltage has not been calibrated for runout;
[0023] FIG. 9 illustrates a simulated optical sensor response for the case where the development voltage has been calibrated for runout according the exemplary feedback and/or feedforward control methods and systems of this invention;
[0024] FIG. 10 illustrates a typical print corresponding to the case where the development voltage has not been calibrated for runout;
[0025] FIG. 11 illustrates a simulated print corresponding to the case where the development voltage has been calibrated for runout according the exemplary feedback and/or feedforward control methods and systems of this invention;
[0026] FIG. 12 is a flowchart of an exemplary embodiment of a method of controlling banding defects using a closed loop feedback and/or feedforward control strategy;
[0027] FIG. 13 is a flowchart of an exemplary embodiment of a method of updating the calibration of the development field of a print engine to control banding defects using a closed loop feedback and/or feedforward control strategy.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0028] These and other features and advantages of this invention are described in, or are apparent from, the following detailed description of various exemplary embodiments of the systems and methods according to this invention.
[0029] FIG. 3 schematically illustrates an exemplary image marking device developer housing 10 , such as an electrophotographic (EP) device developer housing, and one or more optical sensors 50 that can be used to implement a feedback and/or feedforward loop control architecture for controlling banding defects in an image. As shown in FIG. 3 , typical EP devices, such as photocopiers, scanners, laser printers and the like, may include a photoreceptor drum 20 , which may be an organic photoconductive (OPC) drum 20 , that rotates at a constant angular velocity. The EP device shown in FIG. 3 further includes a magnetic roll 30 and a trim bar 40 .
[0030] As the OPC drum 20 rotates, it is electrostatically charged, and a latent image is exposed line by line onto the OPC drum 20 using a scanning laser or an light emitting diode (LED) imager. The latent image is then developed by electrostatically adhering toner particles to the photoreceptor 20 , e.g. OPC drum 20 . The developed image is then transferred from the OPC drum 20 to the output media, e.g., paper. The toner image on the paper is then fused to the paper to make the image on the paper permanent.
[0031] According to various exemplary embodiments of this invention, closed loop feedback and/or feedforward controlled architectures or strategies are disclosed that can be used to determine, control and mitigate banding defects discussed above. Mitigating banding defects is done, according to various exemplary embodiments, by first determining the banding defects in the developed image on the receiving member using one or more optical sensors, then altering the image marking process parameters, e.g., printing parameters, to eliminate the defects.
[0032] Continuing with reference to FIG. 3 , in various exemplary embodiments, the receiving member can be the photoreceptor 20 , the intermediate belt or the sheet of paper. The optical sensors 50 used to determine the banding defects may include, according to various exemplary embodiments, enhanced toner area coverage (ETAC) sensors or other single spot (or point) sensors. According to various alternative exemplary embodiments, the sensors 50 are array-type sensors such as, for example, full-width array (FWA) sensors, and the like.
[0033] According to various exemplary embodiments, the sensors 50 actuate an electromechanical actuator such as, for example, a developer roll voltage V dev (t), where t is time, using a feedback and/or feedforward control loop. The developer roll voltage V dev , according to various exemplary embodiments, is used as an actuator to remove the mean banding level.
[0034] As discussed above, in typical developer housings, the developer roll voltage (V dev ) can be adjusted as a function of time, that is, in the process direction. Accordingly, the developer roll voltage V dev can control uniform banding by removing some amount of banding along the process direction. For example, (V dev ) can lighten the dark lines shown on FIG. 1 . In this approach, the developer roll voltage V dev may be used as a one-dimensional actuator.
[0035] Calibration could occur during machine cycle-up and involves developing a given patch structure, sensing the banding defect on the photoreceptor using an optical sensor (e.g. ETAC), and actuating the development field using a feedback and/or feedforward control strategy, such as for example, repetitive control or adaptive feedforward control strategies. After a uniform density in the developed image is achieved, the resulting periodic control signal is stored as a function of developer roll position using, for example, an encoder. During routine machine operation, controlling and/or mitigating banding defects can be achieved by “playing back” the calibrated development field according to the developer roll position.
[0036] As a particular example, the following discussion considers banding due to developer roll runout. However, the feedback and/or feedforward control calibration strategies described herein are useful and applicable to address banding due to other sources as well. By implementing this invention, both UMC reduction and higher print quality are achieved.
[0037] The exemplary feedback and/or feedforward control strategies or architectures presented herein may be used to mitigate banding defects from any number of sources. However, for illustrative purposes, the feedback and/or feedforward control strategies discussed below will generally focus on controlling banding defects due to developer roll runout along the roll axis.
[0038] The methods and systems according to various exemplary embodiments of this invention are used to achieve a spatially uniform developed image on the photoreceptor despite the periodic disturbance due to runout shown in FIG. 2 . This disturbance has a known spatial period, which is computed as follows:
T d = 2 πρ MR SR , ( 1 )
where T d is the spatial period of the runout disturbance as projected onto the photoreceptor, ρ MR is the radius of the magnetic roll and SR is the speed ratio of the magnetic roll to the photoreceptor.
[0039] In various exemplary embodiments, the systems and methods according to this inventions employ various approaches or techniques for rejecting sinusoidal disturbances of a known period. One exemplary approach or technique is based on the Internal Model Principle. Generally, the Internal Model (IM) principle states that the feedback loop must contain a model of the disturbance to cancel the effect of the disturbance on the system output.
[0040] Another exemplary approach or technique is referred to as adaptive feedforward control (AFC) technique. The AFC technique adaptively constructs a model of the disturbance, which is then “fed forward” and injected into the system to cancel the effect of the periodic disturbance. The control architectures for rejecting banding disturbances based on these two approaches are discussed in more detail below.
[0041] It will be noted that the systems and methods of this invention are not limited to the two approaches or techniques discussed above. One skilled in the art of feedback and/or feedforward control methods may employ other known or to be developed techniques or approaches to model and mitigate banding defects.
[0042] An exemplary embodiment of a closed loop feedback and/or feedforward control structure/architecture 400 is shown in FIG. 4 . As shown in FIG. 4 , r ( 460 ) is the target value for the developed mass average (DMA) of a reference patch (or patches) on the photoreceptor, u ( 450 ) is the magnetic roll voltage V dev as computed by the controller ( 410 ), y ( 470 ) is the measured DMA as determined from an optical sensor 50 , e.g. ETAC sensor (shown in FIG. 3 ), θ ( 480 ) is the angular position of the magnetic roll (shown as 30 in FIG. 3 ), which may be provided and or stored as an encoder reading, and d ( 420 ) represents the banding disturbances impacting the system 100 (shown in FIG. 3 ).
[0043] The controller 410 in this set-up is assumed to contain a built-in model of the disturbance according to the Internal Model Principle. Repetitive control falls under this category and is known to be an effective means for rejecting disturbances of a known period such as the banding disturbance of interest here. An exemplary repetitive control law is provided in the following equation:
u ( z ) = z - N 1 - f ( z - 1 ) z - N ( r - y ( z ) ) , ( 2 )
where z is the z-transform variable, N is the period length of the disturbance, and f(z −1 ) represents a filter designed to ensure that the resulting closed-loop system is stable. One important feature of a repetitive controller is that it places poles at the disturbance frequencies (the internal model of the disturbance), which enables cancellation of the periodic disturbance. This basic control structure 400 can be expanded in a number of ways to handle more complex situations. For example, multiple repetitive controllers 410 could be used to reject multiple periodic disturbances d ( 420 ).
[0044] When implementing a controller in this framework (as well as in the AFC framework described below), one potential issue that needs to be overcome is the size of the test pattern or reference patch (or patches) on the photoreceptor that would need to be measured by the optical sensor in order for the controller to “learn” the disturbance. To illustrate the point, consider an exemplary image marking device. The radius of the magnetic roll is 9 mm and the speed ratio is 1.75, which, according to Eq. (1), gives a spatial period of 32.3 mm. The circumference of the photoreceptor drum is 82.9 mm. Since measurements of multiple periods of the disturbance may be needed to “learn” the disturbance, the patch needed in this example would certainly go beyond any inter-document zone and may even require multiple revolutions of the drum depending on the number of periods measured. Consequently, this learning process could not take place during customer printing. This is generally not a problem, however, because a banding disturbance like that shown in FIG. 1 generally does not change substantially over time and, as a result, would likely require only infrequent characterization.
[0045] Assuming that the banding disturbance properties only change slowly with respect to time enables banding defect calibration. In calibration mode, the method may require printing a test pattern or reference patch of sufficient size for the controller to “learn” the periodic banding disturbance. This mode would occur during, for example, cycle-up prior to customer printing. Its purpose is to establish the baseline control voltage waveform needed to counteract the banding defects. After establishing a uniform image on the photoreceptor, the controller records the resulting development voltage as a function of developer roll position. This is the development field that will then be used during customer printing to counteract banding defects.
[0046] FIG. 5 schematically illustrates another exemplary embodiment of a closed loop feedback and/or feedforward control architecture 500 , such as an Adaptive Feedforward Control (AFC) architecture 500 , that may also be used to control and/calibrate the development field. In the AFC architecture, for a DMA target value r ( 560 ) of a reference patch or test pattern, the controller 510 is designed to achieve nominal performance, which could include rejection of non-periodic disturbances, such as, for example, a proportional-integral-derivative (PID) controller 510 , and the adaptive feedforward controller 515 is designed to cancel the periodic disturbance. To do this, the adaptive feedforward controller 515 adaptively constructs a model of the periodic disturbance and then adds this signal “on top” of the control signal to cancel the effect of the disturbance on the system output. The structure of the disturbance model is Fourier expansion as follows:
d ^ ( i ) = ∑ j = 1 M α j sin ( ω j i ) , ( 3 )
where {circumflex over (d)} ( 525 ) is the disturbance estimate, i is the discreet time index, ω j =2πj/N, N is the length of the disturbance period, and the α j are the model coefficients that are to be estimated from measurement data.
[0047] The error, e, is calculated using the formula
e=r−y (4)
where term r ( 560 ) represents the target DMA value and y ( 570 ) represents the measured DMA as determined from the optical sensor. Given a model of the development process, and the applied control signal, u ( 550 ), estimates of the disturbance model coefficients can be calculated and updated in real-time using a standard least-squares algorithm. In calibration mode, a given reference patch or test pattern would be measured to establish the estimate of the disturbance, {circumflex over (d)} ( 520 ). Once the disturbance estimate converges, the control signal is stored and synchronized to developer roll position as described above. As discussed above, the angular position θ ( 580 ) of the magnetic roll (shown as 30 in FIG. 3 ), may be provided and or stored as an encoder reading.
[0048] FIG. 6 is a flowchart of an exemplary embodiment of a method of establishing the parameters of the feedback and/or feedforward control loop for controlling banding defects. According to various exemplary embodiments, establishing the feedback and/or feedforward control loop starts at step S 100 . Next, during step S 110 , the parameters α j are identified by using a known pattern and measuring the resulting developer roll voltage (V dev ) or full-width amplitude (FWA) signal. When the test pattern is measured, a least squares fit to the resulting data may be used to provide estimates of the parameters α j , thus setting up equations 1-4. Next, once the parameters α j are identified during step S 110 , control continues to step S 120 .
[0049] During step S 120 , the developer roll voltage (V dev ) is initialized and an image is produced. Next, control continues to step S 130 . During step S 130 , developer mass average (DMA) is measured at the different sensor locations. Next, control continues to step S 140 .
[0050] During step S 140 , the controller determines whether there is a large amount of banding. A large amount of banding is a variation which a typical consumer of the product, upon viewing an image of a uniform area, would notice the banding to be objectionable. If a large amount of banding is determined, then control continues to step S 150 . During step S 150 , the developer roll voltage (V dev ) is configured, i.e., updated so as to reduce the amount of banding determined. Following step S 150 , control goes back to step S 130 in order to measure the resulting DMA at the different sensor locations.
[0051] If a large amount of banding is not determined, then control jumps back to step S 140 . During step S 140 , the controller determines again whether there is a large amount of banding.
[0052] To examine the Internal Model Principle based calibration strategy shown in FIG. 4 , the inventors have constructed a simulation based on a magnetic roll-to-photoreceptor drum development system, where runout was present in both the magnetic roll and the photoreceptor drum. FIG. 7 schematically illustrates an exemplary simplified runout model 700 for the image marking device 100 of FIG. 3 employing the feedback and/or feedforward control loop strategies for controlling banding defects.
[0053] As shown in FIG. 7 , the basic model geometry is adapted from an exemplary image marking device schematic, as shown in FIG. 3 . In this setup, runout is modeled using elliptical cross-sections for both the magnetic roll 30 and the photoreceptor drum 20 . Other 3-dimensional forms of runout such as “bowing” runout or “conical” runout were not considered.
[0054] A simulated sensor measurement of a developed image on the photoreceptor drum is shown in FIG. 8 for the case where the level of runout is extreme and the development field has not been calibrated. An example of a print that could result from this level of density variation is shown in FIG. 10 . For this print, ΔE peak-to-peak is approximately 15. After a first-cut attempt at calibrating the development field voltage (V dev ) according to the Internal Model Principle approach described above, the sensor measurement of the developed image is as shown in FIG. 9 . FIG. 11 illustrates a simulated print corresponding to the case where the development voltage has been calibrated for runout according the exemplary feedback and/or feedforward control methods and systems of this invention.
[0055] As indicated in FIGS. 8 and 9 , the peak-to-peak variation in the sensor output has been reduced by more than a factor of 10 after the development field is calibrated. In addition, the sensor response after calibration implies ΔE peak-to-peak is approximately 1. Given further refinements to the approach, the inventors anticipate reducing ΔE peak-to-peak to less than 0.5, which is known to those skilled in the art as the perceptibility threshold for this banding frequency (0.03 cycles/mm).
[0056] FIG. 12 is a flowchart of an exemplary embodiment of a method of controlling banding defects using a closed loop feedback and/or feedforward control strategy. Calibration could occur during machine cycle-up. In various exemplary embodiments, the method begins at step S 1200 , where the calibration routine is started, and continues to step S 1210 where a given patch structure or test pattern is developed on a receiving member. The operation continues to step S 1220 where a banding defect is sensed on the receiving member, e.g. photoreceptor, using an optical sensor, e.g. ETAC, and its extent determined.
[0057] Next, at step S 1230 , based on the extent of the banding sensed and determined, the development field is actuated using a feedback and/or feedforward control strategy, such as, for example, the repetitive control or adaptive feedforward control strategies discussed above. At step S 1240 , it is determined whether a uniform density has been achieved in the developed image. If it is determined that a uniform density has not been achieved, the operation returns to step S 1220 , where the operations of steps S 1220 and S 1230 are performed to determine and correct for the banding defects sensed on the receiving member.
[0058] If however, at step S 1240 , it is determined that a uniform density has been achieved in the developed image, operation continues to step S 1250 , where the resulting periodic control signal is stored as a function of developer roll position using, for example, an encoder. During routine machine operation, at step S 1260 , controlling and/or mitigating banding defects in images can be achieved by “playing back” the calibrated development field according to the developer roll position. The calibration routine continues to step S 1270 where the calibration method ends.
[0059] FIG. 13 is a flowchart of an exemplary embodiment of a method of updating the calibration of the development field of a print engine to control banding defects using a closed loop feedback and/or feedforward control strategy. As shown in FIG. 13 , the method starts at step S 1310 with operation of the print engine. As discussed above, calibration could occur during print engine cycle-up, although it is not limited to such timing or operational characteristics. Next, at step S 1320 , the print engine undergoes the banding calibration procedure or routine shown in FIG. 12 . At step S 1330 , one or more print job operations are performed to determine whether unacceptable banding defects exist in the printed output. At step S 1340 , based on the extent of the banding defects determined and/or the cause of the banding determined, a determination is made whether the calibration routine needs to be updated to compensate and/or mitigate for the banding defects determined. If yes, the operation returns to step S 1320 to perform the banding calibration procedure of FIG. 12 . If not, the operation returns to step S 1330 where the print job operations commence and/or continue.
[0060] In various exemplary embodiments of the systems and methods according to this invention, using a closed-loop feedback and/or feedforward control approach allows the use of components with relaxed tolerances, which would reduce unit machine cost (UMC). Furthermore, using a feedback and/or feedforward control approach would allow controller design to be easily scaled from one product to the next. Moreover, feedback and/or feedforward control is inherently robust to subsystem variations, such as developer material variations.
[0061] The feedback and/or feedforward control calibration approaches discussed above may enable print engines capable of high print quality that use developer rolls with relaxed tolerances. Achieving this goal, would lower UMC and improve print quality. In terms of UMC, the cost of this feedback and/or feedforward control approach may typically involve the cost of an optical sensor (e.g. ETAC) and a position sensor for the magnetic roll. However, optical sensors are currently used to measure developed density on the photoreceptor in many existing print engines.
[0062] Moreover, if the motor controlling the magnetic roll is servo controlled, then the encoder signal for this servo could be used to determine the roll position. Consequently, the cost of this approach could be minimal. Another advantage of the approach is scalability. For instance, speeding up a product would simply require calibrating the controller. Redesign of the architecture is not necessary. Finally, the closed loop feedback and/or feedforward control strategies discussed above could be used to mitigate banding from other sources besides runout due to developer roll or the photoreceptor drum, including for example, banding caused by coating variations on either the developer rolls or the photoreceptor, non-uniform photoreceptor wear, non-uniform charging, and developer material variations.
[0063] While the invention has been described in conjunction with the exemplary embodiments, these embodiments should be viewed as illustrative, not limiting. Various modifications, substitutes, or the like are possible within the spirit and scope of the invention.
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Systems and methods of controlling banding defects on a receiving member in an imaging or printing process using a feedback and/or feedforward control technique. In one exemplary embodiment, a method of controlling banding defects on a receiving member in an imaging or printing process includes (a) determining a toner density on the receiving member, (b) automatically determining the extent of banding on the receiving member by comparing the determined toner density to a reference toner density value, and (c) automatically adjusting the toner density based on a result obtained from the comparison of the measured toner density to the reference toner density value, automatically determining the extent of banding and automatically adjusting the toner density being performed using a feedback and/or feedforward control routine or application.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to hydraulic metering devices used to operate downhole devices, such as sliding sleeve valves.
2. Description of the Related Art
A number of downhole devices are operated hydraulically. At times, it is desirable to operate these devices in a stepped manner to respond to changes in downhole conditions. For example, a production tubing string might have a sliding sleeve valve associated with a production nipple to control the flow of fluid into the production tubing string. It would be desirable to be able to shift the sliding sleeve by increments between an open and a closed position. This adjustability would allow fluid flow into the tubing string through the production nipple to be balanced with fluid flowing into the tubing string from other production nipples.
Attempts have been made to use metering devices to adjustably operate a downhole device in a stepped manner. Unfortunately, most of these arrangements have proven to be complex in construction and operation. For example, PCT Application No. PCT/US00/12329 by Schultz et al., entitled “Hydraulic Control System for Downhole Tools” describes a hydraulic control system for multiple well tool assemblies that includes a metering device. The metering device uses two pumps. One of the pumps transfers fluid from a first hydraulic line to an actuator of the well tool assembly in response to fluctuations in pressure on a second hydraulic line, and the other pump transfers fluid from the second hydraulic line to the actuator in response to fluctuations in pressure on the first hydraulic line. The fact that this system requires multiple pumps with associated hydraulic lines makes the system complex in practice and costly.
U.S. Pat. No. 6,585,051 issued to Purkis describes a number of metering apparatuses for use in a downhole environment to discharge a known volume of fluid into a well tool actuator. These metering devices are relatively complex and, therefore, may be prone to failure during use. Additionally, several of the described metering devices incorporate numerous elastomeric O-rings to create fluid tight seals within the metering devices. The O-rings are prone to wear and failure during operation, making metering of a known volume unreliable.
Additionally, the prior art metering arrangements all meter fluid into a fluid input on the downhole device. This can be problematic in some instances
The present invention addresses the problems of the prior art.
SUMMARY OF THE INVENTION
The invention provides devices and methods for operating a sliding sleeve valve or other downhole well tool that is axially shiftable among a finite number of increments between two extreme configurations such as open and closed configurations. A metering device is described having a pair of piston metering assemblies that operate in parallel fluid flow paths. The first piston metering assembly is a “zero position” piston assembly, which when actuated, moves the sleeve of the well tool from a fully closed position to the zero position. The second piston metering assembly is an incremental piston assembly, which can be repeatedly pressurized and depressurized to meter predetermined amounts of fluid from an actuator sequentially to move the sleeve of the sleeve valve in consecutive increments toward a fully open position. The sleeve valve may be moved back to a fully closed position by reverse pressurizing the metering device.
In other aspects, the invention relates to methods of operating a downhole tool, such as a sliding sleeve valve, using a hydraulic metering device so that the tool is adjusted in increments between two extreme configurations, such as open and closed positions. In practice, the metering device and methods of the present invention are less complex than prior art metering arrangements, and the nature of the components used makes the metering device less prone to wear-induced problems, such as the deterioration of elastomeric O-ring seals.
A further advantage of the metering assembly of the present invention is that the metering assembly can be operably interconnected to either the “open” line (fluid inlet) or “close” line (fluid outlet) of a well tool actuator in order to operate the well tool. In a currently preferred embodiment, the metering assembly is connected to the fluid output of the well tool actuator to meter fluid out of the actuator in incremental known amounts to cause the well tool to be actuated in a stepped, incremental manner.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and further aspects of the invention will be readily appreciated by those of ordinary skill in the art as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference characters designate like or similar elements throughout the several figures of the drawings and wherein:
FIG. 1 is a schematic view of a downhole well tool system having a fully closed sliding sleeve valve associated with a hydraulic metering valve in accordance with the present invention.
FIG. 2 is a schematic view of the arrangement shown in FIG. 1 , now with the sliding sleeve valve in the zero position.
FIG. 3 is a schematic view of the arrangement shown in FIGS. 1 and 2 , now with the sliding sleeve valve in a partially open position.
FIG. 4 is a schematic view of the arrangement shown in FIGS. 1-3 , now with the sliding sleeve valve in a fully open position.
FIGS. 5A-5B present a side, cross-sectional view of portions of the exemplary hydraulic metering valve, in an unpressurized condition as used in the well tool system shown in FIGS. 1-3 , constructed in accordance with the present invention.
FIGS. 6A-6B present a side, cross-sectional view of the device depicted in FIGS. 5A-5B , now in a pressurized position.
FIG. 7 is an enlarged cross-sectional view of a free piston used within the device shown in FIGS. 5A-5B and 6 A- 6 B and surrounding components.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1-4 depict a well tool system 10 that includes a well tool actuator 12 and associated well tool 14 . The well tool 14 is of a variety that is operable in a stepped manner between two extreme positions or configurations. It is noted that the components of the system 10 are shown schematically and, in practice, would be integrated into one or more housings or subs (not shown) in a wellbore production tubing string or similar well tool. One example of a suitable well tool actuator 12 is the “HCM-A” sliding sleeve valve hydraulic actuator that is available commercially from Baker Oil Tools of Houston, Tex. The actuator 12 is provided with a hydraulic “open” line 16 and a hydraulic “close” line 18 . As will be described in detail shortly, fluid pressure is increased within the hydraulic “open” line 16 in order to move the well tool 14 toward an open configuration, and fluid pressure is increased within the “close” line 18 in order to move the well tool 14 toward a closed configuration.
In currently preferred embodiments, and as depicted in FIGS. 1-4 , the well tool 14 comprises a sliding sleeve valve, of a type known in the art. In this embodiment, the sliding sleeve valve includes a generally cylindrical housing 20 and a tubular sleeve 22 that is shiftable with respect to the housing 20 . Alignable fluid flow ports control fluid flow between the radial exterior of the housing 20 of the sleeve valve 14 and the interior flowbore 24 of the housing 20 . The housing 20 contains fluid flow ports 26 with interior fluid seals 28 located on each axial side thereof. The sleeve 22 has lateral ports 30 disposed therethrough. In a fully closed position, shown in FIG. 1 , the ports 30 of the sleeve 22 are not aligned with the ports 26 of the housing 20 , and fluid flow between the radial exterior of the housing 20 and the flowbore 24 is blocked by fluid seals 28 . In a fully opened position ( FIG. 4 ), the ports 30 of the sleeve 22 are fully aligned with the ports 26 of the housing 20 , allowing maximum fluid flow through the sleeve valve 14 . In instances wherein the sleeve valve 14 functions as a fluid flow choke within a production tubing string, it would be desirable to be able to move the sleeve 22 in a stepped manner between intermediate positions that lie between the fully opened and fully closed positions. This would allow the amount of fluid flow to be adjusted in response to changing well conditions, such as an increase in the amount of water content within the production fluid obtained from the surrounding formation and the need to balance the production obtained from one formation with that obtained from other formations.
A hydraulic metering device, generally indicated at 32 , is associated with the close line, or fluid output, 18 of the sleeve valve actuator 12 . Still referring to FIGS. 1-4 , the metering device 32 generally includes an upstream filter 34 , a pair of piston metering assemblies 36 , 38 , and a downstream filter 40 . The downstream filter 40 is operably interconnected with a further hydraulic control line 42 that extends to the surface of the wellbore (not shown). Hydraulic fluid conduit 44 interconnects the upstream filter 34 with the first piston metering assembly 36 , and hydraulic fluid conduit 46 interconnects the upstream filter 34 with the second piston metering assembly 38 . Additionally, a hydraulic fluid conduit 48 interconnects the first piston metering assembly 36 with the downstream filter 40 , while fluid conduit 50 interconnects the second piston metering assembly 36 with the downstream filter 40 . It is noted that the upstream and downstream filters 34 , 40 serve as fluid filters to help remove debris from the hydraulic fluid within the system and also serve to split the flow of fluid into parallel flow paths. Fluid exiting the actuator 12 via the fluid outlet 18 will be split by the upstream filter 34 so that the fluid will pass into both the first piston metering assembly 36 and the second piston metering assembly 38 . Conversely, fluid flowed in the reverse direction, through the control line 42 , the downstream filter 40 will split the flow of fluid into parallel flow paths that will pass through both the first piston metering assembly 36 and the second fluid metering assembly 38 . Thus, there are parallel flow paths through the metering device 32 .
Portions of the hydraulic metering device 32 are more clearly depicted in FIGS. 5A-5B and 6 A- 6 B. The first piston metering assembly 36 is referred to as a “zero position” piston assembly and includes a tubular piston housing 52 with upper and lower end subs 54 , 56 , respectively, at opposite axial ends thereof. A piston chamber 58 is defined within the housing 52 and end subs 54 , 56 . Each of the end subs 54 , 56 contains an axial fluid flow passage 60 defined therein to allow fluid to enter or exit the piston chamber 58 . Thus, end sub 54 serves as a fluid outlet to the piston chamber 58 while end sub 56 provides a fluid inlet. The piston chamber 58 retains a “zero position” free piston 64 that is slidably moveable within the chamber 58 . The free piston 64 contains a spring-biased check valve 66 that permits one-way flow of fluid across the free piston 64 . Details of the construction of the free piston 64 and check valve 66 are more readily apparent with reference to FIG. 7 . As depicted there, the check valve 66 is housed within a fluid passage 67 in the body 68 of the free piston 64 , and includes a valve ball member 70 that is biased against valve seat 72 by compressible spring 74 . It is noted that annular fluid seals 76 surround the body 68 of the free piston 64 to create a fluid seal against the housing 52 .
The second piston metering assembly 38 is referred to as an incremental piston assembly and includes a tubular piston housing 80 with upper and lower end subs 82 , 84 secured at opposite axial ends. Fluid passages 86 are disposed axially through each of the end subs 82 , 84 . An incremental piston chamber 88 is defined within the piston housing 80 between the end subs 82 , 84 . End sub 84 provides a fluid inlet for the chamber 88 while end sub 82 provides a fluid outlet. The piston chamber 88 contains an incremental piston pump, generally shown at 90 . The incremental piston pump 90 is useful for sequentially displacing a predetermined, known amount of fluid through the piston chamber 88 of the incremental piston assembly 38 and includes a piston sleeve 92 which radially surrounds a piston member 94 . The piston member 94 features an enlarged pressure-receiving end 96 , a reduced diameter shaft portion 98 and an enlarged piston head 100 . The piston member 94 is moveable with respect to the sleeve 92 between a retracted position ( FIG. 5B ) and an extended position ( FIG. 6B ). When moved to the extended position, the enlarged piston head 100 displaces a volume of fluid through the fluid outlet of end sub 82 and substantially the same volume of fluid is drawn into the fluid inlet of end sub 84 from the actuator 12 . The enlarged piston head 100 of the piston member 94 contacts an end portion 102 of compression spring member 104 , which is disposed within the chamber 88 . The spring 104 biases the piston member 94 toward the retracted position. Although the spring 104 illustrated in the drawings is a spiral-type spring, those of skill in the art will recognize that other compressible spring designs could just as easily be used, including, for example, stacks of Belleville washers or fluid springs, as are known in the art. When fluid pressure is increased within the hydraulic fluid conduit 46 , it bears upon pressure-receiving end portion 96 to urge the piston member 94 to move axially with respect to the sleeve 92 toward the extended position, and the spring member 104 is compressed by the piston head 100 (see FIG. 6B ). It is noted that, while the pressure-receiving end 96 of the piston member 94 may be disposed within the surrounding sleeve 92 with a relatively close fit, there are no elastomeric or other fluid-tight seals located between the piston member 94 and sleeve 92 . As a result, it is contemplated that some fluid pressure will seep between the piston member 94 and sleeve 92 during operation.
Returning to FIGS. 1-4 , the general operation of the overall tool system 10 using the metering device 32 will now be described. The tool system 10 is run into a wellbore (not shown) with the sliding sleeve valve 14 in the closed position depicted in FIG. 1 . During run in, the metering device 32 is in the initial, unpressurized condition depicted in FIGS. 5A-5B . When it is desired to move the sleeve valve 14 to a partially open position, fluid pressure is decreased in the hydraulic control line 42 relative to the pressure present in the hydraulic line 18 . This pressure differential will cause the zero position free piston 64 to move from its initial position in contact with the lower end cap 56 to the pressurized position shown in FIG. 6A . In the pressurized position, the free piston 64 is in contact with or proximate to the upper end cap 54 . This movement of the free piston 64 will cause the actuator 12 to move the sleeve 22 axially downwardly within its housing 20 so that the ports 30 of the sleeve 22 are moved to a point (as shown in FIG. 2 ) wherein they are close to overlapping the ports 26 of the housing 20 . This position is referred to as the “zero position.” In a currently preferred embodiment, the movement of the free piston 64 will cause the sleeve 22 to displace 10.604″ with respect to the housing 20 .
The first and second piston metering assemblies 36 , 38 are interconnected in hydraulic parallel. Therefore, the pressure differential across the metering device 32 will also cause the incremental piston pump 90 to move from the initial position shown in FIG. 5B to the pressurized position depicted in FIG. 6B , thereby displacing an additional volume of fluid from the actuator 12 . The sleeve 22 will then be displaced an additional amount with respect to the housing 20 such that the ports 30 of the sleeve 22 now slightly overlap the ports 26 of the housing 20 and permit a small amount of fluid to pass through the sleeve valve 14 . Thus, the sleeve valve 14 will be partially open. It is noted that when the incremental piston pump 90 is in the pressurized position, the enlarged pressure-receiving end 96 of the piston member 94 will engage a restriction 106 in the shaft 108 passing through the body of the sleeve 92 , thereby limiting the movement of the piston member 94 with respect to the surrounding sleeve 92 . When the piston member 94 has been displaced in this manner, the spring 104 is compressed, as shown in FIG. 6B .
If it is desired to open the sleeve valve 14 further to allow greater fluid flow, this is accomplished by first reducing the fluid pressure differential across the metering device 32 and then increasing it. As the pressure differential is reduced, the spring 104 of the incremental piston assembly 38 will urge the piston member 94 back to its initial, unpressurized position, as depicted in FIG. 5A . Because there is no elastomeric seal or other fluid tight sealing between the enlarged end 96 of the piston member 94 and the surrounding sleeve 92 , fluid can seep between the piston member 94 and the sleeve 92 and equalize the pressure, thereby allowing the spring 104 to return the piston member 94 to its original position. The free piston 64 of the zero position piston metering assembly 36 will remain in its pressurized position, as shown in FIGS. 6A-6B .
At this point, the pressure differential across the metering device 32 is increased to cause the incremental piston pump 90 to be actuated again so that the piston member 94 is moved to the extended position shown in FIG. 6A . This actuation meters an additional amount of fluid from the actuator 12 moves the sleeve 22 of the sleeve valve 14 an additional incremental amount toward the fully open position shown in FIG. 4 . Those of skill in the art will recognize that the pressure differential across the metering device 32 may be repeatedly increased and decreased in order to move the sleeve 22 in a stepped manner to the fully opened position shown in FIG. 4 .
To return the sliding sleeve valve 14 to its fully closed position, hydraulic fluid is pumped into the fluid conduit 42 to create a reverse pressure differential across the metering device 32 . The zero position free piston 64 will be moved by the increased fluid pressure to the position shown in FIG. 5A . Hydraulic fluid entering the zero position piston metering assembly 36 will also urge the valve ball member 70 of the check valve 66 off the valve seat 72 and allow fluid to pass through the free piston and enter the fluid passage 60 of the end sub 56 and to the actuator 12 . This fluid will cause the actuator to return the sleeve valve 14 to the fully closed position depicted in FIG. 1 . The sliding sleeve valve 14 may be moved to the fully closed position in this manner at any time and regardless of the configuration that the sleeve valve 14 is in (i.e., zero position, partially open, fully open).
In the embodiment described, the metering device 32 is operably associated with the fluid outlet, or “close” line 18 of the actuator 12 . However, it would also be possible to operate the well tool actuator by installing the metering device at the fluid inlet, or “open” line 16 of the actuator 12 , thereby metering fluid into the actuator 12 from the metering device 32 . It should be understood that, whether interconnected on the inlet or outlet side of the actuator 12 , the metering device 32 operates the well tool 14 in a stepped manner by metering known amounts of fluid through the metering device 32 .
A metering device constructed in accordance with the present invention is simple in construction and reliable in operation. Additionally, there are few elastomeric elements, such as O-ring seals needed for operation of the metering device, thereby making the device more resistant to wear-related problems or problems associated with high-temperature downhole environments.
Those of skill in the art will recognize that numerous modifications and changes may be made to the exemplary designs and embodiments described herein and that the invention is limited only by the claims that follow and any equivalents thereof.
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Methods and systems for operating a sliding sleeve valve or other downhole well tool that is axially shiftable among a finite number of increments between two extreme configurations such as open and closed configurations. A metering device is described having a pair of piston metering assemblies that operate in parallel fluid flow paths. The first piston metering assembly moves the sleeve of the well tool from a fully closed position to the zero position. The second piston metering assembly can be repeatedly pressurized and depressurized to meter predetermined amounts of fluid from an actuator sequentially to move the sleeve of the sleeve valve in consecutive increments toward a fully open position.
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TECHNICAL FIELD OF THE INVENTION
[0001] The present disclosure relates to the consolidation of viscous liquids, including ketchup and other condiments, from one container to another.
BACKGROUND OF THE INVENTION
[0002] Restaurants often have various practices to reduce condiment waste. These methods are typically time-consuming and inefficient.
[0003] For example, restaurants which use glass or plastic bottles with removable tops often instruct their waiters to balance one bottle upside down on top of another matching bottle, so that the ketchup (or other condiment) will gravity feed into the lower bottle. The waiter then repeats that process, emptying several bottles to obtain one full bottle.
[0004] Though the above-mentioned technique is very common, it is replete with drawbacks, including the necessity of watching the bottles as one drains into the other, spillage, or danger of broken glass which occurs when one ketchup bottle might fall off and break on the floor. To mitigate these issues, the hospitality industry has developed several approaches, including the following.
[0005] The Non-Clogging Gravity Transfer Connector for Closed Containers, disclosed in U.S. Pat. No. 4,201,252 and issued on May 6, 1980, is a tube-like structure that connects two condiment bottles. This device would not be successful in connecting non-rigid containers, however.
[0006] The Product Saver, disclosed in U.S. Pat. No. 6,470,928 and issued on Oct. 29, 2002, conveys the contents of a upper bottle to a lower bottle, with fittings between which a butterfly valve controls the flow. Again, this device requires two rigid containers.
[0007] The System for Transferring a Viscous Liquid Between Containers, disclosed in U.S. Pat. No. 7,967,040 issued on Jun. 28, 2011, comprising a pair of transfer lids which attach to two containers and a transfer adaptor that connects the transfer lids for transfer of viscous liquids. This device requires containers that match the lids, and still requires two rigid containers of a limited size.
[0008] Restaurants often use large condiment dispensers which are loaded with a commercial bag holding bulk amounts of condiments. The bags in which the condiments are shipped are set into the dispenser and slowly emptied, and when the dispensing apparatus no longer releases condiment during use, the bags are lifted and replaced, with any remaining condiment within the mostly empty bag simply thrown away with the bag.
[0009] The hospitality industry needs a way to better consolidate the remains of commercial bulk product bags.
SUMMARY OF THE INVENTION
[0010] The present disclosure includes an apparatus and method by which commercial restaurant employees can easily consolidate viscous condiments without any danger of spillage, broken glass, or time-intensive baby-sitting of precariously arrange glass bottles.
[0011] The invention consists of a device that connects two commercial bulk condiment bags, allowing the contents of one bag to flow smoothly into the other, reducing waste.
[0012] Novel and inobvious aspects of the invention comprise a device and method of eliminating food waste by transferring food from one flexible container to another. Other features and advantages of the present disclosure will be apparent to those of ordinary skill in the art upon reference to the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] For a better understanding of the disclosure, and to show by way of example how the same may be carried into effect, reference is now made to the detailed description along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts.
[0014] FIG. 1 shows an orthogonal view of one embodiment of the invention.
[0015] FIG. 2 shows a side view of the embodiment of the invention shown in FIG. 1 .
[0016] FIG. 3 shows a bottom view of the embodiment of the invention shown in FIG. 1 .
[0017] FIG. 4 shows a cross sectional side view of one embodiment of the invention along the A-A lines shown in FIG. 3 .
[0018] FIG. 5 shows a front view of the embodiment of the invention.
[0019] FIG. 6A is a cut-away side view showing an optional angled Bag Grip construction.
[0020] FIG. 6B is a cut-away side view showing an optional ratcheted Bag Grip construction.
DETAILED DESCRIPTION OF THE INVENTION
[0021] While the making and using of various embodiments of the present disclosure are discussed in detail below, it should be appreciated that the present disclosure provides many applicable inventive concepts, which can be embodied in a wide variety of specific contexts. The disclosure is primarily described and illustrated hereinafter in conjunction with various embodiments of the presently-described systems and methods. The specific embodiments discussed herein are, however, merely illustrative of specific ways to make and use the disclosure and do not limit the scope of the disclosure.
[0022] As shown in the figures, the current embodiment comprises a hollow Connecting Tube 21 , in which each open End 23 of the Tube 21 is angled. Near each End 23 is a Mounting Ridge 25 that encircles the exterior of each Tube 21 that strengthens the Tube 21 and makes it more rigid. In this embodiment, an Interior Side 29 is formed along the Tube 21 between the Mounting Ridge 25 and the tube's End 23 . An Exterior Side 31 is formed as an extension from the Connecting Tube 21 that mirrors the Interior Side 29 and provides added rigidity to the Tube 21 . The Interior Side 29 and Exterior Side 31 pairing near each End 23 form a Bag Grip 27 , a narrow opening that a user employs to connect the Tube 21 to a bag. The resulting construction allows a user to connect a bag to each End 23 of the Tube 21 .
[0023] In the current embodiment, the Tube 21 also contains a extended Tube Reinforcement 33 between the Mounting Ridges 25 . As shown in FIG. 2 , this embodiment uses a roughly triangular-shaped Tube Reinforcement 33 , but a Tube Reinforcement 33 can be formed of any shape, including a straight reinforcement element that stretches across the Tube 21 between the Mounting Ridges 25 .
[0024] Commercial condiment bags (used to dispense ketchup, mustard, and mayonnaise, among other food stuffs) are often flexible bags which fit into a dispensing container and attach to the container so that restaurant customers press a lever that in turn, dispenses condiment through an exit portal that is used in the dispensing operation to release the condiment.
[0025] The invention takes advantage of the commercial bag portal by connecting the rigid ring that typically surrounds the portal to the Connecting Tube 21 . The user connects the Tube 21 to a dispensing bag by simply placing the tube's End 23 into the portal, twisting the Tube 21 in relation to the bag so the bag's portal ring is pressed into the Bag Grip 27 formed between the Interior Side 29 and Exterior Side 31 of the Tube 21 .
[0026] The invention includes Ends 23 that are angled to more easily be placed into the food bags, but the sloping of the Ends 23 is optional.
[0027] Once a user has connected a bag to each end of the Tube 21 , the user merely squeezes one of the bags, causing food material within the bag being squeezed to flow into the other bag connected to the Tube 21 . The Bag Grip 27 is constructed so a friction connection formed between the food stuff portal ring and the Interior Side 29 and Exterior Side 31 .
[0028] Once the user is finished transferring food from one bag to the other, the user simply disconnects the Tube 21 from the bag, typically using a pulling motion, or a pulling and twisting motion between the bag and Tube 21 .
[0029] The embodiment of the device as built is constructed to allow for an optimum fit for one size of portal ring, but the device can be made to fit multiple sizes by using a decreasing or ratcheted optional Bag Grip 27 construction, as shown in FIGS. 6A and 6B , respectively.
[0030] All embodiments described herein are presented for purposes of illustration and explanation only. These descriptions of one embodiment are not intended to be limiting to the embodiments described. Those skilled in the relevant art will be able to create other embodiments based on this disclosure and the claims that are attached with this application.
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A device and method are disclosed which connects two bulk restaurant condiment bags which allows users to move the food product in one bag into the other, the device comprising a hollow connecting tube sized to fit and secure to the bags.
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BACKGROUND OF THE INVENTION
1. Field of the Invention:
The invention herein pertains to a steam iron soleplate, generator, and steam distributor subassembly using inexpensive parts in an arrangement for easy cleaning and efficient conversion of all water to steam in a simplified arrangement that permits use of any number of soleplate surfaces.
2. Description of the Prior Art:
Recent designs in irons disclose simpler irons that may use plastic parts, may be used as clothes steamers as well as for ironing, are lighter weight, and that are intended to sell at a lower price. These irons use different constructions from the normal rather complex well-known constructions. Typically, such irons may employ the construction shown in U.S. Pat. Nos. 3,260,005 and 3,811,208 showing a soleplate subassembly and semi-plastic construction, respectively.
One of the difficulties in using relatively thin soleplates is applying the heating element to the soleplate without causing the soleplate to warp. Typically, this is not a problem in the normal heavy cast soleplate where the heating element is cast in the soleplate or is welded to it and the heavy soleplate provides a large heat sink and is sufficiently massive for machining of the surface afterward. Additionally, in steam irons it is necessary that the parts be effectively sealed because of the presence of water and the sealing compound applied between separable parts is itself often the source of trouble in creating dri-filming problems where the water tends to boil and bounce on the heated surface rather than wet it and boil off as steam.
SUMMARY OF THE INVENTION
Briefly described, the present invention is directed to a steam iron soleplate, steam generator and steam distributor subassembly that uses a relatively thin soleplate in combination with a coverplate that is spaced from and supported on the soleplate by a peripheral spaced rib to define a steam distributing passage means therebetween. The coverplate is integrally attached to the soleplate by a continuous weld between the rib and soleplate and the steam generating means is provided directly in the coverplate rather than the soleplate and is connected or ducted to the steam passage means below. The heat generating means is directly in the coverplate and the subassembly is put together by stamping out the soleplate, welding the spaced coverplate completely around its periphery to the soleplate to permanently secure the two together and then the rest of the iron is assembled on this base subassembly. Additional ribs may be used to weld the parts together so that the suspended heating means heats the soleplate primarily by conduction through the ribs to the soleplate and a very large steam conversion and distributing area is provided for maximum steam capacity. Thus, the main object of the invention is to provide a simple steam iron subassembly that is easily put together permanently by welding and comprises very few parts.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a plan view of the soleplate subassembly;
FIG. 2 is a cross-sectional view on the line 2--2 of FIG. 1 showing the spacing arrangement; and
FIG. 3 is a perspective view of the completed subassembly.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The soleplate subassembly described is primarily for use with a steam iron of a typically general type as shown in U.S. Pat. No. 3,188,757 of common assignment in that it may be operated dry or, by operating a well-known water valve to drip water into a generator where it flashes into steam and then is distributed under a coverplate to steam ports in the soleplate in the conventional manner. Closing the water valve provides dry operation and such structure is well-known in the prior art and is not repeated here. Usually the irons employ a rather massive aluminum soleplate to provide a large heat sink and this may be die cast or gravity cast with the soleplate having the heating rod or element cast integrally therein for best even heat distribution on the soleplate. The soleplate of such conventional irons generally runs about a half an inch thick, thinning down in the area of the steam distribution passages to less than a half inch. The steam generator and the soleplate around the heater is the thickest portion generally resulting in about a half inch casting.
Referring to FIG. 1, there is shown a wrought soleplate 10 to which the present invention is especially applicable. The advantage of wrought material is that it is possible to get alloys of better corrosion resistance than available in the cast soleplates, the wrought material requires essentially no machining, it has no porosity which is a problem in cast soleplates and it is lighter in weight. Additionally, it provides a highly flexible material choice, can be more easily polished, and provides a smoother ironing surface. It can be stamped directly from rolls and can be purchased clad with a variety of materials such as stainless steel, titanium, and polytetrafluoroethylene (better known as Teflon) to provide smoother and more durable ironing surfaces. Thus, the wrought material, whether clad or not, may be brought in large rolls and complete soleplates stamped out of the rolls. The material is ribbon-like in the sense that it is flat material of approximately 1/8 inch or less throughout. This is what is meant by the term "relatively thin" as used in the claims as being different from the normal massive thick cast soleplates.
The soleplate may be formed with suitable steam ports 12 that can be stamped in any suitable number and orientation in the same assembly line in which the soleplates 10 are stamped. Thus, no drilling is required. The ports and edge of the soleplate may also then be coined to provide a finished relatively thin soleplate with or without either stainless steel clad or other suitable coatings.
In order to provide a simple steam distribution system and provide even heat to the soleplate, a simple formed coverplate 14 is provided. This may be a formed casting that has a continuous depending peripheral rib 16 around the coverplate. Heat is provided by the customary heat generating element or rod 18 that is cast in position directly on the coverplate to form part of the coverplate as shown in FIG. 2. The heating element is generally of the sheath type and normally extends around the soleplate in a loop beginning at the rear of the iron along one side to the forward end and then rearwardly along the other side to enclose the iron except at the rear of the soleplate as shown in FIG. 1. The sheathed heating element has an electrical resistance wire extending through an outer tubular protective sheath with the heating element separated from the outer sheath by an electrical insulating compound resistant to heat such as a mass of granulated and compressed magnesium oxide well-known in the art.
In order to transfer heat from element 18 to the soleplate 10, the peripheral rib 16 is integrally attached to the soleplate, after the desired ports are punched, by a continuous weld 20 completely around the coverplate as shown in FIG. 1. The welding is made by any suitable welding process such as Electron Beam, TIG, MIG, or Laser and the entire periphery is welded to the soleplate to seal the edges of the coverplate to the soleplate. This complete welding eliminates any need for a sealing compound with its tendency to create dri-filming problems since the welding provides an unbroken integral connection between the soleplate and coverplate. Thus, heat transfer to the soleplate from element 18 is primarily by heat conduction through the ribs that space and support the coverplate from the soleplate. In order to stiffen the subassembly, avoid warping, and provide improved support and heat transfer, a central longitudinal rib 22 may be provided and it is also continuously welded to the soleplate in the same manner as shown in FIG. 2. Again, heat transfer through rib 22 is primarily by conduction through the weld to the soleplate so that the combination of the peripheral welded rib 16 and central rib 22 provides for even heating of the relatively thin soleplate. The high heat intensity welding allows the coverplate and soleplate to be joined with no warping or buckling and no local hot spots to separate any cladding material.
For steam distribution in the large distribution chamber 24, additional guide ribs 26 on the bottom of the coverplate can be provided for any suitable labyrinth to distribute steam uniformly to steam ports 12. With the coverplate spaced from the soleplate as shown, a copious steam distribution chamber 24 is provided which, with the suitable guide ribs 26, may direct the steam in any desired path through the soleplate. The arrangement described permits economic application of any number of soleplate surfaces including stainless steel.
Because of the relatively thin light soleplate, it is necessary to generate steam off of the soleplate and this is done by providing a steam generating means in the form of a boiler 28 wholly disposed directly in the upper surface of the coverplate separate and distinct from the usual steam generator in the soleplate. With the construction shown this may be relatively large and in the generally forward portion of the iron as shown in FIG. 1, although its specific location may be other than as shown. Preferably, it is located forward of the longitudinal rib 22 at one end thereof and disposed along the longitudinal center line of the soleplate as is rib 22. Thus, it is symmetrical about the longitudinal center line at the forward end of longitudinal rib 22. Steam generated in the upper surface of the coverplate is disposed to enter distribution chamber 24 by any suitable connection such as directing rib 29 and ducting means 30 to direct the steam down below the coverplate and into large chamber 24 or distributing passage from whence it exits ports 12.
It will be seen that the subassembly is formed by stamping out the soleplate and then punching or coining the steam ports and the edge of the soleplate to round them and smooth them and then placing the cast coverplate in place and welding it continuously around its depending rib to the soleplate to permanently attach it thereto. Thus, a steam distributing chamber 24 is formed and this completed two-part subassembly may then form the base for the rest of the iron components such as attaching at 32. The spaced coverplate provides an ideal shelf or pad 34 on which a thermostat may be mounted in close proximity to the hot portion for sensing the iron temperature.
The present soleplate assembly provides a simple two-part construction where the heat element is embedded, for a maximum heat conduction and maximum heater life, directly in the chamber cover above the relatively thin soleplate. The two parts are welded together at their edges to create heat conduits to the soleplate surface so that heat transfer is primarily by conduction evenly throughout the soleplate. The distribution chamber formed between the parts permits copious steam distribution through any number or orientation of spaced ports punched through the thin soleplate which may be punched directly from rolled alloys and thus permits economic application of any number of surfaces such as stainless steel and a light weight soleplate. The boiler or generator is located directly in the cast coverplate and is of relatively large size to permit complete conversion of water to steam and ample area for mineral deposit storage which means longer iron life. By locating the steam generator in the coverplate rather than the soleplate the invention does not generate a cold spot in the soleplate surface and the large boiler will not flood within standard temperature ranges because of its massiveness and its spacing from the soleplate. Thus, the simple two-piece construction of the subassembly permits all the advantages previously noted.
While there has been described a preferred form of the invention, obvious equivalent variations are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practised otherwise than as specifically described, and the claims are intended to cover such equivalent variations.
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A steam iron soleplate, generator, and distributor subassembly of a thin soleplate with a coverplate spaced from and supported on the soleplate by spaced peripheral rib means to define a steam distributing passage therebetween. The coverplate is integrally attached to the soleplate by a continuous weld between the ribs and soleplate and steam generating means are provided in the upper surface of the cover-plate separate and spaced from the soleplate and ducted below to the steam passage means. A heat generating element forms an integral part of the coverplate for heat transfer to the soleplate through the ribs primarily by conduction. Both the method of assembly and the subassembly itself are disclosed.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to guide bar adjustment mechanisms for chainsaws, and more particularly to an adjustment mechanism having a breakaway adjustment pin.
[0002] Various mechanisms are known for adjusting the tension of the chain on a chainsaw. Nearly all of these mechanisms involve the movement of the guide bar upon which the chain rests. By lengthening the guide bar, the chain tension is increased. Conversely, shortening the guide bar decreases the chain tension.
[0003] A commonly used mechanism for adjusting the position of the guide bar consists of an adjustment pin threaded onto an adjustment screw provided on the body of the chainsaw. The adjustment pin engages a hole in the guide bar. As the adjustment screw is rotated, the pin advances or retreats along the screw, moving the guide bar with it.
[0004] One problem with these adjustment pin type chain tensioning mechanisms occurs during assembly of the guide bar onto the chainsaw body. The pin is not normally visible once the bar is placed onto the body. If the guide bar and the adjustment pin are not properly aligned during assembly, the adjustment pin and/or adjustment screw can be damaged.
BRIEF SUMMARY OF THE INVENTION
[0005] The present invention provides a bar adjustment assembly for a chainsaw including a self-aligning breakaway adjustment pin. The assembly comprises: a shaft, a bar adjustment pin journalled for rotation relative to the shaft, and a pin alignment spring biasing the rotation of the bar adjustment pin toward an engagement position.
[0006] According to a further aspect of the present invention, the assembly further comprises a void for accommodating the bar adjustment pin when the bar adjustment pin is rotated away from the engagement position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is an overall view of a chainsaw having a guide bar adjustment mechanism according to the present invention;
[0008] FIG. 2 is a plan view of a portion of a chainsaw body that houses a guide bar adjustment mechanism according to the present invention;
[0009] FIG. 3 is a plan view of the chainsaw body of FIG. 2 having a misaligned guide bar attached thereto;
[0010] FIG. 4 is a plan view of the chainsaw body of FIG. 2 having a correctly aligned guide bar attached thereto;
[0011] FIG. 5 is a cross section of the chainsaw body and guide bar adjustment mechanism taken along section line 5 - 5 of FIG. 2 showing the assembly direction of the guide bar;
[0012] FIG. 6 is a cross section of the chainsaw body and guide bar adjustment mechanism taken along section line 6 - 6 of FIG. 3 ; and
[0013] FIG. 7 is a cross section of the chainsaw body and guide bar adjustment mechanism taken along section line 7 - 7 of FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
[0014] As shown in FIGS. 1-7 , a guide bar adjustment mechanism 10 for a chainsaw includes a threaded shaft or adjustment screw 12 , an adjustment pin 14 and a pin alignment spring 16 . The adjustment screw 12 is mounted within a void or recess 18 provided in a portion of a chainsaw body 20 .
[0015] The adjustment pin 14 is journalled on the adjustment screw 12 . Matching threads are provided on the adjustment pin 14 and the adjustment screw 12 . When the adjustment screw 12 is rotated by using an appropriate tool on the head 12 a of the adjustment screw 12 , the adjustment pin 14 moves back and forth along the length of the adjustment screw 12 . When the guide bar 24 is properly assembled onto the chainsaw body 20 ( FIGS. 4 and 7 ), the adjustment pin 14 normally engages an adjustment hole or slot 22 in a guide bar 24 . Due to the engagement of the adjustment hole 22 by the adjustment pin 14 , as the adjustment pin 14 moves along the length of the adjustment screw 12 , the guide bar 24 follows.
[0016] During assembly of the chainsaw, as illustrated in FIG. 4 , the guide bar 24 is placed onto the chainsaw body 20 so that the adjustment pin protrudes through the adjustment hole 22 of the guide bar 24 , as shown in FIGS. 4 and 7 . Then, a cover portion 25 of the chainsaw is placed over the guide bar 24 and chainsaw body 20 . The cover portion 25 is secured in place by two bolts 26 or other fasteners (see FIG. 1 ).
[0017] As shown by the broken lines in FIG. 5 , the recess 18 is shaped to allow the guide pin 14 to pivot fully into the recess 18 . Therefore, if the guide bar 24 is incorrectly positioned on the chainsaw body 20 , such that the adjustment hole 22 is not aligned with the adjustment pin 14 , the adjustment pin 14 can pivot out of the way, preventing damage to the adjustment mechanism 10 from occurring ( FIGS. 3 and 6 ).
[0018] The pin alignment spring 16 is a helical torsion spring provided on the adjustment screw to keep the adjustment pin 14 in the correct orientation when the guide bar 24 is not attached. The pin alignment spring 16 is a helical torsion spring having first and second free ends ( 27 , 28 ). The first end 27 of the pin alignment spring 16 engages the adjustment pin 14 , and the second end of the pin alignment spring 16 engages a surface of the chainsaw body 20 within the recess 18 . The pin alignment spring 16 is loosely wrapped on the adjustment screw 12 , such that it is journalled thereon, to allow the pin alignment spring 16 to travel along the adjustment screw 12 with the adjustment pin 14 . Alternatively, other types of springs, such as a helical tension spring, a helical compression spring, a spiral spring, a flat spring, etc., or other known types of biasing means such as elastic bands or straps, resilient foam or gel pads, etc., can be provided as the pin alignment means.
[0019] The pin alignment spring 16 is positioned to bias the pivoting of the adjustment pin 14 out of the recess 18 . When the adjustment pin 14 is positioned fully upright in an engagement position, as shown in FIGS. 2, 5 and 7 , a stop surface 30 meets a surface 31 of the chainsaw body 20 within the recess 18 . This meeting of the two surfaces 30 , 31 prevents the adjustment pin 14 from pivoting any further. Alternatively, other stop mechanisms could be used.
[0020] As described above, when the guide bar 24 is incorrectly positioned on the chainsaw body 20 , the adjustment pin 14 pivots into the recess 18 . When the guide bar 24 is subsequently removed from the chainsaw body 20 , the alignment spring 16 causes the adjustment pin 14 to pivot to its fully upright position so that the guide bar 24 , now being correctly aligned, can be reassembled without any manual repositioning of the adjustment pin 14 .
[0021] It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited.
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A bar adjustment assembly for a chain saw includes a shaft, a bar adjustment pin that is journalled for rotation relative to the shaft, and a pin alignment spring that biases the pin toward an engagement position. A void is provided for accommodating the pin it is rotated away from the engagement position by a guide bar that has been incorrectly attached.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of German patent application 10 2006 029 055.0, filed Jun. 24, 2006, herein incorporated by reference.
BACKGROUND OF THE INVENTION
The invention relates to a two-for-one twisting spindle having a pneumatically actuated threading device.
In two-for-one twisting spindles, the thread is generally drawn off upwardly from the stationary supply bobbin, introduced into the upper end of a thread inlet tube, deflected downwardly and guided by a thread brake into the spindle rotor or into the spindle shaft, which it leaves again in the radial direction through a thread guide channel.
After leaving the thread guide channel, the thread is guided upwardly and, during the twisting, forms a balloon rotating about the supply bobbin. The thread then runs through a thread guide and is wound, twisted, onto a take-up bobbin.
On modern two-for-one twisting machines, the threading of the thread takes place by means of compressed air and a threading injector. Compressed air is fed to the threading injector for the threading process. The air flowing out of the threading injector produces in the thread guide channel an air flow directed outwardly to the mouth of the thread guide channel. A negative pressure is produced in the part of the spindle shaft configured as a hollow spindle. The sucked-in air draws the already held thread into the mouth at the upper end of the thread inlet tube. The air flow conveys the thread outwardly through the thread guide channel. After leaving the thread guide channel, the thread can be grasped manually by the operator and drawn off from the supply bobbin and positioned for further processing steps.
German Patent Publication DE 3012427 C2 discloses a two-for-one twisting spindle having a pneumatically actuated threading device, in which the spindle rotor has a coaxially extending connection channel, through which compressed air is fed. In the storage disc of the spindle rotor, the thread channel feeding thread from above and the connection channel feeding the compressed air from below in each case open, after a deflection, into the thread guide channel of the storage disc. The compressed air entering the connection channel during the threading process flows through the injector and produces the suction action required to suck in the thread in the hollow spindle in the upper part of the spindle rotor. On ending the threading process, the compressed air feed is interrupted again.
German Patent Publication DE 10250423 A1 shows a two-for-one twisting spindle having a pneumatically actuated threading device, in which the compressed air channel in the lower part of the spindle shaft is firstly guided centrally and, before reaching the thread storage disc, is guided as an oblique bore. Adjoining the compressed air channel in the spindle shaft is an air channel in an injector element which opens as an injector into the thread channel and therein produces the required air flow radially outwardly.
The production costs of these known embodiments are high. In particular, the manufacturing of the channels in the spindle shaft is expensive. The efficiency of the known designs is unsatisfactorily low. A measure of the efficiency in this case is the static or dynamic negative pressure which can be produced in the thread inlet tube or in the thread channel as a function of the pressure of the pressure source used. The lower the pressure of the compressed air source for achieving an adequately high negative pressure for sucking in the thread, the more economically or efficiently the threading process can be carried out. The configuration of the air guide in the known embodiments to the thread channel limits the efficiency.
In addition, the abrupt deflection of the air flow through around 90° or more leads to the fact that the compressed air leaving the compressed air channel firstly impinges perpendicularly on the wall of the injector element before the compressed air flow is deflected and accelerated in the injector element. The swirlings occurring at the deflection point reduce the efficiency of the injector element as the compressed air must be fed at a higher pressure to compensate this effect.
SUMILLIMETERSARY OF THE INVENTION
The object of the invention is to develop a known two-for-one twisting spindle in such a way that the quantity of fed compressed air can be reduced at the same or higher produced negative pressure.
This object is achieved by means of a two-for-one twisting spindle wherein, according to the invention, the compressed air feed comprises a connection element with a curved air channel, which connects the feed bore to the injector element, and wherein the connection element is configured as a separate component and the air channel is adapted to the flow requirements. In contrast to the prior art, in which the compressed air feed and the injector element connected thereto offer few design possibilities for improving the flow behavior, the connection element designed as a separate component has the substantial advantage that it can easily be designed in a manner which is optimised in terms of flow in order to contribute to the optimisation of the pneumatically actuated threading device. In addition, production is possible in a simple and economical manner. The inventive configuration of the compressed air feed in terms of flow increases the injector effect. The pressure of the compressed air source can be lowered in comparison to known devices, without the negative pressure produced for sucking in the thread being reduced. Alternatively, the negative pressure is increased with the same pressure of the compressed air source, so the suction effect on the thread is increased. Moreover a calming of the compressed air entering the air channel of the connection element is achieved in that swirlings of the compressed air occurring while flowing through the air channel, which occur after the abrupt deflection during the exit from the feed bore into the connection element, are reduced. This effect also contributes to it being possible to reduce the air pressure of the fed compressed air without reducing the efficiency of carrying out the threading process. Overall, the injector effect in the injector element is improved with a pressure which is reduced compared to the prior art and this increases the economic efficiency of the two-for-one twisting spindle with a pneumatically actuated threading device.
Advantageous configurations of the connection element contribute to the feeding of the compressed air, which is particularly favourable in terms of flow, to the injector element and increase the effect of the injector element.
In an air channel, which has a larger cross section at its inlet than at its outlet, the flow speed of the air is increased. As a result, the injector jet, which is formed by the air exiting into the thread guide channel, is pre-reinforced.
The spindle shaft and the thread guide ring preferably have recesses, into which the connection element can be inserted. The angle position of the thread guide ring on the spindle shaft can be adjusted and fixed by the inserted connection element. If the thread guide ring with its recess has been slipped over the connection element, the thread guide channel and the outlet of the injector element are aligned with one another. It is not possible to rotate the spindle shaft and thread guide ring with respect to one another in the assembled state as the inserted connection element acts as an anti-rotation mechanism.
A connection element, which is comprised of two components rigidly connected to one another, which are mirror-inverted with respect to one another, is simple to produce and less expensive in comparison to a connection element produced in one piece.
If the connection element is comprised of glass fiber-reinforced plastics material, it can be produced economically, has only a low weight and is durable.
A sealing ring between the connection element and the spindle shaft and between the connection element and the injector element, in each case, represents an economical and functionally reliable seal of the compressed air feed.
The configuration of the connection element as a separate component allows easy production and adaptation of the air channel to the flow requirements. This contributes to it being possible to economically produce a two-for-one twisting spindle according to the invention. The economy during the threading process is improved by low compressed air consumption, which is possible because of the increased injector effect.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention will be described with the aid of the figures, in which:
FIG. 1 shows a partial view of a two-for-one twisting spindle with a pneumatically actuated threading device in an axial section,
FIG. 2 shows a perspective view of a disassembled connection element with sealing rings as well as an injector element with a deflection piece,
FIG. 3 shows a perspective view of one half of a divided connection element.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a two-for-one twisting spindle with a spindle bearing arrangement 1 . The spindle shaft 2 configured in one piece is rotatably mounted in the bearing housing 4 by means of a ball bearing arrangement 3 . The bearing housing 4 is fastened to the spindle rail 5 . The spindle shaft 2 carries a drive wharve 6 , a thread guide ring 7 and a bobbin pot 8 with a bobbin carrier base 9 and hollow hub 10 . The hollow hub 10 is mounted by means of ball bearings 11 , 12 on the spindle shaft 2 and has a coaxially thread tube 13 . The thread tube 13 opens into the upper hollow axle 14 of the spindle shaft 2 . The spindle shaft 2 can be rotated about the perpendicularly extending rotational axis 15 . A recess passing through the spindle shaft 2 , with an oval cross section, extends transversely to the rotational axis 15 . An injector element 16 made of plastics material is inserted into the recess. It can be produced as an injection moulded part, economically and so as to fit precisely, corresponding to the flow requirements. The thread channel 17 of the injector element 16 connects the upper hollow axle 14 of the spindle shaft 2 to the thread guide channel 18 of the thread guide ring 7 . The air flow during threading as well as the thread are deflected in the thread channel 17 . The thread in this case runs via a deflection element 19 made of ceramic. The thread guide channel 18 of the thread guide ring 7 extending horizontally and therefore at right angles to the rotational axis 15 of the spindle shaft 2 , at its outer end, has a thread guide 29 made of ceramic. The thread guide ring 7 carries the rotary plate 28 . The bobbin carrier base 9 can be rotated relative to the spindle shaft 2 and is held, when the spindle shaft 2 rotates, in its position with respect to the bearing housing 4 or to the spindle rail 5 by means of the magnetic force of permanent magnets 41 , 42 with magnetic returns.
The injector element 16 can be connected temporarily to a compressed air source 20 . The air flow in the compressed air line 21 can be interrupted by means of a shut-off mechanism 22 . The tube mouth 23 of the compressed air line 21 leading from the compressed air source 20 to the spindle shaft 2 is arranged stationarily below the spindle shaft 2 . A stationarily arranged compressed air feed of this type to the spindle shaft 2 is described in detail, for example, in German Patent Publication DE 3012427 C2. The compressed air line 21 ends at a slight spacing from the feed bore 24 of the spindle shaft 2 . In this configuration, seals between the tube mouth 23 and the spindle shaft 2 can be dispensed with. Compressed air losses are largely avoided. The compressed air is firstly guided to the spindle shaft 2 in the feed bore 24 extending coaxially to the rotational axis 15 . The feed bore 24 opens into a transverse bore 25 . The transverse bore 25 is connected to the injector element 16 by means of the channel 26 of the of the connection element 27 . The air channel 26 extends in a semi-circular manner. The centre line 37 of the air channel 26 and the rotational axis 15 of the spindle shaft 2 lie in one plane. The semi-circle, which is formed by the centre line 37 , has a radius of between 3 millimeters and 6 millimeters.
FIG. 2 shows the connection element 27 and the injector element 16 in the unassembled state. The air channel 26 extends substantially semi-circularly. The deflection in the connection element 27 is 180°. The air channel 26 has a circular cross section and, at its inlet, has a larger cross section than at its outlet which, in the assembled state, rests on the injector element 16 . Accordingly, the air channel diameter D E at the inlet of the air channel 26 is greater than the air channel diameter D A at the outlet of the air channel 26 . The connection element 27 is configured to receive sealing rings 30 , 31 both at the inlet and at the outlet of the air channel 26 . In the installed state of the connection element 27 , the sealing rings 30 , 31 are pressed together and lead to a secure seal between the connection element 27 and the spindle shaft 2 and between the connection element 27 and the injector element 16 . The injector element 16 comprises an injector bore 32 , which opens into the thread channel 17 and which is directed onto the thread guide channel 18 . The injector bore 32 and the thread guide channel 18 are arranged so as to be aligned. The diameter of the injector bore 32 is significantly smaller than the diameter of the thread channel 17 . Consequently a step 40 , as shown in FIG. 1 , is produced. The air leaving the injector bore 32 as an injector jet can flow freely in the direction of the thread guide channel 18 . The injector bore 32 which runs in a straight line has a constant diameter. An injector bore 32 of this type with a length between 5 millimeters and 6 millimeters allows the injector jet to be made uniform.
The thread channel mouth 33 is adapted to the circular shape of the cross section of the spindle shaft 2 and opens directly into the thread guide channel 18 . The deflection element 19 , which is exposed to the friction from the running thread, is pressed into the injector element 16 and held by the resilient holding flaps 34 , 35 . The deflection element 19 , in the installed state, forms the upper wall of the thread channel 17 , as shown in FIG. 1 . While the injector element 16 is produced from plastics material, the deflection element is comprised of highly wear-resistant ceramic.
FIG. 3 shows a connection element half 36 . The interior of the air channel 26 and the recesses 38 , 39 , into which the sealing rings 30 , 31 are placed can easily be seen in the view of FIG. 1 . The centre line 37 of the air channel 26 extends linearly at the inlet of the air channel 26 , then in a semi-circular manner and again linearly at the outlet of the air channel 26 . It can also easily be seen in this view that the air channel diameter D E at the inlet of the air channel 26 is significantly greater than the air channel diameter D A at the outlet of the air channel 26 .
The connection element half 36 shown and a second connection element half, not shown, and designed in a mirror-inverted manner are joined to form the connection element 27 in such a way that the air channel 26 with a circular cross section is formed. If the connection element half 36 and the second connection element half consist of plastics material, the connection element 27 may be produced from the two components, for example by means of ultrasonic welding. In this manner, simple moulds can be used for the injection moulding process and production becomes more economical.
For threading, the thread, for example, is manually drawn off upwardly from the stationary delivery bobbin and held ready in front of the thread inlet tube. The shut-off mechanism 22 is opened and the compressed air flows from the compressed air source 20 through the compressed air line 21 , the feed bore 24 and the transverse bore 25 into the connection element 27 and from there further through the injector bore 32 into the thread channel 17 . The air blown in from the injector bore 32 produces an air flow toward the outlet of the thread guide channel 18 and negative pressure in the thread tube 13 , which, for example, spreads to the mouth of the thread inlet tube. The end of the thread held ready is sucked by the negative pressure into the thread inlet tube and the thread tube 13 , deflected at the deflection element 19 and conveyed further by the air flow through the thread guide channel 18 . At the thread guide 29 , the thread exits with the air flowing out there and can then be manually grasped by the operator. After the threading process, the shut-off mechanism 22 is activated and the connection between the compressed air source 20 and injector bore 32 is interrupted again.
Owing to the configuration of the two-for-one twisting spindle according to the invention, the air pressure of the compressed air source 20 can be reduced in comparison to a known configuration, as shown in German Patent Publication DE 10250423 A1, for example from 3 bar to 1.7 bar, without the negative pressure, with which the thread is sucked in, becoming less. The air consumption during the threading process can therefore be reduced by 60 to 70%. The lower air consumption leads to increased economy of the two-for-one twisting spindle according to the invention.
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Two-for-one twisting spindle having a pneumatically actuated threading device, with a spindle shaft rotatable about a vertical axis partially configured as a hollow shaft with a lower feed bore extending coaxially to the rotational axis, and with an injector element opening into a thread guide channel of a thread guide ring temporarily connectable during threading to a compressed air source. Part of the compressed air feed to the injector element is formed by the feed bore. The compressed air feed comprises a connection element ( 27 ) with a curved air channel ( 26 ), which connects the feed bore ( 24 ) to the injector element ( 16 ). The connection element ( 27 ) is configured as a separate component and the air channel ( 26 ) is adapted to the flow requirements.
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CROSS-REFERENCES TO RELATED APPLICATION
The present patent application is related to the benefit of the following co-pending China and U.S. patent applications: China patent application No. 200610029753.0, titled for “A Parallel Processing System with Self-Consistent Expandable Internal and External Networks”; China patent application No. 200610030472.7, titled for “A Self-Consistent Multi-rank Tensor Expansion Scheme and Multi-MPU Parallel Computing Systems”; China patent application No. 200710042397.0, titled for “A Mixed Torus and Hypercube Multi-rank Tensor Expansion Method”; China patent application No. 200610117704.2, titled for “Routing Strategies for Cellular Networks in MPU Architectures”. The whole contents and disclosure of the abovementioned related patents are expressly incorporated by reference herein as if fully set forth herein.
FIELD OF THE INVENTION
The present invention relates generally to the field of supercomputing systems and multiprocessor architectures, and more particularly to an ultra-scalable supercomputer based on MPU (Master Processing Unit) architecture.
BACKGROUND OF THE INVENTION
With the rapid increase of a single processor processing ability, to construct a high-available, high-density and ultra-scalable supercomputer faces the embarrassing bottleneck of the communication subsystem design, whose developments and innovations dramatically lags behind the computation power. To better manage the consistent balance between the communication and computation in a large-scale supercomputer while to preserve the programmability and application portability, more and more advanced interconnect topologies are put into practice such as IBM BlueGene and Cray RedStorm employing 3-D torus and Columbia QCDOC employing truncated 6-D torus. Those novel multi-dimensional mesh-based architectures with the internally developed design of the advanced interconnect intellectual properties allow systems to comprise higher processor counts and to achieve better overall performance on applications compared to the conventional systems that rely on the commodity interconnect fabrics including the external fat-tree Infiniband or Myrinet federated switch. Additionally, as observed on systems with Myrinet and Infiniband interconnects, intermittent errors on a single link may have a serious impact on the performance of the massively parallel applications by slowing down the communication due to the time required for connection recovery and data retransmission. Alternately, mesh-based network designs overcome this issue by implementing a large portion of data links as traces on the system backplanes and by aggregating several alternative connections into a single bundle attached to a single socket, thus reducing impact caused by the number of possible mechanical faults by an order of magnitude.
Further, due to the absence of the more centralized external federated switch formed by a large number of individual switches, a mesh-based supercomputer is more flexible to be expanded without losing scalability. However, a similar-scale cluster design with several thousand nodes necessarily has to contain much more external cables connecting the nodes to tens of switches that must be located tens of meters or more away from each other. Such scenario is also a serious maintenance disaster, in addition to much higher operating expenses. The fault tolerance ability of a cluster system important for achieving the sustained and reliable computing resources for large-scale realistic applications is always guaranteed at the sacrifice of more redundant switches available, thus increasing the size of external federated switches again. However, the novel mesh-based supercomputers, such as IBM BlueGene, use smart adaptive routing strategies to isolate the fault area while routing messages with existing alternative data links around fault nodes flexibly without demanding much more hardware compensation to retain the communication balance by dynamic fault-tolerant routing algorithms.
The trends of the high-performance computing (HPC) industry strongly indicate the value of the present invention in providing an ultra-scalable supercomputer based on MPU architecture. The MPU architecture is a novel multi-dimensional network topology enabling an ultra-scalable and highly coupled interconnection while, by adding Axon nodes, providing facilitating long-range and collective communications and also for connections to external networks such as the management and external file networks. Preferably, considering both high compatibility with different processor platforms and flexible adaptability with varied application acceleration units while better and stably implementing our own IP cores, we choose the reconfigurable chip as the implementation platform of the switching logic for a processing node or an Axon node.
SUMMARY OF THE INVENTION
The object of the present invention is to provide an ultra-scalable supercomputer based on MPU architecture to achieve the high-performance and sustained computing resources at the scale of TFLOPS, PFLOPS and beyond at cost, power dissipation, and footprint advantages.
Another objective of the present invention is to provide a well-balanced supercomputer between the computation and communication abilities by the novel multi-dimensional interconnect topology as described in herein incorporated, pending China patent application No. 200610029753.0 entitled “A Parallel Processing System with Self-Consistent Expandable Internal and External Networks”. The said novel interconnect topology is used to achieve a network system with low network diameter and high bandwidth for the large-scale expansion.
A further object of the present invention is to provide a flexibly expandable and easily compatible supercomputer using the FPGA-based Inter-process communication Network (FIN) in achieving the ability of leveraging existing robust processor platforms for the computational functionality while focusing on the crucial internally developed interconnect topologies, in order to permit a high degree of seamless improvements with the continuing increase of the user-specific and commodity processors powering the system and to well accommodate compatibility to custom application acceleration units such as vector processing engines. Moreover, the FPGA chip for the router device can be either other reconfigurable chips or application-specific integrated circuits (ASIC) for the implementation of the system connectivity and further, a switching chip and processing cores with other supportive units such as multi-level caches and high-speed connectors can be integrated into one chip to implement a System-on-a-Chip (SoC) design.
The FIN design philosophy further enables designers, developers and end-users to adapt and upgrade the routing functions easily and flexibly. For example, as for a specific custom application, we can implement particular communication patterns in the reconfigurable chip to better balance and accelerate the program running and further, the reconfigurable chip can take over some computational loads off the local CPU subsystem without affecting other functional blocks' configurations and designs. Additionally, in a parallel computer with MPI, we can also implement and optimize basic communication routines and collective communication schemes into the routing chip to reduce the system overhead by better exploiting the intrinsic nature of the MPU-based interconnect architectures.
A further objective of the present invention is to build a multi-MPU supercomputer with a single high-density and cost-efficient processing cell as a supernode. A processing cell comprising several processing nodes and associated Axon nodes becomes a basic construction brick. Through the tensor expansion scheme described in herein incorporated, pending China patent application No. 200610030472.7 entitled “A Self-Consistent Multi-rank Tensor Expansion Scheme and Multi-MPU Parallel Computing Systems”, a ultra-scalable supercomputer is expanded while preserving a short network diameter, a high bisection bandwidth and sufficient alternative data links between processors for high bandwidth and strong fault tolerance.
The preferred hardware implementation of the present invention, a supercomputer system is based on the blade chassis solution considering the footprint and maintenances. The blade chassis solution enables the high-density multi-processor computer system at low cost, low power dissipation and high availability.
A preferred supercomputer at the present invention is to incorporate multiple interconnection networks. A first network implements a point-to-point MPU-based interconnect topology while supporting such collective operations as broadcasting and All-gather communication patterns. In said MPU-based interconnect topology, each of the processing nodes situates at the center of a multi-dimensional cube made up of its neighboring processing nodes and particularly, a boundary processing node situates at the center of a virtual multi-dimensional cube made up of its realistic and imaginary neighboring processing nodes due to the cyclic property of topology while the entire interconnect topology remains consistent and unified.
A second network implements an expansion network by connecting all of the Axon nodes for performing the long-range and collective operations such as global notification and barrier operations. In a multi-dimensional MPU topology, an Axon node connects a subset of processing nodes connected as an embedding of two multi-dimensional cubes of equal size in a preferred embodiment. Herein, these processing nodes are called as the Axon node's attached processing nodes and the Axon node is called as the upstream Axon node of these processing nodes. Next, all of Axon nodes according to their logical positions connect to form another small-scale MPU interconnect topology or a mesh-based topology instead. Additionally, an Axon node also provides its attached processing nodes with connections to external networks such as the management network and the storage file system.
A third network is the Ethernet-based management network for performing the remote monitor and administration operations to the entire system. A forth network is the high-speed external storage network. A processing node can get access to the external file system with the help of its upstream Axon node through the high-speed connections.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates the 2-D MPU interconnection topology.
FIG. 2 schematically illustrates the internal interconnect in a 2-D MPU processing cell.
FIG. 3 schematically illustrates the internal interconnect in a 3-D MPU processing cell.
FIG. 4 schematically illustrates of the 3-D MPU interconnection topology.
FIG. 5 schematically illustrates a generic blade layout that can host multiple generic nodes for performing the computation and communication functions.
FIG. 6 schematically illustrates the internal layout of a system chassis holding up to sixteen blade slots in two layers.
FIG. 7 schematically illustrates the front end of the system chassis configuration.
FIG. 8 schematically illustrates a fully-populated rack layout housing six system chassis or ninety-six blade nodes with supportive devices.
FIG. 9 schematically illustrates the block diagram of a generic node, either a processing node or an Axon node.
FIG. 10 schematically illustrates the functional blocks for the high-speed network logic of a generic node, either a processing node or an Axon node, based on 3-D MPU architecture.
FIG. 11 schematically illustrates the virtual-output-queue switch fabric overview.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The interconnection network topology for the ultra-scalable supercomputer of the present inversion is based on the multi-dimensional MPU architecture connecting a plurality of processing nodes and Axon nodes by multiple independent interconnection networks. Herein, MPU, Master Processing Unit, is termed as a basic processing cell comprising a subset of processing nodes with their upstream Axon nodes and wherein the subset of processing nodes logically connected as an embedding of two virtual multi-dimensional cubes of equal size. The detailed interconnect topology definitions are described in China patent application No. 200610029753.0, titled for “A Parallel Processing System with Self-Consistent Expandable Internal and External Networks”.
An exemplary embodiment of 2-D MPU architecture, the simplest MPU topology, is shown in FIG. 1 and wherein, every eight processing nodes compose a processing cell, logically connected as an embedding of two squares of four processing nodes and each processing node situates at the center of its four neighbors. Two neighboring processing cells are connected by the boundary processing nodes which provide the necessary interface. FIG. 2 is the internal interconnect in a 2-D MPU processing cell. As illustrated in FIG. 1 , eight processing nodes compose a 2-D processing cell and one Axon node is added to connect all of eight attached processing nodes in the same cell for providing communications to external and/or expansion networks. Meanwhile, an expansion network by connecting all of Axon nodes as a two-dimensional torus is built up mainly for the long range and collective operations and moreover, provides connections to external networks.
Considering the contemporary technology and techniques, a preferred embodiment of 3-D MPU architecture is described in detail hereinafter. High-dimensional MPU architectures can be designed and implemented in a similar way with the technology progress in the manufacturing industries. Moreover, in the following descriptions, we will make use of a reconfigurable Field Programming Gate Array (FPGA) technology as the implementation platform of the switching logic for our design approach. Therefore, a FPGA-based IPC Network is termed as FIN responsible for all inter-process communications between processors in the entire system.
However, it is not only constrained to the FPGA and other programmable chips convenient for performing switching logics can be also utilized. Moreover, an Application-Specific Integrated Circuit (ASIC) chip can be developed and further a switching functional block can be embedded into a central processing subsystem to implement a SoC design, should volume reaches to a critical point.
FIG. 3 is the internal interconnect in a 3-D MPU processing cell. Sixteen processing nodes compose a 3-D processing cell, logical connected as an embedding of two virtual cubes and two Axon nodes, A and B, are added to connect all of eight attached processing nodes in a virtual cube. For example, Axon node A connects to processing nodes from A 1 to A 8 and similarly Axon node B connects to the rest eight processing nodes in the same cell for providing communications to external and/or expansion networks.
In the preferred embodiment of 3-D MPU architecture, each processing node logically situates at the center of a three-dimensional cube made up of its eight neighboring processing nodes. For example in FIG. 4 , the processing node B 1 connects to processing nodes from A 1 to A 8 as a cube. Every sixteen processing nodes are connected as an embedding of two three-dimensional cubes. For example in FIG. 4 , eight processing nodes from A 1 to A 8 form a cube and the other eight processing nodes from B 1 to B 8 form the other. By the cube-central connection method, those two cubes are highly coupled. A boundary processing node in a processing cell is situated at a cube made up of its internal and external processing nodes. For example, in processing cell # 4 , B 6 connects to two internal processing nodes i.e. A 6 and A 7 in processing cell # 4 and six external processing nodes i.e. A 5 and A 8 in processing cell # 5 , A 2 and A 3 in processing cell # 7 , and A 1 and A 4 in processing cell # 8 . As shown in the light-green portion in FIG. 4 , those eight processing nodes among neighboring processing cells form a cube for B 6 in processing cell # 4 . The other light-green portion in FIG. 4 shows the neighboring cube for B 5 in processing cell # 1 . Therefore, a first interconnection network is built up by connecting all of the processing nodes in the entire system mainly for the point-to-point and some collective communications such as broadcasting and All-gather operations.
As described in China patent application No. 200610030472.7, titled for “A Self-Consistent Multi-rank Tensor Expansion Scheme and Multi-MPU Parallel Computing Systems”, an Axon node is configured by connecting a subset of processing nodes for providing external interfaces and an expansion network is further built up by connecting all of the Axon nodes still as MPU architecture. Those processing nodes are named attached processing nodes to their Axon node and said Axon node is named the upstream Axon node to its attached processing nodes. Therefore, a second interconnection network can be built by connecting all of Axon node as MPU architecture mainly for the long-range and some collective communications such as global operations.
Additionally, a third interconnection network, defined as the management network for remote monitor and system administration, is also implemented by connecting Axon nodes to the external network such as an Ethernet switch. Herein, each processing node owns an Ethernet connection to its upstream Axon node's Ethernet switch for communication with the external management subsystem.
Additionally, a forth interconnection network, defined as the storage network for access to the external file system, is further implemented by connecting Axon nodes through high-speed channels to the external file subsystem such as Infiniband Storage Area Network (SAN). Herein, an Axon node owns expansion slots supporting Fiber or Infiniband channels to access and external file server switches and then with the upstream Axon node, the processing node can communicate with the external file subsystem.
Processing Node Overview:
A processing node provides the computation and communication ability comprising a central processing subsystem and a router device.
Functional Blocks of Processing Node FPGA (PNF):
Processing Node FPGA, PNF as shown in FIG. 10 , is responsible for communication among neighboring processing nodes, its upstream Axon node and local central processing subsystem. As shown in FIG. 10 , a 3-D PNF commonly comprises a clock and reset module, a management module (Control and Status Registers), a sRIO/PCI-E IP adaptation module, a FIN protocol adaptation module and a switch fabric module, nine Aurora IP adaptation modules and a DMA controller, and wherein sRIO means serial RapidIO and PCI-E means Peripheral Component Interconnect Expansion. As for the functional blocks for the high-speed network logic of an Axon node, the identical functional blocks in a 3-D Axon node perform the same functions in a 3-D processing node while the Aurora IP Adaptation block in an Axon node connects to each of its attached processing nodes instead. The high-speed interconnect interfaces provide the communications for a processing cell with the external interconnects including the management network, the storage network and the expansion network.
The clock and reset module implements the functions to generate the reset and clock signals for the other modules.
The management module implements the array of system registers, handles read and write requests to the registers coming from the sRIO/PCI-E IP adaptation module, makes the contents of the registers available for the other modules that make use of their contents and collect status information from the other modules for storage in the registers, detects activity on data links and coordinates with the local processor subsystem. LEDs show status and events of interest for monitoring the state of the FPGA chip. The system registers are accessible from the local processor subsystem through maintenance requests as the module is connected to the maintenance port of the sRIO/PCI-E IP adaptation module. The array of registers includes parameters required by the switch fabric, status of Aurora links, caption of events such as temporary link errors, etc. Also, registers are used to keep track of the number of packets received/transmitted on each link, buffer fill-levels, error flags etc. The management module also generates signals for driving LEDs mounted on the PCB.
The sRIO/PCI-E IP adaptation implements the high-speed interface towards the local processor subsystem. The module separates maintenance traffic and other types of communication to different blocks; maintenance requests will result in read or write accesses to the management module and all other types of communication will be forwarded to the FIN protocol adaptation module.
The FIN protocol adaptation module wraps the original packets provided by the sRIO/PCI-E IP adaptation module in a proprietary packet format suitable for the FIN switch architecture. The proprietary packet overhead is removed when the packets are sent to the sRIO/PCI-E adaptation module for delivery to the connected local processor subsystem. The module also checks packets for errors and reports such to the management module.
The switch fabric module handles all packet switching within FIN and requires several parameters to be operational and reports errors back to the management module. FIG. 11 is the Virtual Output Queue (VOQ) switch fabric overview. This switch module implements a Virtual Output Queue (VOQ) switch which means providing several individual buffered queues named virtual channels at the receiver and each said receiver can move data across the switch fabric to a specified transmitter according to the routing arbitration. Each said virtual channel is able to buffer one or more full-sized FIN-protocol packets at the receiver. This switch module also implements a Virtual Cut-Through (VCT) transmission mechanism which means a packet entering the switch may begin forwarding to an arbitrated downstream transmitter before all of the flits of the entire packet are stored at the receiver in order to reduce the network latency through a switch.
The Aurora IP adaptation module implements the high-speed Aurora link-layer point-to-point serial links that connect PNF with other processing nodes and also connect PNF with its upstream ANF. This module reports link status including errors to the management module as well. This module also includes the link-level flow control mechanism and the link-level retransmission mechanism to provide a stable link-level high-speed transmission platform for the other modules.
Block Diagram of a Processing Node:
A processing node comprises a central processor subsystem, a CPLD device, an Ethernet PHY, a FPGA-based router device and other supportive devices such as a boot flash, Power VRM, memories slots and a temperature sensor as shown in shown in FIG. 9 . FIG. 9 is the block diagram of a generic node, either a processing node or an Axon node. Dark-black-marked areas are only for the block diagram of an Axon node. As for the block diagram of a processing node, a preferred processing node mainly comprises a central processing subsystem, CPLD, an Ethernet PHY for the management network, a FPGA-based router device for multiple communication networks, a power VRM, several memory slots, a boot flash and a temperature sensor. Said central processing subsystem comprises a central processing unit (CPU), one or more floating-point processing units (FPU), a local embedded multi-level cache memory and other on-chip controllers including I2C controllers, enhanced three-speed Ethernet controllers (TSEC), Double Data Rate 2 (DDR2) SDRAM memory controllers with FCC and high-speed interfaces such as Serial RapidIO interface and/or PCI-Express interface with the FPGA chip. A CPLD chip is equipped on the processing node board, able to reset and configure individual onboard components under control. A FPGA chip is equipped on the processing node board for the inter-process communication networks among all of the processing nodes in the entire MPU supercomputing architecture. A boot flash is equipped on the processing node board to store the boot code, able to be programmed in standard EPROM programmers.
As for the block diagram of an Axon node, a preferred Axon node mainly comprises a central processing subsystem, CPLD, an Ethernet PHY, an Ethernet switch as marked in red area, PCI-Express interfaces as marked in red area, a FPGA-based router device for multiple communication networks, a power VRM, several memory slots, a boot flash and a temperature sensor. The same devices as in the processing node hold the similar functions in the Axon node. Said Ethernet switch connects the Ethernet connections from all of its attached processing nodes for the management network. One or more PCI-Express slots are provided for the external networks. Optionally, one or more PCI-Express expansion cards (Fiber channel or Infiniband) can be inserted into the PCI-Express slots. A FPGA chip is equipped on the Axon node board for the communications between attached processing nodes and external networks including the management network, the storage network and the expansion network for the long-range and collective operations.
Axon Node:
An Axon node is an expansion node to strengthen the communication and management ability comprising both internal interfaces to attached processing nodes and expansion interfaces to other Axon nodes' router chips and external supportive networks. As described in the patent entitled “A Self-Consistent Multi-rank Tensor Expansion Scheme and Multi-MPU Parallel Computing Systems”, an Axon node directly connected to attached processing nodes can be seen as the first-level or one-rank Axon node in the multi-rank tensor expansion scheme while providing interfaces to other one-rank Axon nodes and consequently the expansion network by connecting all of said one-rank Axon nodes as a MPU interconnect topology is defined as the one-rank expansion network to facilitate the long-range communications. Next, a two-rank Axon node further directly connects to a subset of one-rank Axon nodes at the similar manner for providing interfaces to other two-rank Axon nodes. The said subset of one-rank Axon nodes logically forms an embedding of two multi-dimensional cubes of equal size. Also, a two-rank Axon node can share most of functional blocks with a one-rank Axon node at design and implementation. Therefore, another expansion network by connecting all of said two-rank Axon nodes as another MPU interconnect topology is defined as the two-rank expansion network to further reduce the network diameter. Iteratively, a multi-rank tensor expansion network subsystem can be constructed to improve the performance of the global operations. Since the multi-rank expansion scheme is the same as that of the one-rank expansion network, the descriptions hereinafter concentrate on the implementation of the one-rank expansion network or the expansion network for short.
Functional Blocks of Axon Node FPGA (ANF):
Axon Node FPGA, ANF as shown in FIG. 10 , is responsible for communication among attached processing nodes, its local central processing subsystem and multiple external networks. As shown in FIG. 10 , a 3-D PNF commonly comprises a clock and reset module, a management module (Control and Status Registers), a sRIO/PCI-E IP adaptation module, a FIN protocol adaptation module and a switch fabric module, eight Aurora IP adaptation modules and a DMA controller and external expansion interfaces including connectors among neighboring Axon nodes in the expansion network and optionally one or more expansion slots with the external file server network. The identical functional blocks both in PNF and ANF hold the same function and design herein.
The differences between ANF and PNF are that ANF owns external expansion interfaces to multiple external networks. In a multi-rank tensor expansion scheme, a one-rank ANF has also high-speed interfaces with its upstream two-rank ANF.
Block Diagram of an Axon Node:
An Axon node comprises a central processor subsystem, a CPLD device, an Ethernet PHY, an Ethernet switch, a FPGA-based router device, PCI-E expansion interfaces and other supporting devices such as a boot flash, Power VRM, memory slots and a temperature sensor as shown in FIG. 9 . The identical functional units both in processing node and Axon node hold the same function. Optionally, one or more PCI-E expansion cards (Fiber or Infiniband channels) can be inserted added to connect to external networks such as the storage file server network.
Layout of a Generic Blade Node:
Considering the system reliability and footprint, a blade node layout hosing multiple generic nodes is illustrated in FIG. 5 and a generic node can be either processing node or Axon node. A generic blade layout can host multiple generic nodes for performing the computation and communication functions. A preferred generic node, either processing node or Axon node, is assembled on the vertically-plugged board conforming to the Extended COM (Computer-on-Module) Express specification, comprising a processing subsystem including processors, memories located on the System-on-Module board and supporting chipsets. Several such generic node boards are assembled into a blade node through those onboard COM Express connectors. On the blade layout, a power VRM module, a routing device for board-to-backplane communications and other supportive modules such as PCI-E slots are assembled as well. At the rear of the blade layout, a power connector for power supplies and a signal backplane connector for communications are located. At the front panel of the node layout, the Reset and/or Power ON/OFF buttons and LEDs are located for control and monitor.
Layout of a System Chassis:
A 7U system chassis, as shown in FIG. 6 and FIG. 7 , holds up to sixteen blade nodes for performing the computation and communication activities in two layers. FIG. 6 is the internal layout of a system chassis holding up to sixteen blade slots in two layers. In a chassis, all of the communications between blade slots and power supplies are implemented by the backplane. Each blade node can plug directly into the chassis backplane from the front side along the sliding rail upon insertion. The vertically mounted backplane provides a blade slot with both the power connector and the signal connector. The back of the chassis contains sockets for extending high-speed network across the chassis, Ethernet sockets for the management network and power outlets for the external power. The chassis can be removed from the rack for servicing without disrupting the configuration of other system components. FIG. 7 is the front end of the system chassis configuration. All of sixteen processing cells are located into a compute and IO chassis in two layers.
Layout of a System Rack:
Six 7U system chassis are populated in the standard 48U system rack with hot-swappable fan blowers on the bottom and on the top, providing the airflow for the bottom three chassis and top three chassis respectively as shown in FIG. 8 . FIG. 8 is a fully-populated rack layout housing six system chassis or ninety-six blade nodes with supportive devices including hot-swappable fan blowers on the bottom and on the top respectively, providing air flows for the bottom and top three chassis respectively. The gap in the middle of the rack serves as an air vent to remove the hot air exiting the bottom stack to prevent the overheating of the chassis on top. In the absence of the power source for the chassis, each rack can house an AC/DC transformer to convert an external 230V/380V AC current into twelve independent outputs of 48V DC current for distribution to the system modules.
A Multi-MPU Supercomputer:
A multi-MPU supercomputer is a multiprocessor computing architecture comprising a plurality of MPU-based supernodes interconnected by a multi-rank tensor expansion communication subsystem, thus featuring a self-consistent multi-rank MPU-topology scheme. The hardware embodiment of the entire supercomputer consists of a blade node directly inserted into a system chassis while multiple chassis are mounted into a standard rack with cooling and power suppliers, for high reliability and high availability with small footprint, at low cost, and low heat dissipation. Meanwhile, the hardware embodiment of a reconfigurable chip for performing communication guarantees high portability to existing parallel applications and the easy-to-update ability to keep seamlessly consistent with both the technology progress of commodity processor families and the algorithm improvement of customer applications.
Furthermore, a hybrid supercomputer can also adopt a conventional multi-dimensional torus or hypercube interconnect topology for performing the trunk communication system while increase another expansion network by adding Axon nodes through the tensor expansion scheme mainly for facilitating the long-rang operations, as described in China patent application No. 200710042397.0, titled for “A Mixed Torus and Hypercube Multi-rank Tensor Expansion Method”. Herein, a MPU is a processing cell comprising a subset of processing nodes connected on the conventional multi-dimensional torus network and an Axon node connecting to those processing nodes while providing expansion interfaces to external networks. An expansion network is built up by connecting all of said Axon nodes on the multi-dimensional MPU network or the conventional multi-dimensional torus network. Moreover, these said Axon nodes can be termed as one-rank Axon nodes and another set of Axon nodes serving as two-rank Axon nodes can directly connect to one-rank Axon nodes so, similarly, a two-rank expansion network is constructed by connecting all of two-rank Axon nodes. Iteratively, a multi-rank tensor expansion communication subsystem is constructed with the aid of Axon nodes. Meanwhile, Axon nodes also provide the external connections as mentioned above. The heterogeneous system combining a torus topology and the multi-rank tensor expansion scheme is the most straightforward embodiment while sharing most of the above-mentioned exemplary embodiment. However, an ultrascalable supercomputer integrating high-dimensional MPU topology and multi-rank tensor expansion scheme is comparatively preferred.
The routing strategies in MPU architecture can use the switching functions as described in China patent application No. 200610117704.2, titled for “Routing Strategies for Cellular Networks in MPU Architectures”, while enables a deadlock-free adaptive routing pattern in MPU architecture and better support the exploration of intrinsic merits of the MPU architecture.
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The invention provides an ultra-scalable supercomputer based on MPU architecture in achieving the well-balanced performance of hundreds of TFLOPS or PFLOPS range in applications. The supercomputer system design includes the interconnect topology and its corresponding routing strategies, the communication subsystem design and implementation, the software and hardware schematic implementations. The supercomputer comprises a plurality of processing nodes powering the parallel processing and Axon nodes connecting computing nodes while implementing the external interconnections. The interconnect topology can be based on MPU architecture and the communication routing logic as required by switching logics is implemented in the FPGA chips while some modular designs for accelerating particular traffic patterns from applications and meliorating the communication overhead are able to be deployed as well.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent application No. 61/973,587 entitled “Disturbance Detection, Predictive Analysis, and Handling System” filed Apr. 1, 2014, which is hereby incorporated by reference.
FIELD
[0002] The present inventions relate to the field of detection and alert systems. The present inventions more specifically relate to the field of detection, predictive analysis, and handling of a disturbance or potential disturbance.
BACKGROUND
[0003] The reduction of noise disturbances in various medical, commercial, and residential settings is of significant importance. For example, the importance of reducing noise disturbances in hospitals and improving patient sleep experience has been well documented in medical journals, which have demonstrated a correlation between sleep experience and medical outcome. According to hospital survey results, such as the HCAHPS survey, the lowest score nationally is in response to how quiet the area around the patient's room was during the night. Not only does this noise and disturbance affect the health of the patient, but also Medicare uses the results of these surveys to determine the amount of money a hospital is to be reimbursed for patients using Medicare. If the hospital's results are below the national average, they receive a lower payment, while survey results above the national average result in a higher payment.
[0004] While a hospital/medical/healthcare facility is described for purposes of example, in addition to medical or healthcare facilities, the hospitality industry also has a significant need to reduce disturbances to guests and, in particular, to guest sleep experiences. A common complaint is noise that results in the disturbance of guests in neighboring rooms, which can lead to a poor guest experience and subsequently a loss of business.
[0005] Likewise, multi-family residential facilities have a need to reduce disturbances of tenants/occupants for similar reasons. A means of predicting damage in the management of a facility is also of particular importance.
[0006] Accordingly, what is needed is a system which can detect and predict a disturbance, such as to a sleep experience, or detect and predict damage to a facility, and to identify when, how, and what actions should be taken to prevent, reduce, or eliminate these disturbances or damage.
SUMMARY
[0007] Accordingly, a disturbance detection, predictive analysis, and handling system is provided. The system described herein may assist in identifying when, how, and what actions should be taken and by whom to prevent, reduce, or eliminate disturbances. The system described herein may do so by monitoring or sensing activity in real time, performing predictive analytics on the data, and communicating the outcome to achieve a desired result. The system may include sensors and networks to aid in the identification of disturbance and/or damage. The system may also use predictive algorithms and historic disruption data to enhance the accuracy of its prediction of disturbance and/or damage.
[0008] In one illustrative example of implementation of the system, a system may be used in a hospital or assisted living facility for predicting disturbances to patient sleep experience through the use of various sensors. The system may identify when and what actions should be taken, and by whom, to prevent, reduce or eliminate these disturbances. In an alternative example of embodiments, the system may predict disturbances in the hospitality industry to guest sleep experiences. The system in this example may identify when, how, and what actions should be taken and by whom to prevent, reduce, or eliminate these disturbances. In another alternative example of embodiments, the system may predict disturbances to tenant/occupant sleep experience in a multi-family residential setting. The system may identify when, how, and what actions should be taken and by whom to prevent, reduce or eliminate these disturbances. In a further example of embodiments in facility management, the system may predict damage to a facility and identify when, how, and what actions should be taken and by whom to prevent, reduce, or eliminate this damage.
[0009] The system may use one or more sensors to read environmental data such as ambient temperature, noise, humidity, or light. The sensors may be provided in a sensor unit. The sensor unit may be placed in strategic positions throughout a building. For example, in patient rooms at a hospital. The sensor units may report to a central hub, which sends information to a server for processing and prediction. The server may identify or anticipate potential disruptions from the sensor data and alert personnel. Further analytics may be provided using a data analytics engine. The data analytics engine may create a data pattern or signature from the data and compare it with historical data signatures. Using these and other techniques, the data processing/analytics engine may provide a predictive report to users for disruption tracking and anticipation.
[0010] A disturbance detection, predictive analysis, and handling system is disclosed, including a sensor unit having a sound sensor and one or more network communication devices, the sensor unit having a processor programmed to transmit sensor data using the network communication device; a hub having one or more network communication devices, a processor, and data storage component, wherein the processor is programmed to accept and transmit the sensor unit data; a server having a network communication device, processor, and database, wherein the processor is programmed to analyze the sensor unit data; and a reporting device having a reporting software, the reporting device having a network communication device; wherein the network communication devices of the sensor unit, hub, and reporting device are selected from the group of Zigbee, Bluetooth, Wi-Fi, mobile broadband modem, or Ethernet.
[0011] A disturbance detection, predictive analysis, and handling method is disclosed, the method comprising: providing one or more sensors including a sound sensor within a first networked device in a first location; using one or more sensors provided within the first networked device to obtain a first group of sensor reads over a period of time; determining a first example value from the first group of sensor reads using the first networked device; transmitting the first example value from the first networked device to a first hub device; providing one or more sensors including a sound sensor within a second networked device in a second location; using one or more sensors provided within the second networked device to obtain a second group of sensor reads over a period of time; determining a second example value from the second group of sensor reads using the second networked device; transmitting the second example value from the second networked device to the first hub device; transmitting the first example value and second example value to a server; analyzing the first example value and second example value against one or more thresholds; transmitting an alert signal to an alert device; and saving the first example value and second example value to create historical data.
[0012] A disturbance detection, predictive analysis, and handling system is disclosed, the system comprising: a plurality of sensor devices that transmit data to one or more sensor hubs, each sensor device having: a sound sensor, a unique identifier, a personal area network identification, a personal area network communication device, and a microprocessor programmed to determine a highest sound value over a period of time; one or more sensor hubs that accept data from the plurality of sensor devices to a server, each sensor hub having: a sound sensor, a unique identifier, a personal area network identification, a personal area network communication device, a network communication device, and a microprocessor programmed to determine a highest sound value over a period of time and to send sensor values from the plurality of sensor devices to a server using the network communication device; a server which accepts data from the one or more sensor hubs, the server having: a network communication device, a database, and a processor programmed to execute an alert algorithm; a dashboard which accepts data from the server, the dashboard having: a network communication device, and a user interface displaying sensor data; and a data analytics engine that accepts data from the server, the data analytics engine having: a network communication device, a database containing historic sensor data and user-provided data, and a processor programmed to execute analysis algorithms.
[0013] These and other features and advantages of devices, systems, and methods according to this invention are described in, or are apparent from, the following detailed descriptions of various examples of embodiments.
BRIEF DESCRIPTION OF DRAWINGS
[0014] Various examples of embodiments of the systems, devices, and methods according to this invention will be described in detail, with reference to the following figures, wherein:
[0015] FIG. 1 is a representation of an embodiment of a system implemented in a building.
[0016] FIG. 2 is a logical flow diagram between the parts of an example embodiment of the system.
[0017] FIG. 3 is an example embodiment of a process executed by the system.
[0018] FIG. 4 is an example relationship between an example server and example data analytics engine of the disclosed system.
[0019] FIG. 5 is an example logic flow of an example server for use with the system disclosed.
[0020] FIG. 6 is an example logic flow of an example data analytics engine of the system disclosed.
[0021] FIG. 7 is an example implementation of the system in a hospital environment.
[0022] FIG. 8 is a block schematic representation of an example sensor unit.
[0023] FIG. 9 is a block schematic representation of an example alert fob.
[0024] It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary to the understanding of the invention or render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.
DETAILED DESCRIPTION
[0025] The system 101 may be comprised in various embodiments of five primary (non-limiting) components: sensor unit 103 , hub 105 , server 107 , data analytics engine 109 , and dashboard 111 . Additional features such as an alert device 113 , input device 115 , experiential data 157 , and prediction reports 159 may likewise be included. It should be understood that while the figures may disclose a certain number of units, hubs, servers, etc., any appropriate number of components may be used. For example, many sensor units may be used with one hub, many hubs may be used with one remote server, many dashboards may be used with multiple sensor units and hubs, etc. It should also be understood certain components may be removed or combined—for example, removal of the data analytics engine or provision of the data analytics engine within the server.
[0026] FIG. 1 shows an example scenario where a system 101 according to one or more examples of embodiments may be used. In FIG. 1 , sensor units 103 are provided throughout a building, a hub 105 is provided in a central location in the building, and a server 107 and data analytics engine 109 are provided externally. Devices displaying the dashboard 111 or alert devices 113 may also be provided. As will be further described herein, the sensor units 103 may use sensors to detect various attributes about the surrounding environment, transmit those attributes to the hub 105 , which will transmit the acquired data to a server 107 which may relate data to an alert device 113 or dashboard 111 . The data may also be sent to a data analytics engine 109 .
[0027] FIG. 2 shows some of the contents of the primary components of the system and how information may progress from sensor unit 103 to hub 105 to server 107 and onward to a data analytics engine 109 , dashboard 111 , alert device 113 , or prediction report 159 . It should be understood each component may include a processor which is programmed to complete the component's respective steps described herein.
[0028] As shown, the sensor unit 103 is provided with a number of components, including sensors 117 / 119 / 121 , a unique identifier 123 , and network communication 125 . The unit 103 also has sensors, which may include (but is not limited to) a sound sensor 117 , a temperature and/or humidity sensor 119 , and a light sensor 121 . It should be understood that these three sensor types are example sensors for use in the system, and different types of sensors may be added (or the example sensors removed) depending on the application of the sensor system. The sensors 117 / 119 / 121 each may use mechanisms to measure designated information from the environment. The sensors may gather this information with varied frequency. For example, the sensor unit may be configured to require the sound sensor 117 to obtain a sound sample every second, whereas the temperature and/or humidity sensor 119 may be configured to measure samples much less frequently, for example once every ten seconds. In various embodiments, the sound sensor 117 may measure the sound in the area surrounding the device once every millisecond and take the highest read data each second. In other words, each sensor unit may measure the decibel level a thousand times per second and identify the highest decibel for that second. The particular frequency of information obtained and how it may be obtained may be stored in sensor unit 103 firmware as programmed by the manufacturer or altered and updated through the network, for example, to reflect a security update or user preferences.
[0029] The composition of the sensor unit 103 is shown in further detail in FIG. 8 . As shown, a sensor unit 103 may be comprised of externally visible components such as light-emitting diodes (LEDs) 165 , a power supply 173 , reset 169 , and housing (not shown). In various embodiments, the sensor unit may have a unitary body (housing) with a pronged outlet engagement, whereby the unit sits flush with a wall and is plugged into a standard outlet. In another embodiment, the sensor unit may include a power supply adaptable with a universal serial bus (USB) plug (mini, micro, standard, etc.). In other embodiments, the power mechanism may include an external transformer with a cord, or a plug and corresponding external jack. In another embodiment, the sensor unit 103 may be powered by a lithium ion or other type of battery. Combinations of the foregoing and other appropriate known charging mechanisms may also be used. Likewise, the sensor unit 103 may include a voltage regulation circuit to supply proper power to the unit components.
[0030] In various embodiments, the sensor unit 103 may include a temperature/humidity sensor 119 , a light sensor 121 , and a sound sensor 117 . The sound sensor may include a variety of other components to allow for accurate sound readings, including a microphone input, amplifier, amplifier voltage reference, ideal diode envelope detector, and subtractor/rail-to-rail. These are non-limiting examples of components to allow for accurate and useful sound measurement. In various embodiments, the sensor unit 103 may further include one or more network communication mechanisms. For example, the unit may include a radio frequency network module embedded on the microcontroller 161 as well as a Bluetooth module 163 . Both of these modules may be used, for example, to generate a mesh wireless transaction network such as a personal area connection. The sensor unit may include various information storage devices, for example, flash memory 171 . In various embodiments, the sensor unit 103 may also include one or more programming headers 167 and one or more serial port chips 175 that are used in connection with a controller for (for example) bi-directional communication.
[0031] In order to send the acquired ambient information to another device, as shown above, the sensor unit 103 may include a network communication device 125 such as, but not limited to, a radio communication device (Zigbee, Bluetooth, Wi-Fi, mobile broadband modem) or wired communication device such as Ethernet. In various embodiments, the sensor unit 103 may be configured to transmit raw data to a hub 105 . In the non-limiting example above, the sound sensor 117 on the sensor unit 103 measures the surrounding decibel level one thousand times per second, identifying and keeping the highest decibel for that second. The sensor unit may, for example, be configured to send information to the hub 105 every two seconds; therefore, the sensor unit may create and send a data packet including two readings (the highest sampled level in each of those two seconds) to the hub 105 .
[0032] Using a processor and onboard memory (such as flash memory), the sensor unit 103 may gather the sensor data, provide a time stamp associated with the time the sensor data was obtained, provide a unique identification code 123 , and send the data, time, and associated code 123 in one or more data packets to the sensor hub 105 by way of the network communication device 125 . In various embodiments, the sensor unit(s) 103 may be configured to only connect with one particular hub. This may be facilitated by using only a particular radio band, password, or other appropriate means such as a personal area network identification (PAN ID) 133 which may correspondingly be saved on the sensor unit 103 . This PAN ID 133 may correspond with a PAN ID provided on the hub 131 . The sensor unit 103 may also have lights such as LEDs to indicate its connectivity status.
[0033] The sensor hub 105 may have one or more network communication devices 127 , a unique device identifier (unique ID) 129 , and a PAN ID 131 . The sensor hub 105 may also include sensor components 118 / 120 / 122 . The network communication devices 127 may include one or more types of radio communication devices (Zigbee, Bluetooth, Wi-Fi, mobile broadband modem) or wired communication device such as Ethernet. For example, the sensor hub may have a Zigbee, Ethernet, and Wi-Fi network communication device. The sensor hub 105 may also have memory including RAM or flash memory. Likewise, the sensor hub 105 may include a programmable microcontroller, such as a Raspberry Pi. The sensor hub 105 may be configured to use its sensors, which may include (but are not limited to) a sound sensor 118 , temperature and/or humidity sensor 120 , and light sensor 122 in much the same way as a sensor unit 103 . As such, looking at FIG. 1 , the sensor hub 105 may be used to also obtain sensor data in a central location in the building.
[0034] Much of the logic of the system may take place at the server 107 level. In various embodiments, the server may have one or more of the following: a wireless or wired network communication device 135 such as an Ethernet connection, a processor 137 , storage 139 (for example, a database), configuration parameters 141 , and a programmed alert algorithm 143 , among other programmed components, which may include a restful opportunities calculator. For example, the server may be a remote cloud server having storage and processing hardware, such as high frequency Intel Xeon processors and SSD storage. The server may be of any suitable type, for example, Linux (including but not limited to Red Hat and SUSE) or Windows.
[0035] Similarly, the data analytics engine 109 may include one or more of the following: a network communication device 145 , processor 147 , storage 149 , configuration 151 , and analysis algorithms 153 . The processor and storage may be any suitable programmable hardware or data structure, for example, a relational database.
[0036] The remote server 107 and data analytics engine 109 may report results to a variety of output devices such as, but not limited to, an alert device 113 , user dashboard 111 or predictive reports 159 . The alert device 113 may be a variety of devices, such as a cell phone, tablet, or other suitable device capable of receiving texts, emails, or other digital message means. The user dashboard 111 may be a website or application which may provide a graphical user interface displaying historical and predictive data, as well as alerts. Likewise, prediction reports 159 may be sent through the dashboard 111 , email, or other suitable means.
[0037] The system may also accept input devices 115 , which may be for configuration 155 , to clear alerts, or input experiential data 157 . This input device 115 may also house the dashboard 111 . In various embodiments, the dashboard 111 itself may allow for inputs.
[0038] FIG. 3 describes the steps of an example simplified data flow from one component to the next. As shown in step S 201 of FIG. 3 , the sensor unit will query the sensors and receive the reads. Once these reads are received, the sensor unit 103 may determine an example value of each group of reads over a time period, and the example values for each time period may be sent to the hub S 203 . In various embodiments, the network communication device 125 may transmit the data packet to the hub 105 by way of other sensor units using a shortest-path algorithm (i.e. a “daisy chain” transmission). This transmission may append the prior module data to the next module's data, and so on until the hub is reached. In this way, the sensor unit module may act as a router, receiving another unit's data packet, appending its own packet, and routing the combined information to the appropriate next module.
[0039] The sensor hub 105 may receive the unit data, identifier 123 , and timestamps from multiple devices. The hub 105 may aggregate the sensor data S 205 (which may come from multiple sensor devices) and send the data in step S 207 to a server 107 . The hub 105 may have multiple data communication mechanisms 127 . For example, the hub 105 may accept data from the sensor unit(s) 103 using a Bluetooth or Zigbee connection, while it may send data to a server 107 using a wireless card, Ethernet, or other suitable means. The hub 105 may be configured to only accept transmissions from certain sensor unit(s). For example, each sensor unit 103 may use a PAN ID that correlates with the PAN ID of the hub 105 in order to ensure transmission only between the hub 105 and its associated units 103 . Such a configuration can allow for multiple networks in buildings across multiple floors, for example, without confusing the location of the sensor unit(s) 103 . The configuration of the sensor unit 103 and hub 105 may be over a relatively large area, for example, a 75-foot indoor distance between the sensor unit 103 and hub 105 .
[0040] In various embodiments, a personal area network communication (for example, between the multiple sensor devices and hub(s)) may be distinct from the communication between the hub 105 and the server 107 . This is because the server 107 may be a remote cloud server. In this embodiment, the server 107 may not be provided on a personal area network with the hub 105 and sensor units 103 . The server 107 then may be accessed by the hub 105 using an internet connection.
[0041] The hub 105 may be set up by a manufacturer to perform in a particular way. The hub 105 may also be updated with customizations to aid in the functionality of the system or a manufacturer may push firmware (or other) updates through the system to the hub 105 or sensor unit(s) 103 . Optimization may involve the frequency in which a hub 105 sends information to a server 107 . For example, the hub 105 may send information to the server 107 , which may include the sensor information and identifying information, along with a hub identifier, once every fifteen seconds. The hub may or may not store some of the data it is sent by the sensor unit 103 . For example, in the event of an internet service outage preventing uploading to the server 107 , the hub 105 may continue to receive and store several hours of data and send the data to the server 107 when the outage is fixed. In order to facilitate this storage, the hub may have both volatile and non-volatile memory, such as both random access memory (RAM) and a secure digital memory card (SD card).
[0042] The hub 105 may be configured in various ways to upload bundled sensor information to the server 107 (step S 207 ). The hub 105 may be configured to allow two-way communication between the server 107 and the hub 105 . Various security measures may be required for this implementation. For example, a user may create a virtual private network (VPN) to communicate between the hub 105 and server 107 in a secure manner. The hub 105 may use a network; the hub 105 may be configured with the wireless name and password. This may include a guest wireless network; in that instance the hub 105 may be configured with a login script to get the password. In various embodiments, the hub 105 may use a cellular hotspot having login data. The hub 105 in these instances is programmed sufficiently to establish an internet connection. Configuration may be made, for example, by plugging the hub 105 into a laptop or other computer using a universal serial bus (USB) or Ethernet connection. In another embodiment, the hub 105 may create an ad hoc network for configuration. By connecting to the hub 105 , the user may be provided with means to provide the hub with configuration details such as a network name and password. Once it is configured, the hub 105 may have lights such as light-emitting diodes (LEDs) to indicate certain information such as hub 105 connectivity status. The lights may be programmed to blink, change color, or any other means to create message codes.
[0043] The server 107 may receive the sensor data provided by the hub 105 at regular intervals, for example, every fifteen seconds. At a general level, the server 107 may be configured to analyze the data packet contents sent by the hub 105 in step S 209 and also, in step S 211 , send the data to a user-facing dashboard 111 or data analytics engine 109 . The server may determine whether to alert, or otherwise send a report in step S 211 .
[0044] FIG. 4 shows an example relationship between the server 107 and data analytics engine 109 . The server 107 accepts customization 155 and other inputs from a user (for example, setting a sensor unit 103 to be in an unoccupied room or alter the sensor unit's environmental context settings). The server 107 may optionally also accept external report data 157 (or the external report data may be accepted by the analytics engine 109 ). Unlike the data analytics engine 109 , the server 107 receives data from the hub 105 and alerts the alert device 113 . Both the server 107 and analytics engine 109 communicate with the dashboard. The data analytics engine 109 may optionally produce a detailed report 159 and historical data from other sources.
[0045] FIG. 5 shows an example workflow of the server 107 . First, FIG. 5 shows the bundled sensor reads are received from the hub 105 . In various embodiments, the reads include sensor data from multiple sensors including sound, temperature, and light sensors. The sensor data also, as previously described includes a unique identifier 123 and time stamp information. By analyzing the packet contents, the server 107 can determine whether a particular sensor device 103 has stopped functioning or has limited connectivity, based on the time stamp frequency associated with the unique device identifier 123 . The server 107 may also detect abnormal reads and dropped packets.
[0046] Next, the server 107 may save the new sensor read data S 301 for active and historical purposes. As shown in step S 303 , the server 107 queries historical sensor data—the system, in various embodiments, uses a change in data to predict disruption or damage. As such, the active current values read by the sensors may be less important than the historical context or environment. Historical data interpreted in conjunction with the recently obtained data may indicate the development of a positive or negative trend.
[0047] In step S 305 the interpreted data may be provided to a user dashboard 111 . In various embodiments, the sensor reads may need to be changed from raw values to values a user more easily can understand. The dashboard 111 may be a graphical user interface allowing the user to view sensor data based on sensor unit 103 or hub 105 locations. The sensor device 103 or hub 105 location may be determined and transmitted by the server 107 or other system component by way of associating the unique device number 125 with the particular sensor unit 103 or hub 105 as configured in its location. The dashboard 111 may allow the user to see historical data results across the system implementation. For example, a user may be able to display visually the historic sensor data trends over a period of months. The historic sensor data may be displayed across all installed sensor units 103 or hubs 105 and associated with all hubs within the system installation. Likewise, a dashboard may be provided for those with broader access abilities, for example, allowing a regional healthcare administrator to see the sensor trends across many hospitals.
[0048] Looking to step S 307 , in the example of a data packet containing sound information obtained from a sound sensor 117 , the sound information may be normalized using a normalization formula. In various embodiments, a novel way of quantifying the amount of sound over a reference level is used (“score”). For example, if a sound level (for example a decibel input) is obtained from a room and a threshold sound level value set, a “score” may be determined as, in various embodiments, the difference between the sound level input and a maximum allowable sound level.
[0049] This normalized value may be used to compare sound data packet information to produce a “score” or meaningful differentiation between disruptive and non-disruptive sound levels. Where the reference decibel is the maximum allowable sound level, the score represents the duration and intensity of sound above the maximum allowable decibel level for any user-defined period of time in any user-defined location or locations. The practical effect of using this method is an improvement over the current method of average decibel level using sample readings. Unlike existing methods, this “score” allows the comparison of a value over the desired sound level over various periods of time or various locations. By comparing with historical values, trends are revealed allowing users to make change necessary to affect those trends. The trends may be used by the data analytics engine 109 .
[0050] In step S 309 , configuration and sensor unit 103 or hub 105 locations may be obtained. For example, a sound may be disruptive in one context (a hospital room around 1:00 AM) than another (a public area around 3:00 PM). Such nuances may be saved in the server 107 data storage of configuration settings 151 associated with the particular system installation or sensor device (unit or hub) 103 / 105 . The configuration settings 151 may also have adjusted threshold levels depending on location of the sensor unit (public place versus private room, outdoor versus indoor).
[0051] Depending on the configuration settings, the server 107 may query one or more nearby sensor units 103 or hubs 105 for sensor data in step S 311 . By querying for nearby sensor data, if the threshold for alert for one sensor is higher (for example, louder sounds may be allowed in a public area versus room; colder temperatures may be allowed in an outdoor space versus indoors), the disruption may still impact a sensor unit in a different location (for example, noise in a public area may disrupt a bedroom). Whether or not nearby sensor units 103 or hubs 105 are queried for sensor data, the server 107 may still query configuration settings S 313 , S 315 . The server 107 may then determine whether or not to alert S 317 . If the server 107 determines no alert should be sent, the system may do nothing S 321 . If the server 107 determines the readings warrant an alert, an alert will be provided to associated systems S 319 . Associated systems may include cellular phones which may receive an alert in the form of a text message, a dashboard as described above which may display alerts, or any other appropriate means. For example, the sensor device 103 or hub 105 may have audio or visual means for transmitting an alert such as a beep or blinking lights.
[0052] An example alert device may be an independent fob 177 worn by personnel. An example of the components of the fob 177 is provided in FIG. 9 . The fob 177 may have an encasement. The encasement may be made of any suitable material, for example, plastic. The fob 177 may have a spring clip for attachment to a shirt, a hole for a lanyard attachment, or any other suitable attachment means. The fob 177 may include a microcontroller 179 which may include a radio frequency (RF) network module and processor. The fob may further include devices such as, but not limited to, a wireless circuit and/or antenna 181 , a power supply/regulation 183 , connector(s) 185 , LEDs 187 , and a motor 189 . In various embodiments, the fob 177 may vibrate or provide other ways to alert a wearer of an active or potential disruption. The vibration may be enabled by the motor 189 . In various embodiments, the microcontroller 179 having the RF module and/or wireless circuit/antenna 181 may be an end-point network device used with a Zigbee or Bluetooth personal wireless network. In various embodiments, details as to battery life, connectivity, or other messages may be communicated by the fob 177 using LEDs 187 . The power supply and regulation 183 as well as connectors 185 may allow the fob 177 to connect to power (such as a battery) and/or charging sources using any suitable means such as, but not limited to, a USB connection (standard, micro, mini, etc.), rail charging system, and/or induction system (for example, a wireless induction system). In a non-limiting example of a rail charging system, the fob 177 or fobs may be clipped onto a specially-built charging rail, wherein the sides of the rail are charged such that when a device is clipped onto the rail(s) the clip and body contact both sides of the rail and make an electrical connection. This non-limiting example may produce more efficient charging than a wireless induction system.
[0053] In an example implementation, when the fob 177 is first turned on, it may flash one or more LEDs 187 once every few seconds to indicate that it is on but not connected to a network. The fob 177 may then connect to a network using the wireless circuit/antenna 181 and/or microcontroller 179 , which may include an RF Module. The fob 179 may use an increasing frequency technique to pair with the closest sensor unit 103 or hub 105 quickly without using excess power. Once the fob 177 connects to a network (which may, in various embodiments, be the network provided by a hub 105 and/or sensor unit 103 ), the fob 177 may flash the LEDs 187 to indicate its connection and then stop flashing. In various embodiments, the connected hub 105 and/or sensor unit 103 may likewise be programmed to indicate a connection to a fob 177 by flashing.
[0054] The fob 177 may be used, for example, to alert a wearer when the noise levels in a room have reached a threshold. The fob 177 may, in various embodiments, regularly query its connected sensor unit 103 or hub 105 to determine whether this threshold has been reached. The fob 177 may then respond, for example, by vibrating (using a motor 189 ) and/or flashing (using LEDs 187 ) to notify a wearer of the exceeded threshold level. This may allow a wearer to abate the exceeded threshold problem before it becomes a disruption. While in this example, a sensor unit 103 or hub 105 detecting a particular area may pair directly with one or more fobs 177 in that particular area, it should be understood that information obtained throughout a network of units 103 and/or hubs 105 can be transmitted to a connected fob 177 (no matter which sensor unit 103 or hub 105 the fob 177 is connected to). As such, the fob 177 could transmit any number of different types of alerts to a wearer. For example, the fob 177 could notify the wearer of: an alert in any particular room, to check the dashboard 111 or other alert unit 113 , to indicate a particular alarm code for a particular type of harm (a hospital alarm code or patient code, for example), a particular exceeded threshold (exceeded temperature or exceeded detected movement, for example), or any other suitable message. The fob 177 for example could alert the wearer with a variety of means such as vibration and blinking using its components.
[0055] Returning to step S 323 of FIG. 5 , after determining whether to alert, the server 107 may send associated data to the data analytics engine 109 (though it should be understood that at any point in the logic flow of FIG. 5 , data could be sent from the server 107 to data analytics engine 109 ). At a general level shown in FIG. 3 , when the analytics engine 109 receives the data in step S 213 , the analytics engine 109 may, in step S 215 analyze the data and possibly create a predictive report S 217 . This process is shown in more detail in FIG. 6 . The data received from the server 107 is used to create a new data signature S 401 . A data signature, in various embodiments, can be a bundled results history of sensor information. The data signature may reflect a trend over a period of time. In step S 403 the analytics engine 109 may obtain relevant historical signature data. This data may come from a variety of sources, including a combination of historical data reads and other data sources such as surveys. For example, the surveys may reflect whether a person felt disrupted during a period of time. The processing/analytics engine 109 will analyze the time period and correlate sensor unit data during that time to create new historical data signature information. In step S 405 , the data signature is compared with historical data signature information. By executing this comparison in data, the engine may use a disruption anticipation algorithm to anticipate whether or not a disruption may occur. For example, if the sound variance is similar to a disruption sound variance, though the actual decibel levels or raw read data may differ, the trend may lead to report of a disruption. Likewise, if peak noises are made at certain time intervals correlative with a non-disruptive data signature, though the decibel levels may be high, the engine 109 may predict no disruption. This disruption potential metric is provided to a user in step S 407 . In various embodiments, this may take the form of providing a report to an administrator or other interested party.
[0056] In step S 409 , actual disruption data may be obtained. In various embodiments, this may be a survey or other questionnaire given to a patient or resident that reflects their actual disruption impression. This information may be entered back into an accessible database, and the disruption signature data may be updated. In turn, the disruption signature prediction undergoes machine learning, increasing in accuracy through use of the system.
[0057] FIG. 7 presents an example of the system implemented in a hospital. Here, two areas are shown 501 / 503 . These areas may be on multiple floors. Each area may be provided with its own hub 105 , H 1 or H 2 . Each hub may therefore create its own wireless area network (WAN 1 , WAN 2 ) throughout which the sensor units 103 and hubs 105 communicate. The example may use Zigbee-compliant devices. Therefore, communication between the sensors 103 and hub 105 is shown to use means that may or may not be compliant with a shortest-path algorithm. In this non-limiting example, each sensor unit 103 does not communicate directly with the hub 105 . The example shows various noises 509 , and occupied rooms 511 . The example may also show a first and second nurse's station 505 , 507 , which may include a dashboard 111 and/or alert unit 113 . The hospital may have a variety of patient rooms housing sensor units 103 .
[0058] The dashboard may reflect which rooms are occupied 511 and their location. The dashboard may reflect current sensor read levels from the sensor unit 103 within the occupied or unoccupied room. In zone 1 501 , a noise 509 causing a change in sound reading occurs in the lower left-hand room housing sensor unit S 3 . The sound reading may be sent to the hub 105 , which in turn may send information to the server 107 . The server 107 may determine whether the unit is occupied (it is not), whether the adjacent room experienced a change in reading, whether the adjacent room is occupied (it is not). It may calculate whether the adjacent unit showed a disruption (it did not). It may consider the main room housing the nurses' station 505 and sensor hub 105 (having sensors) in calculating the disruption. It may consider the configuration for loudness levels in the main room as compared to patient rooms (for example, higher loudness levels may be allowed in a main area rather than a patient room). It may look to whether the patient room across the main room experienced a change in readings, whether it is occupied, and whether the change constitutes a disruption. If all of these do not show a disruption, the system may or may not decide to provide an alert to the dashboard 111 or alert device 113 . The system may alert personnel to determine whether a noise in an unoccupied room should be alerted to for potential equipment damage.
[0059] The noise may be considered in the production of a sleep report, which provides personnel with the number of sleep opportunities for patients overnight. Sleep opportunities may be determined, in various embodiments, as the number of times a certain sleep interval occurs per night. For example, if a sleep interval is 1.5 hours, the number of sleep opportunities in a nine hour period would be six. The system may generate a sleep opportunity report and, given its occurrence in an unoccupied room and its effect on surrounding rooms, the sound 509 may not be considered disruptive.
[0060] In contrast, in the second area 503 , a change in sound reading levels 509 occurs in the main room near the nurse's station. By checking the adjacent rooms, the system can see the change is also detected in the room housing sensor unit S 8 . Because this unit is occupied, the system may alert the dashboard 111 and alert device 113 to alert personnel to abate the problem before it becomes disruptive. The alert device may continue to alert if the problem is not abated. In various embodiments, it may wait a certain time to re-alert. This may depend on the alert detected by the sensor—for example, if the temperature exceeds a certain threshold, it may take longer than for the violated threshold triggering the alert to be abated. Therefore, the re-alert settings may be configured accordingly.
[0061] This occurrence may be considered by the analytics engine 109 to determine whether, in the context of the readings as a whole (the data signature), a disruptive stay by the patient may be reported. After a patient leaves the hospital after their stay, they may complete a report. The report information may be entered into the system, and the prediction provided by the analytics engine 109 may be updated to reflect the actual reports.
[0062] The system and methods described herein may be implemented in or by software. To this end, the methods may be implemented in a general purpose software package or a specific purpose software package. Multiple system devices can be monitored and combined with the software application, and can be further isolated for review and evaluation. Additional details may also be used and added to the software through one or more fields or entry points, permitting filtering or further characterization of the data obtained by the system. It is understood that the foregoing is provided for purposes of example only, and variations thereon are acceptable. For example, the application may be an application program interface (API), which provides the user the ability to customize the particular software system for the purposes or uses of the particular facility.
[0063] According to one or more examples of embodiments a variety of capabilities is provided when one or more sensors or microsystems are linked in the described system, with particularly advantageous operation being provided when a plurality of sensors or sensing microsystems are used. A variety of capabilities is also provided when the network of sensors or sensing microsystems is connected to the Internet. In addition to the foregoing, when provided access to the Internet, the system can obtain and use, or submit or otherwise provide real time or aggregated sensed data to an outside entity, such as but not limited to a utility company or other service provider, or other data destinations. In addition to data compilation, the external communication provides alarms, alerts, or other information to a user on designated device based on sensed events. Data can also be received from such an outside entity. Likewise, Internet connectivity allows for the system to receive new analysis or control algorithms or other software/firmware upgrades, as well as data usable by the system, such as current and forecasted weather information for inclusion in processing by the predictive algorithm. Internet or remote connectivity also permits the system to receive user commands from the user's computer, network-device, smartphone, or other stationary or portable data communication device. While specific examples are provided, a variety of other useful functions are enabled by network connectivity.
[0064] As described herein, in one or more examples of embodiments, the system, method, and devices described, or method embodied by software, may be implemented by a computer system or in combination with a computer system. The computer system may be or include a processor. The computers for use with the methods and various components described herein may be programmable computers which may be special purpose computers or general purpose computers that execute the system according to the relevant instructions. The computer system can be an embedded system, a personal computer, notebook computer, tablet computer, server computer, mainframe, networked computer, handheld computer, personal digital assistant, workstation, and the like. Other computer system configurations may also be acceptable including, smartphones, cell phones, mobile devices, multiprocessor systems, microprocessor-based or programmable electronics, network PC's, minicomputers, and the like. Preferably, the computing system chosen includes a processor suitable in size to efficiently operate one or more of the various systems or functions.
[0065] The system or portions thereof may also be linked to a distributed computing environment, where tasks are performed by remote processing devices that are linked through a communications network. To this end, the system may be configured or linked to multiple computers in a network, including, but not limited to a local area network, a wide area network, a wireless network, and the Internet. Therefore information and data may be transferred within the network or system by wireless means, by hardwire connection or combinations thereof. Wireless communication may be by Wi-Fi, Bluetooth, RF, and other now known or future developed means. The sensors or microsystems are each configured to communicate using a wireless communication protocol such as Wi-Fi, ZigBee, or Z-Wave. The wireless communications among the multiple sensing sensors or microsystems can be achieved in a networked fashion using a wireless router, on an ad hoc or peer-to-peer basis, various combinations thereof, or any other method that can be used to achieve wireless communication.
[0066] The computer can also include a display, provision for data input and output, etc. Furthermore, the computer or computers may be operatively or functionally connected to one or more mass storage devices, such as, but not limited to a database. The database and/or server(s) may be local or cloud based. The memory storage can be volatile or non-volatile and can include removable storage media. The system may also include computer-readable media which may include any computer readable media or medium that may be used to carry or store desired program code that may be accessed by a computer. The invention can also be embodied as computer readable code on a computer readable medium. To this end, the computer readable medium may be any data storage device that can store data which can be thereafter read by a computer system. Examples of computer readable medium include read-only memory, RAM, CD-ROM, CD-R, CD-RW, magnetic tapes, and other optical data storage devices, memory cards, USB flash drives, solid-state drives, etc. The computer readable medium can also be distributed over a network coupled computer system so that the computer readable code is stored and executed in a distributed fashion.
[0067] These devices include a graphical user interface (GUI) or a communication means by which commands may be entered and content, notification, and alerts may be displayed or communicated. For example, the computer may include a user interface that allows navigation of objects. The computer may implement or include an application that enables a user to display and interact with text, images, videos, data, and other information and content.
[0068] Aspects of the system and method described herein can be implemented on software running on a computer system. The system or method herein, therefore, may be operated by computer-executable instructions, such as but not limited to program modules, executable on a computer. Examples of program modules include, but are not limited to, routines, programs, objects, components, data structures and the like which perform particular tasks or implement particular instructions. The software system may also be operable for supporting the transfer of information within a network.
[0069] The systems and devices described may include physical hardware and firmware configurations, along with hardware, firmware, and software programming that is capable of carrying out the currently described methods. A person skilled in the art would understand that the physical hardware and firmware configurations and the hardware, firmware, and software programming that embody the physical and functional features described herein can be implemented without undue experimentation using publicly available hardware and firmware components and known programming tools and development platforms.
[0070] It is further contemplated that the system may be further arranged with objects or devices capable of performing tasks including, but not limited to: operating the one or more physical environment systems according to a schedule and sensed occupancies; providing a user interface for easy modification; providing feedback on the user display regarding occupant usage and usage patterns; learning about the preferences, habits, and occupancy patterns of the building occupants by virtue of sensor detection patterns; adapting to the learned preferences, habits, and occupancy patterns by static and/or dynamic modification; modeling or otherwise characterizing one or more capabilities of the system and its components; and optimizing the system based on the determined characteristics or data of the physical environment and/or the learned occupant preferences, habits, and occupancy patterns.
[0071] As utilized herein, the terms “approximately,” “about,” “substantially”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.
[0072] It should be noted that references to relative positions (e.g., “top” and “bottom”) in this description are merely used to identify various elements as are oriented in the figures. It should be recognized that the orientation of particular components may vary greatly depending on the application in which they are used.
[0073] For the purpose of this disclosure, the term “coupled” means the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or moveable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such joining may be permanent in nature or may be removable or releasable in nature.
[0074] It is also important to note that the construction and arrangement of the system, methods, and devices as shown in the various examples of embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements show as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied (e.g. by variations in the number of engagement slots or size of the engagement slots or type of engagement). The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the various examples of embodiments without departing from the spirit or scope of the present inventions.
[0075] While this invention has been described in conjunction with the examples of embodiments outlined above, various alternatives, modifications, variations, improvements and/or substantial equivalents, whether known or that are or may be presently foreseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the examples of embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit or scope of the invention. Therefore, the invention is intended to embrace all known or earlier developed alternatives, modifications, variations, improvements and/or substantial equivalents.
[0076] The technical effects and technical problems in the specification are exemplary and are not limiting. It should be noted that the embodiments described in the specification may have other technical effects and can solve other technical problems.
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A disturbance detection, predictive analysis, and handling system and method is provided. The system and method may assist in identifying when, how, and what actions should be taken and by whom to prevent, reduce, or eliminate disturbances. The system and method may do so by monitoring or sensing activity in real time, performing predictive analytics on the data, and communicating the outcome to achieve a desired result. The system and method may include sensors provided within a sensor unit in communication with a hub. The sensor unit and hub may communicate over a personal area network. The system and method may also include a server and analytics engine to aid in the identification of disturbance and/or damage. The system and method may also use predictive algorithms and historic disruption data to enhance the accuracy of its prediction of disturbance and/or damage.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to British Patent Application No. 1008499.4, filed May 21, 2010, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
The technical field relates to a method for the detection of a component malfunction along the life of an Internal Combustion Engine (ICE).
BACKGROUND
Components malfunction in internal combustion engines give rise to numerous problems and it is desirable to have a reliable method for detecting them. For example, an incorrect combustion within one or more cylinders in an internal combustion engine with controlled ignition is generally indicated as misfire. Misfire events have very negative effects on engine performance, on emissions values and could also cause damages on the catalyst. European and OBDII legislation require detecting misfire events causing excess emissions.
Most current cylinder misfire detection methods use the angular acceleration of the drive shaft in order to find a misfiring cylinder. As already well known these methods are not perfectly suitable since the angular acceleration of the drive shaft is influenced not only by misfire but also, for example, by the roughness of the road and by very sudden decelerations. Other detection methods use other signals or detailed mathematical models in order to estimate the misfire condition.
The most widespread method for detecting misfire treat this argument as a component monitoring, comparing the value of a signal built from directly measured signals (for example the phonic wheel angular position) with some thresholds: if these thresholds are exceeded then a misfire is detected. This approach may lead to false detections and, in general, to an unsuitable way to monitor the combustion since an issue on the combustion could be the effect of different phenomena. So a more suitable logic is needed in order to identify, during the engine life, the misfire events avoiding false detections. Moreover, known pattern recognition models are only static models that do not take into account, during the engine life, the variations of the engine system having effect on the misfire detection.
At least a first object is to provide a method of detecting components malfunction or other undesirable events that takes into account possible variations of the components behavior during engine life and the associate components drift. At least a further object is to provide a malfunctioning detection method suitable for detecting misfire events and that takes into account possible variations during engine life of the phenomena associated and of the possible components drift. At least another object is to provide a malfunction detection method for components of an internal combustion engine that does not use complex devices and that takes advantage from the computational capabilities of the Electronic Control Unit (ECU) of the 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
An embodiment provides for a method for the detection of a component malfunction along the life of an Internal Combustion Engine, said engine, having at least a cylinder and being controlled by an Electronic Control Unit (ECU), the method comprising defining a pre-determined component malfunction classifier at the start of engine life and setting said classifier as active classifier, defining a validity condition for said active classifier, acquiring in real time a set of relevant signals relating to the operation of said component, feeding said signals to said active classifier in order to determine the occurrence or not of a malfunction of said component, and in case the validity condition of said actual classifier is not satisfied, defining a new classifier using the most recent relevant signals recorded by said ECU, and substituting the actual classifier with said new classifier. One of the advantages of the above method is that it allows to detect a malfunctioning of a component along the life of the engine, taking into account variations of behavior of the component due to drift of the same over time or due to any other cause.
According to an embodiment, said pre-determined classifier is defined by means of a training session in order to train said classifier to distinguish the occurrence or not of a malfunction of said component, said training session comprising the input into said classifier of a plurality of signals subdivided in signals pertaining to a malfunction of said component and signals pertaining to a regular functioning of said component. This embodiment advantageously allows defining, at the start of engine life, two subsets for an associated classifier where one subset is able to classify normal behavior of the component and the other subset is able to classify a malfunctioning of the component.
In a further embodiment the validity condition of said active classifier is evaluated as a function of the mean and of the variance values of the input signals pertaining to said component. This embodiment advantageously allows defining a validity condition for the active classifier.
In a further embodiment said validity condition is satisfied if the absolute value of the difference between the original mean of the signals pertaining to a regular functioning of said component and the mean of the signals calculated using the most recent relevant signals is lower than a minimum threshold or higher than a maximum threshold. This embodiment allows detecting when the validity condition for the active classifier is satisfied, using data pertaining to the functioning of said component.
In a still further embodiment said validity condition is satisfied if the absolute value of the difference between the original variance of the signals pertaining to a regular functioning of said component and the variance of the signals calculated using the most recent relevant signals is lower than a minimum threshold or higher than a maximum threshold. This embodiment allows a robust detection of the validity condition for the active classifier.
In a still further embodiment, a search for a new classifier is performed continuously during the life of said engine. This embodiment allows precalculating a new classifier that can readily be substituted to the active classifier is the validity condition for the active classifier is not anymore satisfied.
According to an embodiment said component is a cylinder of said engine and said malfunction is a misfire.
The method according to one of its aspects can be carried out with the help of a computer program comprising a program-code for carrying out all the steps of the method described above, and in the form of computer program product comprising the computer program. The computer program product can be embodied as a control apparatus for an internal combustion engine, comprising an Electronic Control Unit (ECU), a data carrier associated to the ECU, and the computer program stored in a data carrier, so that the control apparatus defines the embodiments described in the same way as the method. In this case, when the control apparatus executes the computer program all the steps of the method described above are carried out.
The method according to a further embodiment can be also embodied as an electromagnetic signal, said signal being modulated to carry a sequence of data bits which represents a computer program to carry out all steps of the method.
A still further aspect of the disclosure provides an internal combustion engine having at least a cylinder and comprising an Electronic Control Unit (ECU) specially arranged for carrying out the method claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and:
FIG. 1 is a schematic diagram that illustrates a misfire detection logic for the method according to an embodiment;
FIG. 2 is a diagram that illustrates a training session for a generic engine cylinder according to an embodiment of the method;
FIG. 3 is a diagram that illustrates a real time classification for an engine having multiple cylinders according to an embodiment of the method;
FIG. 4 exemplifies different groups of samples plotted in a configuration space, according to an embodiment of the method; and
FIG. 5 illustrates a series of steps according to an embodiment of the method.
DETAILED DESCRIPTION
The following detailed description is merely exemplary in nature and is not intended to limit application and uses. Furthermore, there is no intention to be bound by any theory presented in the preceding background or summary or the following detailed description.
Pattern recognition and more in general classification problems are solved, in literature, by different methods. Generically pattern recognition/classification methods (from well-known literature) work in the following way. First they extract from a training set of time-variant signals a set of information/parameters of different kinds related to the pattern recognition method chosen. This information is used to define the classifier. Secondly in real time, the pattern recognition method, using the classifier built in the first step, evaluates the samples in input in order to classify them.
Therefore, starting from a training set of multidimensional samples, classification procedures permits to: (i) reduce the dimensions of the multi-dimensional space of the inputted samples, projecting them into directions that have the largest variance; (ii) create a classification rule where a pre-determined number of classes (or groups) is defined. The classes are determined minimizing the within-classes variance and maximizing the between-classes variance. The within-classes variance is the variance of the samples of the same class, while the between-classes variance is the variance between samples of different classes. The result looks like a projection matrix (in order to perform a real-time projection of the input samples into the new less-dimensional space) that has the property to separate in an optimal way the samples used as training set; and (iii) classify the inputted samples by means of the classification rule: in this way each sample is assigned to the most appropriate class, taking into account the classification rule provided by point (ii).
On the basis of what described above, the logic of an embodiment of the invention, also depicted in FIG. 1 , comprises three main steps training session: original classifier identification, real time classification between misfiring and not-misfiring cylinders, and evaluation of the drift of the system during engine life and identification of a new optimal classifier.
Describing first the training session, we note that a pre-determined classifier is built by means of a training dataset. In this dataset, the classifier identifies the optimal parameters for the misfire detection on each of the cylinders. In this way a set of pre-calibrated parameters are evaluated identifying the pre-determined Classifier. The number of classes, in the present case is two: misfiring cylinder and non-misfiring cylinder. For each cylinder, a separate classifier is trained, using faulty and not faulty samples. The classifier is thus trained to distinguish if a specific cylinder is misfiring or not.
FIG. 2 illustrates schematically the training logic for each cylinder “i” in a multi-cylinder engine. Specifically, a cylinder 20 and piston 40 group belonging to an Internal Combustion Engine (ICE) 10 is depicted and in which a fuel injector 30 injects a quantity of fuel into a combustion chamber 50 . As soon as the valve 60 closes, the fuel is ignited to start the combustion.
The input signals (X, Y, and Z in FIG. 2 ) are a subset of the signals measured and calculated in the ECU. The choice of the signals used as inputs is driven by a preliminary analysis on the whole signals set recorded by ECU. For example the signal chosen may be:
X(t)=[X1(t), X2(t), . . . Xn(t)]→input vector, where: X1(t)=RPM signal
X2(t)=Crankshaft acceleration signal, and Xn(t)=Rail pressure signal.
A preferred choice is to use as inputs signals (or combinations of them) signals that, from common experience, are strictly related to the problem to be solved. As a guideline, the choice of the input signals may follow two rules: (i) samples that must be assigned to different classes (e.g.: misfire or no-misfire) must be well separated, and (ii) samples related to different misfiring cylinders must be well separated.
A further example of input signals suitable for the detection of a cylinder misfire are: X(t): Lores Period (period between two combustion events, Y(t): Crankwheel Speed Gradient, and Z(t): Difference between consecutive 90° period of crankwheel signal. With these signals, the samples remain well-separated in different clusters.
Concerning the real time classification, at the start of the engine life the classifier used is a pre-determined classifier. By means of a real-time logic, the new values of the same input signals used in the training session are considered by the classifier in order to distinguish between a misfiring and a non-misfiring cylinder. In order to classify the test samples the space must be divided into regions belonging to different classes. One possibility is to assign to the test sample the cluster with the smallest Mahalanobis distance. This, as other methods, permits to assign to each testing sample a class.
FIG. 3 illustrates the functioning of the four classifiers for a 4-cylinder engine. In parallel a method that performs an optimal classifier evaluation is executed during the whole engine life. This method continuously searches for an optimal classifier, comparing the new classifier to the actual classifier used. The aim of this optimal classifier evaluation logic is to estimate the drift of the no-faulty class during engine life. In this way the parameters of the classifiers can be adjusted in order to permit to the real-time methods to distinguish better between a faulty sample from a no-faulty sample. This operation can be performed in different ways.
A possible way is to calculate a time variant multidimensional mean value of the samples in input for each cylinder, considering obviously only the sub-space of the input signals. A proper logic on this mean and also on the samples multidimensional variance can lead to consider the drift during the engine life in order to have a sort of auto-adaptive learning of the best classifier for each cylinder, as exemplified in FIG. 4 . This approach constitutes an important improvement respect to more classical pattern recognition methods since this approach to misfire recognition using an auto-adaptive logic is able to consider the drifts during engine life. The two elliptical clouds depicting non misfiring samples in FIG. 5 above have the following meaning: (i) the position on the multidimensional space of the inputs of misfiring samples, during engine life, remains distant from the non-misfiring samples; (ii) during engine life the non-misfiring samples will drift on the multidimensional space of the inputs. Monitoring this drift allows to consider there related values in order to adjust the classifier parameters.
These classifiers are calculated by means of statistical methods, therefore if means and variances of the clouds of samples changes, also the classes definition should be modified. In other words, during engine life, the inputs recorded by the ECU will be used as new training datasets. For this purpose, for example, the flow chart of FIG. 5 may be considered.
Namely, a set of conditions is used to determine if the current classifier can still be used or, if due for example to components drifts over time, a new classifier must be substituted. In particular, for each cylinder the following means and variances of the signals pertaining to cylinder i are set for each ClassOk_i, namely the class related to non-misfiring samples of cylinder i.
A Mean_New(ClassOk_i) parameter is set that represents the new mean of the non-misfiring samples calculated on the “n” last recorded samples and a Mean_Original(ClassOk_i) parameter is also set that represents the original mean value of the non-misfiring samples calculated in the training phase. The absolute value difference between these values, namely |Mean_New(ClassOk_i)−Mean_Original(ClassOk_i)| is calculated and it is compared to a maximum and a minimum drift mean threshold according to the following equation 1:
MinDriftMeanThreshold<|Mean_New(ClassOk — i )−Mean_Original(ClassOk — i )|<MaxDriftMeanThreshold. (Eq. 1)
At the same time, a Var_New(ClassOk_i) parameter is set that represents the new variance of the non-misfiring samples calculated on the “n” last recorded samples and a Variance_Original(ClassOk_i) parameter is also set that represents the original variance value of the non-misfiring samples calculated in the training phase. The absolute value difference between these values, namely |Var_New(ClassOk_i)−Var_Original(ClassOk_i)| is calculated and it is compared to a maximum and a minimum drift variance threshold according to the following equation 2:
MinDriftVarThreshold<|Var_New(ClassOk — i )−Var_Original(ClassOk — i )<|MaxDriftVarThreshold (Eq. 2)
These conditions have the meaning that, if the absolute value difference between the means or the variances is respectively lower than a minimum drift mean MinDriftMeanThreshold or a minimum drift variance threshold MinDriftVarThreshold, the actual classifier is still valid and can still be used. Also, if the absolute value difference between the means or between the variances is respectively higher than a maximum drift mean MaxDriftMeanThreshold or than a maximum drift variance threshold MaxDriftVarThreshold, a misfire is being detected and the actual classifier is still considered valid.
The combination of these equations therefore define a validity condition for said active classifier. On the contrary, this validity condition is not satisfied, when equations 1 and 2 are evaluated simultaneously and at least one of the conditions on the mean or on the variance is not satisfied. In this case, a new optimal classifier is calculated as schematically illustrated in FIG. 5 .
Moreover, it is to be noted that the conditions of equations 1 and 2 express the idea that a classifier that is not anymore valid due to components drift can be detected by the fact that the absolute value difference between the means or between the variances of the signals is greater than a minimum threshold and thus is not negligible and it is smaller than a maximum threshold and thus it is not relative to a non-misfiring cylinder.
Experiments performed on real four-cylinder common rail compression ignition engines, in which some misfire events have been introduced, have shown that corresponding datasets have been obtained that can be divided into two sets. The no-misfire samples are grouped together in all cases for all cylinders: this means the possibility to define a no-faulty condition for the pattern recognition method.
In case of misfire on one cylinder, the signals considered react in a different way depending on the cylinder in the compression stroke: this gives the possibility to the pattern recognition method to distinguish well the effect of a misfire of one cylinder on the misfiring cylinder and on the others; If the misfiring cylinder is changed also the reciprocal disposition of the samples related to the different cylinders changes: this assures that the classifier distinguishes well the misfiring cylinder from the others.
The above considerations ensure that the method is robust and applicable in a wide variety of engine and engine conditions. Furthermore, as an example, the mean and variance for each cylinder are calculated considering the behavior of the relative cylinder during an interval of time of some seconds. In any case the sampling frequency may be adapted to the specific component monitoring with the proviso that the current state of electronic technology allows high sampling frequencies. Also, it must be considered that the method as being exemplified with reference to cylinder misfire problems, but it can be readily applied to the detection of malfunction of other components of the engine.
While at least one exemplary embodiment has been presented in the foregoing summary and 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 in any way. Rather, the foregoing summary and detailed description will provide those skilled in the art with a convenient road map for implementing at least one 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 as set forth in the appended claims and their legal equivalents.
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A method is provided for the detection of a component malfunction along the life of an Internal Combustion Engine. The engine, having at least a cylinder and being controlled by an Electronic Control Unit (ECU), the method includes, but is not limited to defining a pre-determined component malfunction classifier at the start of engine life and setting the classifier as active classifier, defining a validity condition for said active classifier, acquiring in real time a set of relevant signals relating to the operation of the component, feeding the signals to said active classifier in order to determine the occurrence or not of a malfunction of the component, and in case the validity condition of said actual classifier is not satisfied, defining a new classifier using the most recent relevant signals recorded by the ECU, and substituting the actual classifier with the new classifier.
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PRIORITY
The present invention claims priority based on 35 USC section 119 and provisional application Ser. No. 60/727,555 filed on Oct. 18, 2005.
FIELD OF THE INVENTION
The present invention relates to portable toilets having a disposable liner and more particularly to a portable toilet for a general use at any time when such toilets would be useful for example in the car or camping.
BACKGROUND OF THE INVENTION
There has long been portable toilets for use at construction and camping sites. These toilets have often been little more than large bowls requiring sanitary cleaning after each use and being inconvenient for many users.
As we have become a more mobile society, the use of the automobile has been increasing over the years. However, public toilets have been decreasing in numbers especially along the long stretches of empty highways.
A toilet may be available at a service station; however, these service station toilets are usually not cleaned frequently, and these service station toilets are unappealing and may spread disease. It would be desirable to be able to avoid the service station toilets in order to prevent disease.
Furthermore, public toilets may be unsafe and visited by predators especially during the late evening hours. It would be desirable to be able to avoid these public toilets despite their availability.
Bedpans for capturing the release of waste from bedridden individuals are known in the art. Bedpans can have various sizes and shapes depending upon their use and can be composed of materials including both metal and plastic and are either reusable or disposable.
U.S. Pat. No. 5,903,932 to Whitesel discloses a portable toilet seat arranged to receive a liner. The liner is a film of hydrophobic material with a drainage pad attached to the center.
U.S. Pat. No. 6,385,790 to Abraham discloses a portable toilet apparatus which includes a seat elevating structure. The seat elevating structure preferably includes an annular bellows having a tubular accordion outer bellows sidewall, an annular upper bellows wall an annular lower bellows wall.
U.S. Pat. No. 6,532,605 to Howell discloses a liner which may be readily utilized in a toilet receptacle such as a child's potty or a bedpan.
U.S. Pat. No. 6,789,277 to Spitzer discloses a method and apparatus to collect dispose and measure liquid output from bedridden individual.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a simple design which can be made in different sizes. In youth or adult sizes, the toilet may be used by either gender while in the automobile, boat, plane or camping or at a location with no active plant plumbing.
It is an object of the invention to provide a toilet which does not require chemicals and which does not require cleaning. Consequently, it is an object of the invention to provide a toilet with all the convenience of a disposable diaper.
It is an object of the invention to make use of the toilet and having the necessary accessories to protect the seat of the vehicle and to ensure the privacy of the user of the toilet.
It is in the object of the invention to provide a self-contained portable device which may be sealed and carried safely.
Is an object of the invention to provide a self-contained portable device which is biodegradable.
It is an object of the invention to provide a portable toilet apparatus which can be reduced in overall size in order for a compact storage.
It is an object of the present invention to provide an apparatus which is lightweight, durable and inexpensive to manufacture.
It is an object of the present invention to provide a self-contained portable device which can be used to avoid service station toilets and which can be used to avoid public toilets especially during late evening hours.
The present invention includes an annular base having an aperture to accept an insert for the base. The insert includes a pad to absorb liquid, a first collar, a second collar and an inner container of flexible material.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which, like reference numerals identify like elements, and in which:
FIG. 1 illustrates a perspective view of the base of the present invention;
FIG. 2 illustrates a cross-sectional view of the side of the base of the present invention;
FIG. 3 illustrates a view of the top of the base of the present invention;
FIG. 4 illustrates a view of the top of the insert of the present invention;
FIG. 5 illustrates a cross-sectional view of the side of the insert of the present invention;
FIG. 6 illustrates a view of the top of the first sheet of the present invention;
FIG. 7 illustrates a view of the top of the first collar of the present invention;
FIG. 8 illustrates a view of the top of the second collar of the present invention;
FIG. 9 illustrates a view of the top of the second sheet of the present invention;
FIG. 10 illustrates a perspective view of the assembly of the base and insert of the present invention;
FIG. 11 illustrates a view of additional elements of the system of the present invention.
DETAILED DESCRIPTION
The term excrement or waste as used herein is meant to include but not limited to urine, solid and liquid feces, stool, body fluids, vomit and any other substance cast out as waste from the body.
The term super-absorbing material as used herein is meant to include but is not limited to a gel, silica, resins such as hydrolyzed starch-acylonitrile graft polymers or neutralized starch-acrylic acid graft polymer, absorbent powders, desiccating agents, chemical compounds such as polyacylamide, polyacrylate or potassium, crystals and other similar liquid absorbing substances or materials known to the skill in the art.
The term absorption mechanism or absorbent layer material is used herein is a layer of material that is absorbent to various materials for example, the absorbent layer material could be made of materials including but not limited to artificial and natural fibers, paper materials, sponge, cloth, cotton and any other similar liquid absorbing materials known to those skilled in the art. The absorption layer material optionally has a super absorbing material that has increased liquid absorbency.
The term attachment apparatus is meant to include but not limited to Velcro, snaps, buttons, string, glue, tape, adhesive elastic, fasteners and any other affixing devices known to those skilled in the art.
The present invention is applicable for use in any setting including but not limited to cars, airplanes, trucks, trailers, boats, the vast outdoors, homes, playing, hiking, hospitals, medical offices, emergency rooms, public and private facilities or any other similar setting where the device could be needed by the individual.
FIG. 1 illustrates a perspective view of the base 102 of the present invention which is shown for illustration as annular but could be other shapes. The base 102 could be formed from plastic, polyurethane, metal, glass, polymers, or a foam material such as polyethylene and various polymers and other similar liquid impervious materials known to those of skill in the art. Alternatively, the base 102 could be formed from a hollow flexible material such as an air filled inner tube. Additionally, the annular base 102 could be formed from a biodegradable material so that it can be used safely with landfills and fills. One variation uses a starch based material which may require a water resistant sleeve so that it will not dissolve. The annular base 102 includes an aperture 104 for accepting the insert 410 .
FIG. 2 illustrates a cross-sectional view of the side of the annular base 102 . The dimension ‘a’ should approximate the dimension ‘b’ as shown in FIG. 5 .
FIG. 3 illustrates a view of the top of the annular base 102 showing the aperture 104 .
FIG. 4 illustrates a view of the top of the insert 104 including a receptacle 412 for the waste.
FIG. 5 illustrates a cross-sectional view of the side of the insert 410 . The receptacle 412 for the waste includes an inner container 524 which may be formed from flexible absorbent material, an outer container 526 which may be water resistant and formed from flexible absorbent material and a pad 414 formed from absorbent material to absorb liquid. The pad 414 may be positioned between the inner container 524 and the outer container 526 to form a bag like structure.
The insert 410 additionally includes a first collar 522 and a second collar 528 , both of which may be formed from rigid material and substantially conforms to the base 102 . The inner container 524 and the outer container 526 extend to and are attached between the first collar 522 and the second collar 528 . The attachment apparatus attaches the first collar 522 , the inner container 524 , the outer container 526 and the second collar 528 together around the periphery of the insert 410 . Optionally, a first sheet 520 may extend over the top surface of the first collar 522 and may be formed from absorbent material in order to absorb escaping liquid. In a similar fashion, a second sheet 530 may extend over the bottom surface of the second collar 528 in order to absorb escaping liquid. Optionally, additional absorbent layers 521 , for example five or six layers, maybe positioned between the first sheet 520 and the second sheet 530 . The first sheet 520 , the first collar 522 , the second collar 528 and the second sheet 530 have dimensions which correspond to the dimensions of the base 102 .
FIG. 6 illustrates a view of the top of the first sheet 520 having an aperture 521 corresponding in dimensions approximately to the aperture 104 . The collar 522 , 528 may fold and may possibly be sealed by tabs and placed into a refuse bag provided in the kit.
FIG. 7 illustrates a view of the top of the first collar 522 having an aperture 523 which corresponds to the dimensions approximately of the aperture 104 .
FIG. 8 illustrates a view of the top of the second collar 528 having an aperture 529 which corresponds dimensionally and approximately to the aperture 104 .
FIG. 9 illustrates a view of the top of the second sheet 530 having an aperture 531 which corresponds dimensionally and approximately to the aperture 104 .
FIG. 10 illustrates a method of manufacture of the present invention. The annular base 102 is formed with aperture 104 . The first collar 522 is attached to the inner container 524 , to the outer container 526 and to the second collar 528 . The first sheet 520 covers the top of the first collar 522 , and the second sheet 530 covers the bottom of the second collar 528 .
The base 102 can be reused. The insert 410 is inserted into the base 102 . The user places waste material into the insert 410 , and the insert 410 is folded, removed and discarded to the refuse bag.
The system of the present invention includes the base 104 the insert 410 and the articles shown in FIG. 11 . In FIG. 11 , a storage case 1102 is illustrated for portability, and an apron 1106 is illustrated which may be rectangular or trapezoidal in shape and include elastic band 1110 and an attachment apparatus 1108 . Additionally FIG. 11 illustrates a protective sheet 1104 to lay down on the seat of the vehicle.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed.
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A portable toilet for holding waste includes a base having an aperture, an insert for being mounted in the base. The insert includes a first collar coupled to a first container, a second collar, and a second container and the insert including a pad between the first container and the second container.
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The invention concerns thermoplastic molding compositions and in particular glass-fibers-reinforced polycarbonate molding compositions.
The invention is based on the surprising and unexpected finding that the impact performance of a thermoplastic composition containing aromatic polycarbonate resin and glass fiber-reinforcing agents is improved upon the incorporation therewith of a particular silicone rubber powder. The silicone rubber powder, added at a level of about 0.5 to 4 percent, relative to the weight of the composition, is characterized in that it contains a mixture of (a) a polydiorganosiloxane and (b) silica said glass fibers being of the type which do not, per se, adhere to the polycarbonate matrix in which they are incorporated.
Thermoplastic aromatic polycarbonate resins are well known and are readily available in commerce. While the impact resistance of polycarbonates makes these resins the material of choice in a variety of demanding applications, attempts at improving this property continue. The literature includes a large number of patents directed to this subject. Reinforcing agents for polymeric matrices and for polycarbonate resins am well known; also commercial polycarbonate compositions which are reinforced with glass fibers are readily available in commerce. The silicone rubber powder of the invention is also well known. Of particular relevance in the present context is a paper by R. Buch et al "Silicone-Based Additives for Thermoplastic Resins Providing improved Impact Strength, Processing and Fire Retardant Synergy". This prior art paper (Dow Corning Corporation) disclosed certain Silicone Powder Resin Modifiers products termed RM 4-7081 and RM 4-7051 to be useful in reducing the rate of heat release and the evolution rates of smoke and carbon monoxide of burning plastics, including polycarbonate. The relevant properties of compositions containing 99 and 95% polycarbonate, the balance in each composition being RM 4-7081, are reported. Also disclosed is the impact strength improvement for engineering resins such as polyphenylene ether (PPE) and PPS. Improved impact strength of polycarbonate compositions is not reported.
Also related is Canadian patent application 2,083,014 which disclosed the silicone rubber powder of the present invention as a component in a composition containing poly(phenylene ether) resin.
Polycarbonate molding compositions which contain additive amounts of organosiloxane compounds are known: JP 5,262,960 is said to disclose a low viscosity polycarbonate resin composition which contain organo siloxane and a catalyst. The composition is said to exhibit lower melt viscosity and improved fluidity and moldability without loss of mechanical properties; JP 5,086,278 is considered to disclose an organosiloxane compound and a catalyst as additives to a polycarbonate resin. EP 505,869 disclosed a polycarbonate composition containing a siloxane compound, characterized in its high dimensional stability. Polycarbonate compositions containing a cyclosiloxane compound were disclosed in U.S. Pat. No. 3,751,519 to have good release properties. A thermal oxidative stabilized polycarbonate composition containing a hydrocarbonoxy siloxane compound has been disclosed in U.S. Pat. No. 4,197,384.
It has now been discovered that certain silicone rubber powders, preferably produced in accordance with the procedure disclosed in U.S. Pat. No. 5,153,238 which is incorporated herein by reference, are useful as impact modifier in thermoplastic molding compositions containing polycarbonate and certain reinforcing agents.
DESCRIPTION OF THE FIGURES
FIG. 1 is a scanning electron micrograph (magnification 215) of the fracture surface of an article molded of a composition containing only fibers and polycarbonate resin The micrograph evidences no adhesion in the interface between fibers and matrix. The glass fibers of this composition are suitable in the preparation of the inventive composition.
FIG. 2 is a micrograph (X212) of the corresponding fracture surface of an article molded of a composition containing only polycarbonate resin and glass fibers which are outside the scope of the present invention; there is considerable adhesion of the glass fibers to the matrix. These fibers are outside the scope of the instant invention.
DETAILED DESCRIPTION OF THE INVENTION
The inventive composition contains polycarbonate resin, a positive amount of up to about 40 percent, preferably about 5 to 30 percent by weight of glass fibers (as defined below) and about 0.5 to about 4, preferably about 1 to 3 percent of the silicone rubber powder.
The polycarbonate resins within the scope of the present invention include (co)polycarbonates and mixtures thereof.
The (co)polycarbonates generally have a weight average molecular weight of 10,000-200,000, preferably 20,000-80,000 and their melt flow rate, per ASTM D-1238 at 300° C., is about 1 to about 65 g/10 min., preferably about 2-15 g/10 min. They may be prepared, for example, by the known diphasic interface process from a carbonic acid derivative such as phosgene and dihydroxy compounds by polycondensation (see German Offenlegungsschriften 2,063,050; 2,063,052; 1,570,703; 2,211,956; 2,211,957 and 2,248,817; French Patent 1,561,518; and the monograph H. Schnell, "Chemistry and Physics of Polycarbonates", Interscience Publishers, New York, N.Y., 1964, all incorporated herein by reference).
In the present context, dihydroxy compounds suitable for the preparation of the polycarbonates of the inventor conform to the structural formulae (1) or (2). ##STR1## wherein A denotes an alkylene group with 1 to 8 carbon atoms, an alkylidene group with 2 to 8 carbon atoms, a cycloalkylene group with 5 to 15 carbon atoms, a cycloalkylidene group with 5 to 15 carbon atoms, a carbonyl group, an oxygen atom, a sulfur atom, --SO-- or --SO 2 -- or a radical conforming to ##STR2## e and g both denote the number 0 to 1; Z denotes F, Cl, Br or C 1 -C 4 -alkyl and if several Z radicals are substituents in one aryl radical, they may be identical or different from one another; d denotes an integer of from 0 to 4; and f denotes an integer of from 0 to 3.
Among the dihydroxy compounds useful in the practice of the invention are hydroquinone, resorcinol, bis-(hydroxyphenyl)-alkanes, bis-(hydroxyphenyl)-ethers, bis-(hydroxyphenyl)-ketones, bis-(hydroxyphenyl)-sulfoxides, bis-(hydroxyphenyl)-sulfides, bis-(hydroxyphenyl)-sulfones, and α,α-bis-(hydroxyphenyl)-diisopropyl-benzenes, as well as their nuclear-alkylated compounds. These and further suitable aromatic dihydroxy compounds are described, for example, in U.S. Pat. Nos. 3,028,356; 2,999,835; 3,148,172; 2,991,273; 3,271,367; and 2,999,846, all incorporated herein by reference.
Further examples of suitable bisphenols are 2,2-bis-(4-hydroxyphenyl)-propane (bisphenol A), 2,4-bis-(4-hydroxyphenyl)-2-methyl-butane, 1,1-bis-(4-hydroxyphenyl)-cyclohexane, α, α'-bis-(4-hydroxy-phenyl)-p-diisopropylbenzene, 2,2-bis-(3-methyl-4-hydroxyphenyl)-propane, 2,2-bis-(3-chloro-4-hydroxyphenyl)-propane, bis-(3,5-dimethyl-4-hydroxyphenyl)-methane, 2,2-bis-(3,5-dimethyl-4-hydroxyphenyl)-propane, bis-(3,5-dimethyl-4-hydroxyphenyl)-sulfide, bis-(3,5-dimethyl-4-hydroxyphenyl)-sulfoxide, bis-(3,5-dimethyl-4-hydroxyphenyl)-sulfone, dihydroxy-benzophenone, 2,4-bis-(3,5-dimethyl-4-hydroxyphenyl)-cyclohexane, α,α'-bis-(3,5-dimethyl-4-hydroxyphenyl)-p-diisopropylbenzene and 4,4'-sulfonyl diphenol.
Examples of particularly preferred aromatic bisphenols are 2,2,-bis-(4-hydroxyphenyl)-propane, 2,2-bis-(3,5-dimethyl-4-hydroxyphenyl)-propane and 1,1-bis-(4-hydroxyphenyl)-cyclohexane.
The most preferred bisphenol is 2,2-bis-(4-hydroxyphenyl)-propane (bisphenol A).
The polycarbonates of the invention may entail in their structure units derived from one or more of the suitable bisphenols.
Among the resins suitable in the practice of the invention are included phenolphthalein-based polycarbonate, copolycarbonates and terpolycarbonates such as are described in U.S. Pat. Nos. 3,036,036 and 4,210,741, both incorporated by reference herein.
The polycarbonates of the invention may also be branched by condensing therein small quantities, e.g., 0.05-2.0 mol % (relative to the bisphenols) of polyhydroxyl compounds.
Polycarbonates of this type have been described, for example, in German Offenlegungsschriften 1,570,533; 2,116,974 and 2,113,374; British Patents 885,442 and 1,079,821 and U.S. Pat. No. 3,544,514. The following are some examples of polyhydroxyl compounds which may be used for this purpose: phloroglucinol; 4,6-dimethyl-2,4,6-tri-(4-hydroxyphenyl)-heptane; 1,3,5-tri-(4-hydroxphenyl)-benzene; 1,1,1-tri-(4-hydroxyphenyl)-ethane; tri-(4-hydroxyphenyl)-phenylmethane; 2,2-bis- 4,4-(4,4'-dihydroxydiphenyl)!-cyclohexyl-propane; 2,4-bis-(4-hydroxy-1-isopropylidine)-phenol; 2,6-bis-(2'-dihydroxy-5'-methylbenzyl)-4-methylphenol; 2,4-dihydroxy-benzoic acid; 2-(4-hydroxyphenyl)-2-(2,4-dihydroxyphenyl)-propane and 1,4-bis-(4,4'-dihydroxytriphenylmethyl)-benzene. Some of the other polyfunctional compounds are 2,4-dihydroxy-benzoic acid, trimesic acid, cyanuric chloride and 3,3-bis-(4-hydroxyphenyl)2-oxo-2,3-dihydroindole.
In addition to the polycondensation process mentioned above, other processes for the preparation of the polycarbonates of the invention are polycondensation in a homogeneous phase and transesterification. The suitable processes are disclosed in the incorporated herein by references, U.S. Pat. Nos. 3,028,365; 2,999,846; 3,153,008; and 2,991,273.
The preferred process for the preparation of polycarbonates is the interfacial polycondensation process.
Other methods of synthesis in forming the polycarbonates of the invention such as disclosed in U.S. Pat. No. 3,912,688, incorporated herein by reference, may be used.
Suitable polycarbonate resins are available in commerce, for instance, Makrolon FCR, Makrolon 2600, Makrolon 2800 and Makrolon 3100, all of which are bisphenol based homopolycarbonate resins differing in terms of their respective molecular weights and characterized in that their melt flow indices (MFR) per ASTM D-1238 are about 16.5-24, 13-16, 7.5-13.0 and 3.5-6.5 g/10 min., respectively. These are products of Bayer Corporation of Pittsburgh, Pa.
A polycarbonate resin suitable in the practice of the invention is known and its structure and methods of preparation have been disclosed, for example in U.S. Pat. Nos. 3,030,331; 3,169,121; 3,395,119; 3,729,447; 4,255,556; 4,260,731; 4,369,303 and 4,714,746 all of which are incorporated by reference herein.
Reinforcing agents in the context of the present invention are glass fibers of the type which do not, per se, adhere to the polycarbonate matrix in which they are incorporated. Stated another way, fracture surfaces of articles molded of compositions which consist of only polycarbonate resin and suitable glass fibers, show under scanning electron microscope (SEM) at magnification of about 215, virtually no adhesion between the resin and glass fibers. A better appreciation of such lack of adhesion may be gained from examining FIG. 1 which is a relevant SEM photograph. Accordingly, the fracture surface show the interface of the glass fibers and matrix to evidence no adhesion.
The preferred glass fibers are in the form of chopped strands of long glass fibers, having average diameters in the range of from about 8 to 20 μm and an average length of about 3 to 6 mm. Both sized and unsized glass fibers may be used. Among the suitable glass fibers which are available commercially mention may be made of OCF's product which is available under the trade designation OCF415DF.
The silicone rubber powder of the invention has an average particle size of about 1 to 1000 microns and contains (i) 100 parts by weight (pbw) of a polydiorganosiloxane and (ii) about 10 to 80 pbw,preferably about 20 to 50 pbw of a finely divided silica filler.
The polydiorganosiloxane which is characterized in that its viscosity at 25° C. is about 10 6 to 10 9 centipoise is a (co)polymeric resin having siloxane structural units represented by the general formula ##STR3## wherein R, R' and R" independently denote hydrogen, C 1-10 -alkyl, alkenyl, cycloalkyl radicals or aryl groups, and where p is about 1000 to 8000, preferably about 3000-6000 and where the relative weight proportions of n and m are 98.5-100: 0-1.5, preferably 99:1, and where
X denotes a member selected from the group consisting of ##STR4## where R denotes hydrogen, C 1-10 -alkyl, alkenyl, cycloalkyl radicals or aryl groups and where q is 1-10.
The organic groups of the polydiorganosiloxane, which may optionally be halogenated, are preferably lower alkyl radicals containing 1-4 carbon atoms, phenyl and halogen substituted alkyl radicals. Examples include resins containing dimethylsiloxy units, phenylmethylsiloxy units and dimethylsiloxy units and diphenyl siloxy units. Most preferably, the polydiorganosiloxane contains vinyl group(s) or epoxy group(s) at its chain termination(s) and/or along its main chain. The methods for the preparation of suitable polydiorganosiloxane are well known; a typical method comprise the acid- or base-catalyzed polymerization of cyclic diorganosiloxanes.
The silica filler required in the silicone rubber powder is a finely divided silica selected from among fumed silica and precipitated silica or silica gel. These are well known forms of silica and are readily available in commerce. The suitable silica is characterized in that its surface area is at least 50 m 2 /g, preferably 50 to 900 m 2 /g.
An additional embodiment entails use of treated silica which contains sites bonded to groups X as defined above; the manufacture of treated silica, typically by reacting the silanol groups on the silica surface with about 1-2% by weight of an organic alkyl halide compound or an organosilicon halide compound, is known in the art.
Among the suitable compounds mention may be made of low molecular weight liquid hydroxy- or alkoxy-terminated polydiorganosiloxanes, hexaorganosiloxanes and hexaorganosilazanes.
The procedure for the preparation of the silicone rubber powder has been described in detail in U.S. Pat. No. 5,153,238 the specification of which is incorporated herein by reference. Suitable silicone rubber powder is available in commerce from Dow Corning Corporation under the trademark RM 4-7051 and RM 4-7081.
The preparation of the composition of the invention is carried out following conventional procedures and by use of conventional means such as single, preferably twin screw extruders. Conventional thermoplastic processes are suitable in molding useful articles from the inventive composition.
Conventional additives may be incorporated in the composition of the invention in the usual quantities. Mention may be made of a thermal stabilizer, a mold release agent, a pigment, a flame retarding agent, a uv stabilizer, a hydrolysis stabilizer, a gamma radiation stabilizer and a plasticizer for polycarbonate compositions.
EXAMPLES
Compositions within the scope of the invention, Examples B and C below, have been prepared and their properties determined as summarized below. In preparing the compositions, the polycarbonate resin was Makrolon 2608 polycarbonate, a product of Bayer (a homopolymer based on bisphenol A, having a melt flow rate of about 11 g/10 min. determined in accordance with ASTM D -1238). The silicon powder was Dow Corning's 4-7051 and the glass fibers were OCF415DF. The relative amounts of the components is in percent by weight. A summary of the tests is presented in the table below. FIG. 1 shows the fracture surface of an article molded of Example A.
______________________________________Example A B C______________________________________Polycarbonate, % 86.0 85.0 84.0glass fibers, % 14.0 14.0 14.0silicone powder, % 0.0 1.0 2.0melt flow rate, g/10 min. 9.0 9.0 8.5impact strength, ft. lb/inch 1.6 2.4 3.4notched Izod @ 1/8"______________________________________
A corresponding set of examples which except for the glass fibers was identical in all respects to the above was prepared and determined. In these, examples D, E and F below, the glass fibers were EPG 3090 glass fibers which are outside the scope of the present invention. Scanning electron micrograph of the fracture surface of an article molded of composition D is shown in FIG. 2. Clearly, in this composition which contain only glass fibers and polycarbonate matrix, there is considerable adhesion of glass fibers to the matrix indicating these fibers to be outside the scope of the instant invention.
______________________________________Example D E F______________________________________Polycarbonate, % 86.0 85.0 84.0glass fibers, % 14.0 14.0 14.0silicone powder, % 0.0 1.0 2.0melt flow rate, g/10 min. 9.1 8.8 9.2impact strength, ft. lb/inch 1.1 1.4 1.6notched Izod @ 1/8"______________________________________
Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims.
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The invention is based on the surprising and unexpected finding that the impact performance of a thermoplastic composition containing aromatic polycarbonate resin and glass fibers is improved upon incorporation therewith of a particular silicone rubber powder. The silicone rubber powder, added at a level of about 0.5 to 4 percent, relative to the weight of the composition, is characterized in that it contains a mixture of (a) a polydiorganosiloxane and (b) silica, said glass fibers being of the type which do not, per se, adhere to the polycarbonate matrix in which they are incorporated.
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TECHNICAL FIELD
[0001] An apparatus and a method for moving fluids in a wellbore.
BACKGROUND OF THE INVENTION
[0002] The removal of liquids which accumulate in producing wells is required in order to enhance production from the well and the overall operation of the production system. In particular, liquids removal is necessary for the dewatering of gas wells and the removal of oil from wells where mixed oil and gas exists in the underground reservoir. If the liquids, such as water and/or oil, are not removed, the liquids tend to accumulate and fill or load up the well, which restricts the flow of the gas to the surface. Eventually, the liquids may choke off gas production completely. Therefore, a problem to be overcome is to remove the liquids continually to avoid their accumulation in the well.
[0003] One approach to this problem is to use a gas lift system which uses the natural gas pressure in the reservoir to lift the liquids from the well. In a gas lift system, a tubing string is typically located in the well which extends from the surface into the accumulated liquids such that the accumulated liquids may flow into the tubing string. The gas then enters the tubing string from the underground reservoir at chosen intervals along the tubing string to cause the liquids within the tubing string to rise to the surface. A freely moveable plunger or pig may be located in the tubing string to minimize the penetration of the gas through the liquids. Where the gas lift system uses the pressurized gas from the reservoir to transport slugs of the liquid to the surface, a small diameter tubing string for producing the liquids is often required so that the gas pressure and the gas velocity are sufficient to carry the liquids to the surface. However, the requirement for small diameter tubing may significantly restrict the flow of the liquids and reduce the gas production. As well, the produced gas and liquids are typically well mixed at the surface, which may cause problems in surface production lines, such as hydrate formation or freezing. Further, gas lift systems have been found to be unsuitable where the downhole gas pressure or the gas velocity is low and thus, the gas is unable to overcome the pressure head of the liquids to carry the liquids to the surface.
[0004] Other gas lift systems have been designed which only periodically or intermittently lift the liquids to the surface in a cyclical operation in order to allow the natural gas pressure to develop in the well between the cycles to a critical level necessary to lift the liquids. Examples of such systems are described in U.S. Pat. No. 2,136,229 (Baldwin et al), U.S. Pat. No. 4,596,516 (Scott et al) and U.S. Pat. No. 4,465,435 (Copas). Some of these systems use a timer operated valve, located in the outlet of the tubing containing the liquids. The valve is set to periodically open at a timed interval equal to the time required for the natural gas pressure in the well to recover following the release of such pressure. Other systems use valves sensitive to a predetermined differential pressure between the liquids in the tubing string and the gas to control the periodic opening of the valve to allow lifting of the liquids by the gas.
[0005] Other gas lift systems introduce pressurized fluid into the well from an outside source in addition to the natural gas from the reservoir, as shown in U.S. Pat. No. 2,132,738 (Knox), U.S. Pat. No. 6,322,333 (Knight), U.S. Pat. No. 7,546,870 (Dotson), and U.S. Pat. No. 7,566,208 (Santos). However, the introduction of the pressurized fluid into the well to lift the liquids requires the use of a compressor which tends to increase both the cost and complexity of the production apparatus required.
[0006] A further approach to the problem of liquid loading is shown in Canadian Patent No. 1,167,760 (Prather) which describes a reciprocating surface pump which is powered by the natural gas pressure from the reservoir. The reciprocating surface pump is connected to a string of sucker rods which are connected to a conventional downhole pump. In essence, the gas from the well is conducted to the surface where it drives the reciprocating surface pump. The reciprocating pump then powers the downhole pump, which pumps the liquids to the surface. Several disadvantages are exhibited by this system. First, the system requires a reciprocating pump at the surface. Second, as the gas is conducted to the surface for powering the reciprocating pump, the reciprocating pump must be designed as a pressure vessel which is able to withstand the pressure differential between the atmosphere and the downhole pressure. Third, there will be some energy loss as the gas travels from the bottom of the well to the reciprocating pump on the surface. Fourth, reciprocation of the sucker rods within the tubing string results in wearing of the tubing string and energy loss due to friction between the sucker rods and the tubing string.
[0007] Other systems for removing liquids from producing wells are described in U.S. Pat. No. 5,860,795 (Ridley et al), U.S. Pat. No. 6,234,770 (Ridley et al), U.S. Pat. No. 7,204,314 (Lauritzen et al) and U.S. Pat. No. 7,789,142 (Dotson).
[0008] There continues to be a need for apparatus and methods for moving fluids through a wellbore which make use of the gas pressure present within the wellbore. Further, there continues to be a need for such apparatus which can be inserted in the wellbore and contained in the wellbore during their operation.
SUMMARY OF THE INVENTION
[0009] References in this document to orientations, to operating parameters, to ranges, to lower limits of ranges, and to upper limits of ranges are not intended to provide strict boundaries for the scope of the invention, but should be construed to mean “approximately” or “about” or “substantially”, within the scope of the teachings of this document, unless expressly stated otherwise.
[0010] As used herein, “proximal” means located relatively toward an intended “uphole” end, “upper” end and/or “surface” end of a wellbore. As used herein, “above” means relatively proximal.
[0011] As used herein, “distal” means located relatively away from an intended “uphole” end, “upper” end and/or “surface” end of a wellbore. As used herein, “below” means relatively distal.
[0012] As used herein, “fluid” includes a liquid, a gas and/or a combination of liquids and/or gases, including a multiphase fluid, which may also contain a small amount of solid material.
[0013] The present invention relates to an apparatus and a method for moving fluids in a wellbore using a gas pressure of a gas phase which is contained in the wellbore. The present invention includes features which may be adapted for use with the inventions described in U.S. Pat. No. 5,860,795 (Ridley et al) and U.S. Pat. No. 6,234,770 (Ridley et al). Alternatively, the inventions described in U.S. Pat. No. 5,860,795 (Ridley et al) and U.S. Pat. No. 6,234,770 (Ridley et al) may be adapted for use with features of the present invention.
[0014] The apparatus of the invention is configured to be inserted in a wellbore. The apparatus has a proximal end and a distal end.
[0015] In some embodiments, the apparatus may be comprised of a sealing device which is adapted for sealing the wellbore in order to provide an upper wellbore section and a lower wellbore section, a first pump for pumping liquids from the lower wellbore section, a pump drive for driving the first pump, wherein the pump drive is powered by a lower wellbore gas pressure of a lower wellbore gas phase which is contained in the lower wellbore section, a gas inlet in communication with the lower wellbore section for receiving the lower wellbore gas phase in order to supply the gas phase to the pump drive, and a gas outlet in communication with the upper wellbore section for exhausting the lower wellbore gas phase from the pump drive into the upper wellbore section.
[0016] The apparatus of the invention may be adapted to be inserted in a wellbore in any suitable manner. In some embodiments, components of the apparatus may be axially spaced along the length of the apparatus between the proximal end and the distal end so that the components are arranged end-to-end along the apparatus. In some embodiments, components of the apparatus may be located at a single axial position along the length of the apparatus between the proximal end and the distal end so that the components are arranged side-by-side along the apparatus. In some embodiments, components of the apparatus may be configured as a combination of end-to-end and side-by-side arrangements along the length of the apparatus between the proximal end and the distal end. A consideration in configuring the components of the apparatus is the diameter of the wellbore into which the apparatus will be inserted.
[0017] The apparatus of the invention may be inserted in a wellbore in any suitable manner. In some embodiments, the apparatus may be lowered into a wellbore on a pipe string, on coiled tubing, on a wireline or on a slickline.
[0018] In some embodiments, the sealing device may be located axially between the proximal end and the distal end of the apparatus so that the proximal end will be positioned in the upper wellbore section and so that the distal end will be positioned in the lower wellbore section.
[0019] The sealing device may be comprised of any suitable structure, device or apparatus. In some embodiments, the sealing device may be comprised of a packer. The packer may be actuated in any suitable manner. In some embodiments, the packer may be an inflatable packer. In some embodiments, the packer may be a mechanically actuated packer. In some embodiments, a mechanically actuated packer may be actuated by manipulation of a pipe string or coiled tubing to which the apparatus is attached.
[0020] In some embodiments, the first pump may be a reciprocating pump and the pump drive may be a reciprocating pump drive. In some embodiments, the first pump may be a rotary pump and the pump drive may be a rotary pump drive. Some features of the invention may be suitable for use with both reciprocating and rotary pumps and pump drives. Some features of the invention may be more suitable for use with reciprocating pumps and pump drives, or may be more suitable for use with rotary pumps and pump drives.
[0021] In some embodiments, the first pump may be similar in structure to embodiments of the first pump which are described in U.S. Pat. No. 5,860,795 (Ridley et al) and U.S. Pat. No. 6,234,770 (Ridley et al). In some embodiments, the pump drive may be similar in structure to embodiments of the pump drive which are described in U.S. Pat. No. 5,860,795 (Ridley et al) and U.S. Pat. No. 6,234,770 (Ridley et al).
[0022] In some embodiments, the first pump and the pump drive may be axially spaced along the length of the apparatus between the proximal end and the distal end. In some embodiments, the first pump may be located axially between the pump drive and the distal end.
[0023] The first pump has a first pump inlet. In some embodiments, the first pump inlet may communicate with the lower wellbore section. In some embodiments, a first pump inlet line may connect the first pump with the first pump inlet. The first pump has a first pump outlet. In some embodiments, the first pump outlet may communicate with the upper wellbore section. In some embodiments, a first pump outlet line may connect the first pump with the first pump outlet. In some embodiments, the first pump inlet may be adjacent to the distal end of the apparatus. In some embodiments, the first pump outlet may be adjacent to the proximal end of the apparatus. In some embodiments, the first pump inlet line may extend axially through the apparatus between the first pump and the first pump inlet. In some embodiments, the first pump outlet line may extend axially through the apparatus between the first pump and the first pump outlet.
[0024] In some embodiments, the apparatus may be further comprised of a first pump outlet check valve which is positioned in the first pump outlet line adjacent to the first pump outlet, for preventing fluids from passing from the upper wellbore section through the first pump outlet line.
[0025] In some embodiments, the apparatus may be further comprised of a pressure relief device positioned in the first pump outlet line between the first pump outlet and the first pump outlet check valve. In some embodiments, the pressure relief device may be comprised of a pressure relief valve or a burst disc.
[0026] The gas inlet may be comprised of any suitable opening or combination of openings in the apparatus which is suitable for enabling the lower wellbore gas phase to enter the apparatus.
[0027] The gas outlet may be comprised of any suitable opening or combination of openings in the apparatus which is suitable for enabling the lower wellbore gas phase to be exhausted into the upper wellbore section.
[0028] In some embodiments, the apparatus of the invention may be further comprised of a second pump for pumping fluids from the upper wellbore section into the lower wellbore section. The second pump may be driven by the pump drive. In some embodiments, the second pump may be similar in structure to embodiments of the second pump which are described in U.S. Pat. No. 5,860,795 (Ridley et al) and U.S. Pat. No. 6,234,770 (Ridley et al).
[0029] In some embodiments, the first pump, the second pump and the pump drive may be axially spaced along the length of the apparatus between the proximal end and the distal end.
[0030] In some embodiments, the second pump may be located axially between the pump drive and the distal end. In some embodiments, the second pump may be located axially between the pump drive and the distal end. In some embodiments, the second pump may be located axially between the pump drive and the first pump.
[0031] The second pump has a second pump inlet. In some embodiments, the second pump inlet may communicate with the upper wellbore section. In some embodiments, a second pump inlet line may connect the second pump with the second pump inlet. The second pump has a second pump outlet. In some embodiments, the second pump outlet may communicate with the lower wellbore section. In some embodiments, a second pump outlet line may connect the second pump with the second pump outlet. In some embodiments, the second pump inlet may be adjacent to the proximal end of the apparatus. In some embodiments, the second pump outlet may be adjacent to the distal end of the apparatus. In some embodiments, the second pump inlet line may extend axially through the apparatus between the second pump inlet and the second pump. In some embodiments, the second pump outlet line may extend axially through the apparatus between the second pump and the second pump outlet.
[0032] In some embodiments, the second pump may be adapted to be driven directly by the lower wellbore gas phase in addition to being driven by the pump drive.
[0033] In some embodiments, the apparatus of the invention may be further comprised of a vent for venting to the upper wellbore section a vented portion of the lower wellbore gas phase which is contained in the lower wellbore section so that the vented portion of the lower wellbore gas phase bypasses the pump drive.
[0034] In some embodiments, the vent may be associated with the gas inlet so that the vented portion of the lower wellbore gas phase is a portion of the lower wellbore gas phase which is received at the gas inlet. In some embodiments, the vent may be associated with the gas outlet so that the vented portion of the lower wellbore gas phase is vented through the gas outlet.
[0035] In some embodiments, the apparatus may be further comprised of a vent valve associated with the vent. In some embodiments, the vent valve may be configured so that the vent is open when the lower wellbore gas pressure is above a threshold gas pressure and so that the vent is closed when the lower wellbore gas pressure is below the threshold gas pressure. The vent valve may be configured to open and close in any suitable manner. In some embodiments, the vent valve may be configured to open and close automatically in response to the lower wellbore gas pressure. In some embodiments, the vent valve may be configured to open and close manually and/or in response to a command provided by a person or controller.
[0036] In some embodiments, the pump drive may be a reciprocating pump drive.
[0037] If the pump drive is a reciprocating pump drive, the apparatus of the invention may be further comprised of a switch for alternately directing the lower wellbore gas phase to opposite sides of the pump drive in order to reciprocate the pump drive.
[0038] In some embodiments, the switch may be comprised of a reciprocating switch valve for directing the lower wellbore gas phase to opposite sides of the pump drive and a reciprocating control valve for controlling the switch valve. The control valve may use a control portion of the lower wellbore gas phase which is received at the gas inlet to reciprocate the switch valve. The apparatus may be further comprised of a control line for delivering the control portion of the lower wellbore gas phase to the control valve. The control line may be configured so that the lower wellbore gas phase is received at the gas inlet and is delivered to the switch valve and to the control valve in parallel.
[0039] In some embodiments, the switch valve may be comprised of a plurality of switch valve pistons and a switch valve linkage connecting the switch valve pistons so that the switch valve pistons reciprocate together. The control portion of the lower wellbore gas phase may be alternately directed to opposite sides of all of the switch valve pistons by the control valve in order to reciprocate the switch valve.
[0040] In some embodiments, the method of the invention may be comprised of sealing a wellbore in order to provide an upper wellbore section and a lower wellbore section, supplying a lower wellbore gas phase which is contained in the lower wellbore section to a pump drive in order to power the pump drive, and driving a first pump with the pump drive in order to pump fluids from the lower wellbore section.
[0041] In some embodiments, the method of the invention may be further comprised of driving a second pump with the pump drive in order to pump fluids from the upper wellbore section into the lower wellbore section.
[0042] In some embodiments, the method of the invention may be further comprised of venting to the upper wellbore section a vented portion of the lower wellbore gas phase so that the vented portion of the lower wellbore gas phase bypasses the pump drive. In some embodiments, the venting may occur when the lower wellbore gas pressure is above a threshold gas pressure.
[0043] Exemplary aspects of the apparatus and method of the invention may be directed at one or more features of the invention.
[0044] In a first exemplary apparatus aspect, the invention is an apparatus for insertion in a wellbore in order to move fluids in the wellbore, wherein the wellbore communicates with an underground reservoir containing reservoir fluids such that the reservoir fluids enter the wellbore, wherein the reservoir fluids are comprised of a gas phase, and wherein the apparatus comprises:
(a) a sealing device adapted for sealing the wellbore in order to provide an upper wellbore section proximal to the sealing device and a lower wellbore section distal to the sealing device, so that a lower wellbore gas phase which is contained in the lower wellbore section is maintained at a lower wellbore gas pressure; (b) a first pump for pumping fluids from the lower wellbore section; (c) a second pump for pumping fluids from the upper wellbore section into the lower wellbore section; (d) a pump drive operably connected to the first pump and the second pump, for driving the first pump and the second pump, wherein the pump drive is adapted to be powered using the lower wellbore gas pressure of the lower wellbore gas phase; (e) a gas inlet in communication with the lower wellbore section, for receiving the lower wellbore gas phase from the lower wellbore section in order to supply the lower wellbore gas phase to the pump drive; and (f) a gas outlet in communication with the upper wellbore section, for exhausting the lower wellbore gas phase from the pump drive into the upper wellbore section.
[0051] In a second exemplary apparatus aspect, the invention is an apparatus for insertion in a wellbore in order to move fluids in the wellbore, wherein the wellbore communicates with an underground reservoir containing reservoir fluids such that the reservoir fluids enter the wellbore, wherein the reservoir fluids are comprised of a gas phase, and wherein the apparatus comprises:
(a) a sealing device adapted for sealing the wellbore in order to provide an upper wellbore section proximal to the sealing device and a lower wellbore section distal to the sealing device, so that a lower wellbore gas phase which is contained in the lower wellbore section is maintained at a lower wellbore gas pressure; (b) a first pump for pumping fluids from the lower wellbore section; (c) a pump drive operably connected to the first pump, for driving the first pump, wherein the pump drive is adapted to be powered using the lower wellbore gas pressure of the lower wellbore gas phase; (d) a gas inlet in communication with the lower wellbore section, for receiving the lower wellbore gas phase from the lower wellbore section in order to supply the lower wellbore gas phase to the pump drive; (e) a gas outlet in communication with the upper wellbore section, for exhausting the lower wellbore gas phase from the pump drive into the upper wellbore section; and (f) a vent for venting to the upper wellbore section a vented portion of the lower wellbore gas phase so that the vented portion of the lower wellbore gas phase bypasses the pump drive.
[0058] In a third exemplary apparatus aspect, the invention is an apparatus for insertion in a wellbore in order to move fluids in the wellbore, wherein the wellbore communicates with an underground reservoir containing reservoir fluids such that the reservoir fluids enter the wellbore, wherein the reservoir fluids are comprised of a gas phase, and wherein the apparatus comprises:
(a) a sealing device adapted for sealing the wellbore in order to provide an upper wellbore section proximal to the sealing device and a lower wellbore section distal to the sealing device, so that a lower wellbore gas phase which is contained in the lower wellbore section is maintained at a lower wellbore gas pressure; (b) a reciprocating first pump for pumping fluids from the lower wellbore section; (c) a reciprocating pump drive operably connected to the first pump, for driving the first pump, wherein the pump drive is adapted to be powered using the lower wellbore gas pressure of the lower wellbore gas phase; (d) a gas inlet in communication with the lower wellbore section, for receiving the lower wellbore gas phase from the lower wellbore section in order to supply the lower wellbore gas phase to the pump drive; (e) a gas outlet in communication with the upper wellbore section, for exhausting the lower wellbore gas phase from the pump drive into the upper wellbore section; and (f) a switch for alternately directing the lower wellbore gas phase received at the gas inlet to opposite sides of the pump drive in order to reciprocate the pump drive, wherein the switch is comprised of:
(i) a reciprocating switch valve, wherein the switch valve reciprocates between a first switch valve position in which the lower wellbore gas phase is directed to a first side of the pump drive and a second switch valve position in which the lower wellbore gas phase is directed to a second side of the pump drive; (ii) a reciprocating control valve, wherein the control valve is reciprocated by the pump drive between a first control valve position in which a control portion of the lower wellbore gas phase which is received at the gas inlet is directed to a first side of the switch valve in order to reciprocate the switch valve to the first switch valve position and a second control valve position in which the control portion of the lower wellbore gas phase is directed to a second side of the switch valve in order to reciprocate the switch valve to the second switch valve position; and (iii) a control line for delivering the control portion of the lower wellbore gas phase to the control valve, wherein the control line is configured so that the lower wellbore gas phase is received at the gas inlet and is delivered to the switch valve and to the control valve in parallel.
[0068] In a fourth exemplary apparatus aspect, the invention is an apparatus for insertion in a wellbore in order to move fluids in the wellbore, wherein the wellbore communicates with an underground reservoir containing reservoir fluids such that the reservoir fluids enter the wellbore, wherein the reservoir fluids are comprised of a gas phase, and wherein the apparatus comprises:
(a) a sealing device adapted for sealing the wellbore in order to provide an upper wellbore section proximal to the sealing device and a lower wellbore section distal to the sealing device, so that a lower wellbore gas phase which is contained in the lower wellbore section is maintained at a lower wellbore gas pressure; (b) a reciprocating first pump for pumping fluids from the lower wellbore section; (c) a reciprocating pump drive operably connected to the first pump, for driving the first pump, wherein the pump drive is adapted to be powered using the lower wellbore gas pressure of the lower wellbore gas phase; (d) a gas inlet in communication with the lower wellbore section, for receiving the lower wellbore gas phase from the lower wellbore section in order to supply the lower wellbore gas phase to the pump drive; (e) a gas outlet in communication with the upper wellbore section, for exhausting the lower wellbore gas phase from the pump drive into the upper wellbore section; and (f) a switch for alternately directing the lower wellbore gas phase received at the gas inlet to opposite sides of the pump drive in order to reciprocate the pump drive, wherein the switch is comprised of:
(i) a reciprocating switch valve, wherein the switch valve reciprocates between a first switch valve position in which the lower wellbore gas phase is directed to a first side of the pump drive and a second switch valve position in which the lower wellbore gas phase is directed to a second side of the pump drive, wherein the switch valve is comprised of a plurality of switch valve pistons and a switch valve linkage connecting the switch valve pistons so that the switch valve pistons reciprocate together; and (ii) a reciprocating control valve, wherein the control valve is reciprocated by the pump drive between a first control valve position in which a control portion of the lower wellbore gas phase is directed to a first side of all of the switch valve pistons in order to reciprocate the switch valve to the first switch valve position and a second control valve position in which the control portion of the lower wellbore gas phase is directed to a second side of all of the switch valve pistons in order to reciprocate the switch valve to the second switch valve position.
[0077] These exemplary apparatus aspects of the invention may each further comprise one or more other features of the apparatus of the invention.
[0078] In a first exemplary method aspect, the invention is a method for moving fluids in a wellbore, wherein the wellbore communicates with an underground reservoir containing reservoir fluids such that the reservoir fluids enter the wellbore, wherein the reservoir fluids are comprised of a gas phase, and wherein the method comprises:
(a) sealing the wellbore in order to provide an upper wellbore section and a lower wellbore section, so that a lower wellbore gas phase which is contained in the lower wellbore section is maintained at a lower wellbore gas pressure; (b) supplying the lower wellbore gas phase to a pump drive in order to power the pump drive, wherein the pump drive is adapted to be powered using the lower wellbore gas pressure of the lower wellbore gas phase; (c) driving a first pump with the pump drive in order to pump fluids from the lower wellbore section; and (d) driving a second pump with the pump drive in order to pump fluids from the upper wellbore section into the lower wellbore section.
[0083] In a second exemplary method aspect, the invention is a method for moving fluids in a wellbore, wherein the wellbore communicates with an underground reservoir containing reservoir fluids such that the reservoir fluids enter the wellbore, wherein the reservoir fluids are comprised of a gas phase, and wherein the method comprises:
(a) sealing the wellbore in order to provide an upper wellbore section and a lower wellbore section, so that a lower wellbore gas phase which is contained in the lower wellbore section is maintained at a lower wellbore gas pressure; (b) supplying the lower wellbore gas phase to a pump drive in order to power the pump drive, wherein the pump drive is adapted to be powered using the lower wellbore gas pressure of the lower wellbore gas phase; (c) driving a first pump with the pump drive in order to pump fluids from the lower wellbore section; and (d) venting to the upper wellbore section a vented portion of the lower wellbore gas phase so that the vented portion of the lower wellbore gas phase bypasses the pump drive.
[0088] These exemplary method aspects of the invention may both further comprise one or more other features of the method of the invention.
BRIEF DESCRIPTION OF DRAWINGS
[0089] Embodiments of the invention will now be described with reference to the accompanying drawings, in which:
[0090] FIG. 1 is a schematic drawing depicting an exemplary embodiment of the apparatus of the invention positioned in a wellbore.
[0091] FIGS. 2A-2D is a schematic longitudinal section assembly drawing of the exemplary embodiment of the apparatus depicted in FIG. 1 , wherein FIG. 2B is an extension of FIG. 2A , FIG. 2C is an extension of FIG. 2B , and FIG. 2D is an extension of FIG. 2C , showing the control valve in the first control valve position, showing the switch valve in the first switch valve position, and showing the pump drive at the upper end of the pump drive stroke.
[0092] FIGS. 3A-3D is a schematic longitudinal section assembly drawing of the exemplary embodiment of the apparatus depicted in FIG. 1 , wherein FIG. 3B is an extension of FIG. 3A , FIG. 3C is an extension of FIG. 3B , and FIG. 3D is an extension of FIG. 3C , showing the control valve in the second control valve position, showing the switch valve in the second switch valve position, and showing the pump drive at the lower end of the pump drive stroke.
DETAILED DESCRIPTION
[0093] An exemplary embodiment of the apparatus of the invention is depicted in FIGS. 1-3 .
[0094] FIG. 1 is a schematic drawing depicting the exemplary embodiment positioned in a wellbore. FIG. 2 is a schematic longitudinal section assembly drawing of the exemplary embodiment, showing the control valve in the first control valve position, showing the switch valve in the first switch valve position, and showing the pump drive at the upper end of the pump drive stroke. FIG. 3 is a schematic longitudinal section assembly drawing of the exemplary embodiment, showing the control valve in the second control valve position, showing the switch valve in the second switch valve position, and showing the pump drive at the upper end of the pump drive stroke.
[0095] Referring to FIG. 1 , the exemplary embodiment of the apparatus ( 10 ) has a proximal end ( 12 ) and a distal end ( 14 ). In the exemplary embodiment, the apparatus ( 10 ) is comprised of a plurality of components which are axially spaced along the length of the apparatus ( 10 ) between the proximal end ( 12 ) and the distal end ( 14 ) so that the components are arranged end-to-end along the apparatus ( 10 ).
[0096] Referring to FIG. 1 , the apparatus ( 10 ) is depicted positioned in a wellbore ( 16 ) in an exemplary configuration for use of the apparatus ( 10 ). In the exemplary configuration, the wellbore ( 16 ) extends into or through an underground reservoir ( 18 ) containing reservoir fluids (not shown). The reservoir fluids are typically comprised of a gas phase (such as natural gas) and at least one liquid phase (such as hydrocarbons and/or water).
[0097] In the exemplary configuration, the wellbore ( 16 ) is lined with a production casing ( 20 ) which is perforated adjacent to the reservoir ( 18 ) so that the wellbore ( 16 ) communicates with the reservoir ( 18 ) and so that the reservoir fluids can enter the wellbore ( 16 ). In FIG. 1 , the casing ( 20 ) is shown extending for the entire length of the wellbore ( 16 ). In FIGS. 2-3 , for clarity in depicting the apparatus ( 10 ), the casing ( 20 ) is shown extending only for a portion of the length of the wellbore ( 16 ).
[0098] In the exemplary configuration, the apparatus ( 10 ) may be used to produce a liquid and/or a gas from the wellbore ( 16 ). As a result, FIG. 1 depicts schematically a liquid line ( 22 ) and a gas line ( 24 ) which extend from adjacent to the proximal end ( 12 ) of the apparatus ( 10 ) toward a ground surface end of the wellbore ( 16 ). In the exemplary configuration, the liquid line ( 22 ) may be comprised of a production tubing (not shown) and the gas line ( 24 ) may be comprised of an annular space or annulus between the casing ( 20 ) and the production tubing.
[0099] In the exemplary embodiment, from the proximal end ( 12 ) to the distal end ( 14 ) of the apparatus ( 10 ), the components include a packer transition sub ( 30 ), a packer sub ( 32 ), a vent valve sub ( 34 ), a crossover spacer sub ( 36 ), a switch valve sub ( 38 ), a control valve sub ( 40 ), a pump drive sub ( 42 ), a second pump sub ( 44 ), and a first pump sub ( 46 ).
[0100] In other embodiments, additional components, including but not limited to spacer subs (not shown) may be included in the apparatus ( 10 ) to provide a desired axial distance between components of the apparatus ( 10 ). As a non-limiting example, one or more spacer subs may be included to provide a desired axial distance between the packer sub ( 32 ) and the pump subs ( 44 , 46 ).
[0101] Referring to FIGS. 2-3 , in the exemplary embodiment, the packer transition sub ( 30 ) is connected with the packer sub ( 32 ) with a collar ( 50 ). A proximal end of the collar ( 50 ) is comprised of an inwardly projecting flange ( 52 ) which engages a shoulder ( 54 ) on the packer transition sub ( 30 ). A distal end of the collar ( 50 ) is provided with internal threads which engage with external threads on a proximal end of the packer sub ( 32 ) to provide a threaded connection ( 56 ) between the collar ( 50 ) and the packer sub ( 32 ).
[0102] Referring to FIGS. 2-3 , in the exemplary embodiment, the packer sub ( 32 ) is comprised of a proximal packer sub ( 60 ) and a main packer sub ( 62 ). The proximal packer sub ( 60 ) is connected with the main packer sub ( 62 ) by a threaded connection ( 64 ). A distal end of the main packer sub ( 62 ) is provided with external threads.
[0103] Referring to FIGS. 2-3 , in the exemplary embodiment, the vent valve sub ( 34 ) is comprised of a proximal vent valve sub ( 70 ), a main vent valve sub ( 72 ), and a distal vent valve sub ( 74 ). In the exemplary embodiment, the proximal vent valve sub ( 70 ) is welded to the main vent valve sub ( 72 ) and the main vent valve sub ( 72 ) is welded to the distal vent valve sub ( 74 ).
[0104] Referring to FIGS. 2-3 , in the exemplary embodiment, a proximal end of the proximal vent valve sub ( 70 ) is provided with internal threads and a distal end of the distal vent valve sub ( 74 ) is provided with external threads.
[0105] In the exemplary embodiment, the distal end of the main packer sub ( 62 ) is connected with the proximal end of the proximal vent valve sub ( 70 ) by a threaded connection.
[0106] In the exemplary embodiment, the crossover spacer sub ( 36 ), the switch valve sub ( 38 ), the control valve sub ( 40 ), the pump drive sub ( 42 ), the second pump sub ( 44 ) and the first pump sub ( 46 ) are all contained within a main housing ( 80 ). In the exemplary embodiment, a proximal end of the main housing ( 80 ) is provided with internal threads which engage with the external threads on the distal end of the distal vent valve sub ( 74 ) to provide a threaded connection ( 82 ) between the distal vent valve sub ( 74 ) and the main housing ( 80 ).
[0107] In the exemplary embodiment, a proximal end of the packer transition sub ( 30 ) defines the proximal end ( 12 ) of the apparatus ( 10 ). In the exemplary embodiment, the main housing ( 80 ) extends distally below the first pump sub ( 46 ) so that a distal end of the main housing ( 80 ) defines the distal end ( 14 ) of the apparatus ( 10 ).
[0108] In the exemplary embodiment, the packer transition sub ( 30 ) contains and/or defines conduits for providing communication between the apparatus ( 10 ) and the wellbore ( 16 ) adjacent to the proximal end ( 12 ) of the apparatus ( 10 ), and for providing communication between the packer transition sub ( 30 ) and components of the apparatus ( 10 ) below the packer transition sub ( 30 ), as discussed in detail below.
[0109] In the exemplary embodiment, the packer transition sub ( 30 ) also defines a first pump outlet ( 84 ), a second pump inlet ( 86 ), and a gas outlet ( 88 ) adjacent to the proximal end ( 12 ) of the apparatus ( 10 ). A screen (not shown) may be provided at the second pump inlet ( 86 ) to inhibit the introduction of solids into the apparatus ( 10 ).
[0110] In the exemplary configuration of the apparatus ( 10 ) in a wellbore ( 16 ), the first pump outlet ( 84 ) may be connected with a liquid line ( 22 ) and the gas outlet ( 88 ) may be connected with a gas line ( 24 ), as depicted schematically in FIG. 1 .
[0111] In the exemplary embodiment, the packer sub ( 32 ) contains and/or defines conduits for providing communication between the packer sub ( 32 ) and components of the apparatus ( 10 ) above and below the packer sub ( 32 ), as discussed in detail below.
[0112] The packer sub ( 32 ) also contains or carries a packer ( 90 ) as a sealing device for sealing the wellbore ( 16 ) to provide an upper wellbore section ( 92 ) proximal to the packer ( 90 ) and a lower wellbore section ( 94 ) distal to the packer ( 90 ).
[0113] Referring to FIG. 1 , in the exemplary configuration for use of the apparatus ( 10 ), the lower wellbore section ( 94 ) communicates with the reservoir ( 18 ) so that the reservoir fluids enter the lower wellbore section ( 94 ), with the result that the lower wellbore section ( 94 ) contains a lower wellbore gas phase (not shown) at a lower wellbore gas pressure. The packer ( 90 ) maintains the lower wellbore gas phase at the lower wellbore gas pressure by isolating the lower wellbore section ( 94 ) from the upper wellbore section ( 92 ).
[0114] In the exemplary embodiment, the packer ( 90 ) is a mechanical packer which is mechanically actuated by manipulating a pipe string, coiled tubing or other running string (not shown) to which the apparatus ( 10 ) may be attached. In other embodiments, the packer ( 90 ) may be any suitable type of sealing device which is capable of providing a seal between the apparatus ( 10 ) and the wellbore ( 16 ) in order to seal the wellbore ( 16 ), as would be well known to a person skilled in the art. As a result, for simplicity, many details of the packer ( 90 ) are not shown in FIGS. 1-3 .
[0115] In the exemplary embodiment, the vent valve sub ( 34 ) contains and/or defines conduits for providing communication between the vent valve sub ( 34 ) and components of the apparatus ( 10 ) above and below the vent valve sub ( 34 ), as discussed in detail below.
[0116] In the exemplary embodiment, the vent valve sub ( 34 ) also provides a gas inlet ( 100 ) for receiving the lower wellbore gas phase from the lower wellbore section ( 94 ). In the exemplary embodiment, the gas inlet ( 100 ) is comprised of three separate gas inlet ports ( 104 ) which are spaced around the circumference of the vent valve sub ( 34 ). In other embodiments, the gas inlet ( 100 ) may be comprised of a single gas inlet port ( 104 ) or any suitable number of gas inlet ports ( 104 ). In the exemplary embodiment, the gas inlet ( 100 ) is also comprised of a gas inlet chamber ( 106 ) which connects the gas inlet ports ( 104 ).
[0117] In the exemplary embodiment, the vent valve sub ( 34 ) also defines a vent ( 110 ) for venting a vented portion of the lower wellbore gas phase to the upper wellbore section ( 92 ). In the exemplary embodiment, the vent ( 110 ) is associated with the gas inlet ( 100 ) so that the vented portion of the lower wellbore gas phase is a portion of the lower wellbore gas phase which is received at the gas inlet ( 100 ).
[0118] In the exemplary embodiment, a vent valve ( 112 ) is associated with the vent ( 110 ). In the exemplary embodiment, the vent valve ( 112 ) is configured so that the vent ( 110 ) is open when the lower wellbore gas pressure is above a threshold gas pressure and so that the vent ( 110 ) is closed when the lower wellbore gas pressure is below a threshold gas pressure.
[0119] The vent ( 110 ) and the vent valve ( 112 ) can reduce the likelihood of damage to the apparatus ( 10 ) due to being exposed to an excess lower wellbore gas pressure. Accordingly, in the exemplary embodiment, the vent valve ( 112 ) is configured so that the threshold gas pressure is less than a pressure which will cause damage to the apparatus ( 10 ).
[0120] The vent ( 110 ) and the vent valve ( 112 ) can also facilitate additional production of the lower wellbore gas phase to the ground surface through the vent ( 110 ) in circumstances where high volumes of the lower wellbore gas phase and/or a high lower wellbore gas pressure are present.
[0121] In the exemplary embodiment, before being released to the upper wellbore section ( 92 ), the vented portion of the lower wellbore gas phase is vented to a gas outlet chamber ( 114 ) which is defined by the packer sub ( 32 ) and which communicates with the gas outlet ( 88 ).
[0122] In the exemplary embodiment, the crossover spacer sub ( 36 ) is comprised of a crossover spacer ( 120 ), which contains and/or defines conduits for providing communication between the crossover spacer sub ( 36 ) and components of the apparatus ( 10 ) above and below the crossover spacer sub ( 36 ), as discussed in detail below.
[0123] In the exemplary embodiment, a gasket ( 122 ) is provided between the vent valve sub ( 34 ) and the crossover spacer ( 120 ).
[0124] In the exemplary embodiment, the switch valve sub ( 38 ) contains and/or defines conduits for providing communication between the switch valve sub ( 38 ) and components of the apparatus ( 10 ) above and below the switch valve sub ( 38 ), as discussed in detail below.
[0125] The switch valve sub ( 38 ) also contains a switch valve ( 130 ). As a result, the switch valve sub ( 38 ) also contains and/or defines conduits which are associated with the functioning of the switch valve ( 130 ), as discussed in detail below.
[0126] In the exemplary embodiment, the switch valve ( 130 ) is a reciprocating switch valve which reciprocates between a first switch valve position ( 132 ) as shown in FIG. 2 and a second switch valve position ( 134 ) as shown in FIG. 3 .
[0127] In the exemplary embodiment, the switch valve sub ( 38 ) and the switch valve ( 130 ) are constructed as a modular component. More particularly, in the exemplary embodiment, the switch valve ( 130 ) is comprised of a first switch valve module ( 136 ) and a second switch valve module ( 138 ). The switch valve modules ( 136 , 138 ) are separated by a switch valve module spacer ( 140 ).
[0128] The first switch valve module ( 136 ) is comprised of a first switch valve piston ( 142 ) contained in a first switch valve cylinder ( 144 ) which is defined by the first switch valve module ( 136 ), and the second switch valve module ( 138 ) is comprised of a second switch valve piston ( 146 ) contained in a second switch valve cylinder ( 148 ) which is defined by the second switch valve module ( 138 ). The switch valve cylinders ( 144 , 148 ) are separated by the switch valve module spacer ( 140 ). A switch valve linkage ( 150 ) extends through the switch valve module spacer ( 140 ) and connects the switch valve pistons ( 142 , 146 ) with threaded connections so that the switch valve pistons ( 142 , 146 ) reciprocate together.
[0129] A groove in the outer surface of the first switch valve piston ( 142 ) defines a first switch valve port ( 152 ). A groove in the outer surface of the second switch valve piston ( 146 ) defines a second switch valve port ( 154 ). O-ring seals ( 156 ) are provided on the outer surfaces of the switch valve pistons ( 142 , 146 ) on both sides of the switch valve ports ( 146 , 148 ) to seal and isolate the switch valve ports ( 146 , 148 ).
[0130] Since the switch valve sub ( 38 ) and the switch valve ( 130 ) in the exemplary embodiment are constructed as a modular component, the switch valve ( 130 ) may easily be comprised of a single switch valve piston or may be comprised of more than two switch valve pistons simply by varying the number of switch valve modules and switch valve spacers which are included in the switch valve sub ( 38 ). In other embodiments, the switch valve sub ( 38 ) may be configured so that a plurality of switch valve pistons may be contained in a single switch valve cylinder, and/or the switch valve sub ( 38 ) may be configured as a non-modular component.
[0131] In the exemplary embodiment, a gasket ( 158 ) is provided between the crossover spacer ( 120 ) and the switch valve sub ( 38 ), and gaskets ( 160 ) are provided between each of the switch valve modules ( 136 , 138 ) and the switch valve module spacer ( 140 ).
[0132] In the exemplary embodiment, the control valve sub ( 40 ) contains and/or defines conduits for providing communication between the control valve sub ( 40 ) and components of the apparatus ( 10 ) above and below the control valve sub ( 40 ), as discussed in detail below.
[0133] The control valve sub ( 40 ) also contains a control valve ( 170 ). As a result, the control valve sub ( 40 ) also contains and/or defines conduits which are associated with the functioning of the control valve ( 170 ), as discussed in detail below.
[0134] In the exemplary embodiment, the control valve ( 170 ) is a reciprocating control valve which reciprocates between a first control valve position ( 172 ) as shown in FIG. 2 and a second control valve position ( 174 ) as shown in FIG. 3 .
[0135] In the exemplary embodiment, the control valve sub ( 40 ) and the control valve ( 170 ) are constructed as a modular component. More particularly, in the exemplary embodiment, the control valve ( 170 ) is comprised of first control valve module ( 176 ), a second control valve module ( 178 ), and a third control valve module ( 180 ). The first control valve module ( 176 ) and the second control valve module ( 178 ) are separated by a proximal control valve spacer ( 182 ). The second control valve module ( 178 ) and the third control valve module ( 180 ) are separated by a distal control valve spacer ( 184 ).
[0136] In the exemplary embodiment, the control valve ( 170 ) is comprised of a control valve piston ( 186 ) which is slidably carried on a control valve shaft ( 188 ). The control valve piston ( 186 ) and the control valve shaft ( 188 ) are contained in a control valve cylinder ( 189 ) which is defined by the control valve modules ( 176 , 178 , 180 ). A proximal control valve actuating member ( 190 ) is fixed to a proximal end of the control valve shaft ( 188 ) with a threaded connection. A distal control valve actuating member ( 192 ) is fixed to a distal end of the control valve shaft ( 188 ) with a threaded connection. The reciprocating movement of the control valve ( 170 ) is limited by a proximal control valve stop ( 194 ) which is defined by the proximal control valve spacer ( 182 ) and a distal control valve stop ( 196 ) which is defined by the distal control valve spacer ( 184 ).
[0137] Two grooves in the outer surface of the control valve piston ( 186 ) define a first control valve port ( 198 ) and a second control valve port ( 200 ). O-ring seals ( 202 ) are provided on the outer surface of the control valve piston ( 186 ) on both sides of the control valve ports ( 198 , 200 ) to seal and isolate the control valve ports ( 188 , 190 ).
[0138] Since the control valve sub ( 40 ) and the control valve ( 170 ) in the exemplary embodiment are constructed as a modular component, the number of control valve modules may easily be varied in order to accommodate a lesser or greater amount of reciprocation of the control valve shaft ( 188 ).
[0139] In the exemplary embodiment, the switch valve sub ( 38 ) and the control valve sub ( 40 ) are separated by a spacer plate ( 204 ). In the exemplary embodiment, gaskets ( 206 ) are provided between the switch valve sub ( 38 ) and the spacer plate ( 204 ) and between the spacer plate ( 204 ) and the control valve sub ( 40 ).
[0140] In the exemplary embodiment, gaskets ( 208 ) are also provided between the first and second control valve modules ( 176 , 178 ) and the proximal control valve spacer ( 182 ) and between the second and third control valve modules ( 178 , 180 ) and the distal control valve spacer ( 184 ).
[0141] In the exemplary embodiment, the pump drive sub ( 42 ) contains and/or defines conduits for providing communication between the pump drive sub ( 42 ) and components of the apparatus ( 10 ) above and below the pump drive sub ( 42 ), as discussed in detail below.
[0142] The pump drive sub ( 42 ) also contains a pump drive ( 220 ). As a result, the pump drive sub ( 42 ) also contains and/or defines conduits which are associated with the functioning of the pump drive ( 220 ), as discussed in detail below.
[0143] In the exemplary embodiment, the pump drive ( 220 ) is a reciprocating pump drive which reciprocates between a first pump drive position ( 222 ) as shown in FIG. 2 and a second pump drive position ( 224 ) as shown in FIG. 3 .
[0144] In the exemplary embodiment, the pump drive sub ( 42 ) and the pump drive ( 220 ) are constructed as a modular component. More particularly, in the exemplary embodiment, the pump drive ( 220 ) is comprised of a first pump drive module ( 226 ), a second pump drive module ( 228 ), a third pump drive module ( 230 ), and a fourth pump drive module ( 232 ).
[0145] The pump drive modules ( 226 , 228 , 230 , 232 ) are separated by pump drive spacers ( 234 ). In the exemplary embodiment, gaskets ( 235 ) are provided between the pump drive modules ( 226 , 228 , 230 , 232 ) and the spacers ( 234 ).
[0146] In the exemplary embodiment, each of the pump drive modules ( 226 , 228 , 230 , 232 ) provides a pump drive stage so that the pump drive ( 220 ) in the exemplary embodiment is comprised of four pump drive stages. In the exemplary embodiment, each pump drive module ( 226 , 228 , 230 , 232 ) is comprised of a pump drive piston ( 236 ) and a pump drive module shaft ( 238 ) contained in a pump drive cylinder ( 240 ) which is defined by the corresponding pump drive module. The pump drive cylinders ( 240 ) are separated by the pump drive spacers ( 234 ).
[0147] Each pump drive module shaft ( 238 ) is fixed to its corresponding pump drive piston ( 236 ) with a threaded connection, extends from a distal end of the pump drive piston ( 236 ), and terminates below the distal end of its corresponding pump drive cylinder ( 240 ). In the exemplary embodiment, all of the pump drive pistons ( 236 ) are interconnected by the pump drive module shafts ( 238 ) with threaded connections so that the pump drive pistons ( 236 ) reciprocate together. The pump drive module shaft ( 238 ) of the most distal pump drive stage extends below the pump drive sub ( 42 ).
[0148] O-ring seals ( 242 ) are provided on the outer surface of the pump drive pistons ( 236 ) so that the pump drive pistons ( 236 ) sealingly engage the pump drive cylinders ( 240 ).
[0149] Since the pump drive sub ( 42 ) and the pump drive ( 220 ) in the exemplary embodiment are constructed as a modular component, the number of pump drive stages may easily be varied to provide fewer than four pump stages or more than four pump stages in order to reduce or increase the power of the pump drive ( 220 ).
[0150] In the exemplary embodiment, the control valve sub ( 40 ) and the pump drive sub ( 42 ) are separated by a spacer plate ( 244 ). In the exemplary embodiment, gaskets ( 246 ) are provided between the control valve sub ( 40 ) and the spacer plate ( 244 ) and between the spacer plate ( 244 ) and the pump drive sub ( 42 ).
[0151] In the exemplary embodiment, a control valve connector shaft ( 246 ) extends through the spacer plate ( 244 ) and is fixed to the most proximal pump drive piston ( 236 ) and the distal control valve actuating member ( 192 ) with threaded connections so that the pump drive pistons ( 236 ) and the control valve shaft ( 188 ) reciprocate together.
[0152] In the exemplary embodiment, the second pump sub ( 44 ) contains and/or defines conduits for providing communication between the second pump sub ( 44 ) and components of the apparatus ( 10 ) above and below the second pump sub ( 44 ), as discussed in detail below.
[0153] The second pump sub ( 44 ) also contains a second pump ( 260 ) for pumping fluids from the upper wellbore section ( 92 ) into the lower wellbore section ( 94 ). As a result, the second pump sub ( 44 ) also contains and/or defines conduits which are associated with the functioning of the second pump ( 260 ), as discussed in detail below.
[0154] In the exemplary embodiment, the second pump ( 260 ) is a reciprocating pump which reciprocates between a first second pump position ( 262 ) as shown in FIG. 2 and a second second pump position ( 264 ) as shown in FIG. 3 .
[0155] In the exemplary embodiment, the second pump sub ( 44 ) and the second pump ( 260 ) are constructed as a modular component. More particularly, in the exemplary embodiment, the second pump ( 260 ) is comprised of a single second pump module ( 266 ) so that the second pump ( 260 ) is comprised of a single second pump stage.
[0156] In the exemplary embodiment, the second pump module ( 266 ) is comprised of a second pump piston ( 268 ) contained in a second pump cylinder ( 270 ) which is defined by the second pump module ( 266 ). The second pump piston ( 268 ) is fixed to the most distal pump drive module shaft ( 238 ) with a threaded connection so that the second pump piston ( 268 ) and the pump drive pistons ( 236 ) reciprocate together.
[0157] O-ring seals ( 272 ) are provided in the outer surface of the second pump piston ( 268 ) so that the second pump piston ( 268 ) sealingly engages the second pump cylinder ( 270 ).
[0158] Since the second pump sub ( 44 ) and the second pump ( 260 ) in the exemplary embodiment are constructed as a modular component, the number of second pump stages may easily be increased (similar to providing more than one pump drive stage) to provide more than one second pump stage in order to increase the pumping pressure and/or the pumping flowrate of the second pump ( 260 ).
[0159] In the exemplary embodiment, the pump drive sub ( 42 ) and the second pump sub ( 44 ) are separated by a spacer plate ( 274 ). In the exemplary embodiment, gaskets ( 276 ) are provided between the pump drive sub ( 42 ) and the spacer plate ( 274 ) and between the spacer plate ( 274 ) and the second pump sub ( 44 ).
[0160] In the exemplary embodiment, the most distal pump drive module shaft ( 238 ) extends through the spacer plate ( 274 ) in order to enable the most distal pump drive module shaft ( 238 ) to connect with the second pump piston ( 268 ).
[0161] In the exemplary embodiment, the first pump sub ( 46 ) contains and/or defines conduits for providing communication with components of the apparatus ( 10 ) above the first pump sub ( 46 ), as discussed in detail below.
[0162] The first pump sub ( 46 ) also contains a first pump ( 280 ) for pumping fluids from the lower wellbore section ( 94 ). As a result, the first pump sub ( 46 ) also contains and/or defines conduits which are associated with the functioning of the first pump ( 280 ), as discussed in detail below.
[0163] In the exemplary embodiment, the first pump ( 280 ) is a reciprocating pump which reciprocates between a first first pump position ( 282 ) as shown in FIG. 2 and a second first pump position ( 284 ) as shown in FIG. 3 .
[0164] In the exemplary embodiment, the first pump sub ( 46 ) and the first pump ( 280 ) are constructed as a modular component. More particularly, in the exemplary embodiment, the first pump ( 280 ) is comprised of a single first pump module ( 286 ) so that the second pump ( 260 ) is comprised of a single first pump stage.
[0165] In the exemplary embodiment, the first pump module ( 286 ) is comprised of a first pump piston ( 288 ) and a first pump module shaft ( 290 ) contained in a first pump cylinder ( 292 ) which is defined by the first pump module ( 286 ).
[0166] The first pump module shaft ( 290 ) is fixed to the first pump piston ( 288 ) with a threaded connection, extends from a proximal end of the first pump piston ( 288 ), and is fixed to the second pump piston ( 268 ) with a threaded connection so that the first pump piston ( 288 ) and the second pump piston ( 268 ) reciprocate together.
[0167] O-ring seals ( 294 ) are provided in the outer surface of the first pump piston ( 288 ) so that the first pump piston ( 288 ) sealingly engages the first pump cylinder ( 292 ).
[0168] Since the first pump sub ( 46 ) and the first pump ( 280 ) in the exemplary embodiment are constructed as a modular component, the number of first pump stages may easily be increased (similar to providing more than one pump drive stage) to provide more than one first pump stage in order to increase the pumping pressure and/or the pumping flowrate of the first pump ( 280 ).
[0169] In the exemplary embodiment, the second pump sub ( 44 ) and the first pump sub ( 46 ) are separated by a spacer plate ( 296 ). In the exemplary embodiment, gaskets ( 298 ) are provided between the second pump sub ( 44 ) and the spacer plate ( 296 ) and between the spacer plate ( 296 ) and the first pump sub ( 46 ).
[0170] In the exemplary embodiment, the first pump module shaft ( 290 ) extends through the spacer plate ( 296 ) in order to enable the first pump module shaft ( 290 ) to connect with the second pump piston ( 268 ).
[0171] In the exemplary embodiment, a bottom plate ( 310 ) is provided at the distal end of the first pump sub ( 46 ). The bottom plate ( 310 ) contains and/or defines conduits for providing communication between the apparatus ( 10 ) and the wellbore ( 16 ) adjacent to the distal end ( 14 ) of the apparatus ( 10 ), and for providing communication between the bottom plate ( 310 ) and components of the apparatus ( 10 ) above the bottom plate ( 310 ), as discussed in detail below.
[0172] In the exemplary embodiment, the bottom plate ( 310 ) also defines a first pump inlet ( 312 ) and second pump outlet ( 314 ) adjacent to the distal end ( 14 ) of the apparatus ( 10 ). A screen (not shown) may be provided at the first pump inlet ( 312 ) to inhibit the introduction of solids into the apparatus ( 10 ).
[0173] In the exemplary embodiment, a gasket ( 316 ) is provided between the first pump sub ( 46 ) and the bottom plate ( 310 ).
[0174] As previously mentioned, each of the components of the apparatus ( 10 ) contains and/or defines conduits which are utilized for the operation of the apparatus ( 10 ).
[0175] The conduits include axial conduits and radial conduits. Axial conduits extend generally axially through the components and radial conduits extend generally radially from axial conduits.
[0176] In the exemplary embodiment, the components of the apparatus ( 10 ) are configured so that at least some of the components and modules of the apparatus ( 10 ) include the same configuration of axial conduits. In the exemplary embodiment, not all of the axial conduits may be used in each component, and some of the axial conduits may be extra or spare axial conduits which may not be used at all in the apparatus ( 10 ). In the exemplary embodiment, each of the axial conduits is located at a similar position in each of the components and modules. This configuration of the axial conduits simplifies the fabrication of the components and modules and assists in facilitating construction of the components as modular components.
[0177] Referring to FIGS. 2-3 , in the exemplary embodiment, the apparatus ( 10 ) is comprised of the following axial conduits:
axial conduit ( 401 ): this axial conduit ( 401 ) houses the switch valve pistons ( 142 , 146 ), the control valve piston ( 186 ), the pump drive pistons ( 236 ), the second pump piston ( 268 ), and the first pump piston ( 288 ); axial conduit ( 402 ): this axial conduit ( 402 ), with associated radial conduits, is used to provide communication between the control valve ( 170 ) and a first side ( 328 ) of the switch valve pistons ( 142 , 146 ); axial conduit ( 404 ): this axial conduit ( 404 ), with associated radial conduits, is used to provide a control line ( 330 ) for delivering a control portion of the lower wellbore gas phase to the control valve ( 170 ); axial conduit ( 405 ): this axial conduit ( 405 ), with associated radial conduits, is used to provide communication between the switch valve ( 130 ) and a first side ( 332 ) of the pump drive pistons ( 236 ), and to provide communication between the switch valve ( 130 ) and a first side ( 334 ) of the second pump piston ( 268 ); axial conduit ( 406 ): this axial conduit ( 406 ), with associated radial conduits, is used to provide communication between the first pump ( 280 ) and the first pump outlet ( 84 ); axial conduit ( 407 ): this axial conduit ( 407 ), with associated radial conduits, is used to provide communication between the gas inlet ( 100 ) and the switch valve ( 130 ) axial conduit ( 407 ′): this axial conduit ( 407 ′), with associated radial conduits, is used to provide communication between the switch valve ( 130 ) and a second side ( 338 ) of the pump drive pistons ( 236 ); axial conduit ( 408 ): this axial conduit ( 408 ), with associated radial conduits, is used to provide communication between the switch valve ( 130 ) and the gas outlet ( 88 ), to provide communication between the control valve ( 170 ) and the gas outlet ( 88 ), and to provide communication between the vent ( 100 ) and the gas outlet ( 88 ); axial conduit ( 410 ): this axial conduit ( 410 ), with associated radial conduits, is used to provide communication between the second pump inlet ( 86 ) and a second side ( 342 ) of the second pump piston ( 268 ), and to provide communication between the second side ( 342 ) of the second pump piston ( 268 ) and the second pump outlet ( 314 ). The axial conduit ( 410 ) and its associated radial conduits provide a second pump inlet line between the second pump inlet ( 86 ) and the second pump ( 260 ); axial conduit ( 411 ): this axial conduit ( 402 ), with associated radial conduits, is used to provide communication between the control valve ( 170 ) and a second side ( 344 ) of the switch valve pistons ( 142 , 146 ).
[0188] In the exemplary embodiment, additional axial conduits ( 412 , 414 ), with associated radial conduits, are used to provide communication between the first pump ( 280 ) and the first pump inlet ( 312 ). More specifically, in the exemplary embodiment, axial conduit ( 412 ) is used to provide communication between a first side ( 346 ) of the first pump piston ( 288 ) and the first pump inlet ( 312 ) and axial conduit ( 414 ) is used to provide communication between a second side ( 348 ) of the first pump piston ( 288 ) and the first pump inlet ( 312 ). The axial conduit ( 406 ), the axial conduits ( 412 , 414 ) and their associated radial conduits provide a first pump outlet line between the first pump ( 280 ) and the first pump outlet ( 84 ).
[0189] The operation of the exemplary embodiment of the apparatus ( 10 ) is now described, with reference to FIG. 2 and FIG. 3 .
[0190] In FIG. 2 , the apparatus ( 10 ) is depicted in a first apparatus position, with the switch valve ( 130 ) in the first switch valve position ( 132 ), with the control valve ( 170 ) in the first control valve position ( 172 ), with the pump drive ( 220 ) in the first pump drive position ( 222 ), with the second pump ( 260 ) in the first second pump position ( 262 ), and with the first pump ( 280 ) in the first first pump position ( 282 ).
[0191] In FIG. 3 , the apparatus ( 10 ) is depicted in a second apparatus position, with the switch valve ( 130 ) in the second switch valve position ( 134 ), with the control valve ( 170 ) in the second control valve position ( 174 ), with the pump drive ( 220 ) in the second pump drive position ( 224 ), with the second pump ( 260 ) in the second second pump position ( 264 ), and with the first pump ( 280 ) in the second first pump position ( 284 ).
[0192] The apparatus ( 10 ) is alternated between the first apparatus position and the second apparatus position by the combined operation of the pump drive ( 220 ) and a switch comprising the switch valve ( 130 ) and the control valve ( 170 ).
[0193] FIGS. 2-3 are based upon the exemplary configuration for the apparatus ( 10 ) in a wellbore ( 16 ), as depicted schematically in FIG. 1 .
[0194] As a result, in FIGS. 2-3 , the first pump outlet ( 84 ), the second pump inlet ( 86 ), and the gas outlet ( 88 ) communicate with the upper wellbore section ( 92 ), and the first pump inlet ( 312 ), the second pump outlet ( 314 ) and the gas inlet ( 100 ) communicate with the lower wellbore section ( 94 ).
[0195] Referring to FIGS. 2-3 , the lower wellbore gas phase enters the apparatus ( 10 ) at the gas inlet ( 100 ), The gas inlet ( 100 ) communicates with the axial conduit ( 407 ) and with the vent ( 110 ). If the lower wellbore gas pressure is above a threshold gas pressure, the vent valve ( 112 ) is open so that a vented portion of the lower wellbore gas phase is vented to the gas outlet ( 88 ) via the axial conduit ( 408 ), thereby bypassing the pump drive ( 220 ). If the lower wellbore gas pressure is below the threshold gas pressure, the vent valve ( 112 ) is closed so that the only path for the lower wellbore gas phase through the apparatus ( 10 ) is through the axial conduit ( 407 ).
[0196] The axial conduit ( 402 ) is associated with radial conduits ( 402 a , 402 b , 402 c ). The radial conduit ( 402 a ) provides communication between the axial conduit ( 402 ) and the first side ( 328 ) of the switch valve piston ( 142 ). The radial conduit ( 402 b ) provides communication between the axial conduit ( 402 ) and the first side ( 328 ) of the switch valve piston ( 146 ). The radial conduit ( 402 c ) provides communication between the axial conduit ( 402 ) and the control valve ( 170 ).
[0197] The axial conduit ( 405 ) is associated with radial conduits ( 405 a , 405 b , 405 c ). The radial conduit ( 405 a ) provides communication between the axial conduit ( 405 ) and the switch valve ( 130 ). The radial conduits ( 405 b ) provide communication between the axial conduit ( 405 ) and the first side ( 332 ) of the pump drive pistons ( 236 ). The radial conduit ( 405 c ) provides communication between the axial conduit ( 405 ) and the first side ( 334 ) of the second pump piston ( 268 ). As a result, it can be seen that in the exemplary embodiment, the second pump ( 260 ) is adapted to be driven both by the pump drive ( 220 ) and directly by the lower wellbore gas pressure of the lower wellbore gas phase being exerted on the first side ( 334 ) of the second pump piston ( 268 ).
[0198] The axial conduit ( 407 ) is associated with radial conduits ( 407 a , 407 b ). The radial conduits ( 407 a , 407 b ) both provide communication between the axial conduit ( 407 ) and the switch valve ( 130 ). The axial conduit ( 407 ) delivers the lower wellbore gas phase in parallel to the switch valve ( 130 ) via radial conduits ( 407 a , 407 b ) and to the control valve ( 170 ) via control line ( 330 ).
[0199] The axial conduit ( 407 ′) is associated with radial conduits ( 407 ′ a , 407 ′ b ). The radial conduit ( 407 ′ a ) provides communication between the axial conduit ( 407 ′) and the switch valve ( 130 ). The radial conduits ( 407 ′ b ) provide communication between the axial conduit ( 407 ′) and the second side ( 338 ) of the pump drive pistons ( 236 ).
[0200] The axial conduit ( 408 ) is associated with radial conduits ( 408 a , 408 b , 408 c , 408 d ). The radial conduits ( 408 a , 408 b ) provide communication between the axial conduit ( 408 ) and the switch valve ( 130 ). The radial conduits ( 408 c , 408 d ) provide communication between the axial conduit ( 408 ) and the control valve ( 170 ).
[0201] The axial conduit ( 411 ) is associated with radial conduits ( 411 a , 411 b , 411 c ). The radial conduit ( 411 a ) provides communication between the axial conduit ( 411 ) and the second side ( 344 ) of the first switch valve piston ( 142 ). The radial conduit ( 411 b ) provides communication between the axial conduit ( 411 ) and the second side ( 344 ) of the second switch valve piston ( 146 ). The radial conduit ( 411 c ) provides communication between the axial conduit ( 411 ) and the control valve ( 170 ).
[0202] Referring to FIG. 2 , in the first apparatus position:
(a) the radial conduit ( 407 a ) and the radial conduit ( 405 a ) are both aligned with the first switch valve port ( 152 ) so that the lower wellbore gas phase is delivered from the gas inlet ( 100 ) to the first side ( 332 ) of the pump drive pistons ( 236 ) and to the first side ( 334 ) of the second pump piston ( 268 ), thereby urging the pump drive pistons ( 236 ) toward the first pump drive position ( 222 ) and urging the second pump piston ( 268 ) toward the first second pump position ( 264 ); (b) the radial conduit ( 407 ′ a ) and the radial conduit ( 408 b ) are both aligned with the second switch valve port ( 154 ) so that the lower wellbore gas phase is delivered from the second side ( 338 ) of the pump drive pistons ( 236 ) to the gas outlet ( 88 ), thereby purging the second side ( 338 ) of the pump drive pistons ( 236 ) of the lower wellbore gas phase; (c) the radial conduit ( 408 c ) and the radial conduit ( 411 c ) are both aligned with the first control valve port ( 198 ) so that the lower wellbore gas phase is delivered from the second side ( 344 ) of the switch valve pistons ( 142 , 146 ) to the gas outlet ( 88 ), thereby purging the second side ( 344 ) of the switch valve pistons ( 142 , 146 ) of the lower wellbore gas phase; and (d) the control line ( 330 ) and the radial conduit ( 402 c ) are both aligned with the second control valve port ( 200 ) so that the lower wellbore gas phase is delivered from the gas inlet ( 100 ) to the first side ( 328 ) of the switch valve pistons ( 142 , 146 ), thereby urging the switch valve pistons ( 142 , 146 ) toward the first switch valve position ( 132 ).
[0207] Referring to FIG. 3 , in the second apparatus position:
(a) the radial conduit ( 405 a ) and the radial conduit ( 408 a ) are both aligned with the first switch valve port ( 152 ) so that the lower wellbore gas phase is delivered from the first side ( 332 ) of the pump drive pistons ( 236 ) and from the first side ( 334 ) of the second pump piston ( 268 ) to the gas outlet ( 88 ), thereby purging the first side ( 332 ) of the pump drive pistons ( 236 ) and the first side ( 334 ) of the second pump piston ( 268 ) of the lower wellbore gas phase; (b) the radial conduit ( 407 b ) and the radial conduit ( 407 ′ a ) are both aligned with the second switch valve port ( 154 ) so that the lower wellbore gas phase is delivered from the gas inlet ( 100 ) to the second side ( 338 ) of the pump drive pistons ( 236 ), thereby urging the pump drive pistons ( 236 ) toward the second pump drive position ( 224 ); (c) the control line ( 330 ) and the radial conduit ( 411 c ) are both aligned with the first control valve port ( 198 ) so that the lower wellbore gas phase is delivered from the gas inlet ( 100 ) to the second side ( 344 ) of the switch valve pistons ( 142 , 146 ), thereby urging the switch valve pistons ( 142 , 146 ) toward the second switch valve position ( 134 ); and (d) the radial conduit ( 408 d ) and the radial conduit ( 402 c ) are both aligned with the second control valve port ( 200 ) so that the lower wellbore gas phase is delivered from the second side ( 344 ) of the switch valve pistons ( 142 , 146 ) to the gas outlet ( 88 ), thereby purging the first side ( 328 ) of the switch valve pistons ( 142 , 146 ) of the lower wellbore gas phase.
[0212] Referring to FIG. 2 and FIG. 3 , it can be seen that the reciprocation of the pump drive pistons ( 236 ) is controlled by the switch valve ( 130 ), that the reciprocation of the switch valve pistons ( 142 , 146 ) is controlled by the control valve ( 170 ), and that the reciprocation of the control valve piston ( 186 ) is controlled by the pump drive ( 220 ).
[0213] More particularly, the reciprocation of the control valve piston ( 186 ) is caused by the reciprocation of the control valve shaft ( 188 ), which is connected with the control valve connector shaft ( 248 ), and by the resulting reciprocation between the control valve stops ( 194 , 196 ) of the control valve actuating members ( 190 , 192 ), which are connected with the control valve shaft ( 188 ). The reciprocation of the control valve connector shaft ( 248 ) is in turn caused by the reciprocation of the pump drive pistons ( 236 ).
[0214] The second pump piston ( 268 ) and the first pump piston ( 288 ) are both connected with the pump drive ( 220 ). As a result, reciprocation of the pump drive pistons ( 236 ) causes reciprocation of both the second pump piston ( 268 ) and the first pump piston ( 288 ).
[0215] The axial conduit ( 410 ) is associated with radial conduits ( 410 a , 410 b ). The radial conduit ( 410 a ) provides communication between the axial conduit ( 410 ) and the second pump inlet ( 86 ). The radial conduit ( 410 b ) provides communication between the axial conduit ( 410 ) and the second pump ( 260 ). The axial conduit ( 410 ) and the radial conduits ( 410 a , 410 b ) together provide the second pump inlet line ( 340 ).
[0216] In the exemplary embodiment, the second pump ( 260 ) is a single acting pump, so that only the second side ( 342 ) of the second pump piston ( 268 ) is used to pump fluids from the upper wellbore section ( 92 ) to the lower wellbore section ( 94 ). As a result, in the exemplary embodiment, the radial conduit ( 410 b ) more particularly provides communication between the axial conduit ( 410 ) and the second side ( 342 ) of the second pump piston ( 268 ).
[0217] In the exemplary embodiment, a second pump check valve ( 350 ) is provided in the axial conduit ( 410 ) on each side of the junction between the axial conduit ( 410 ) and the radial conduit ( 410 b ), to facilitate pumping by the second pump ( 260 ) from the upper wellbore section ( 92 ) into the lower wellbore section ( 94 ) as the second pump piston ( 268 ) reciprocates.
[0218] The axial conduit ( 406 ) is associated with radial conduits ( 406 a , 406 b ). The radial conduit ( 406 a ) provides communication between the axial conduit ( 410 ) and a pressure relief port ( 360 ) adjacent to the proximal end ( 12 ) of the apparatus ( 10 ). In the exemplary embodiment, a pressure relief device ( 362 ) is provided in the radial conduit ( 406 a ). In the exemplary embodiment, the pressure relief device ( 362 ) is comprised of a burst disc. The radial conduit ( 410 b ) provides communication between the axial conduit ( 410 ) and the axial conduits ( 412 , 414 ).
[0219] The axial conduit ( 412 ) is associated with radial conduits ( 412 a , 412 b ). The radial conduit ( 412 a ) provides communication between the axial conduit ( 412 ) and the first pump ( 280 ). The radial conduit ( 412 b ) provides communication between the axial conduit ( 412 ) and the first pump inlet ( 312 ).
[0220] The axial conduit ( 414 ) is associated with radial conduits ( 414 a , 414 b ). The radial conduit ( 414 a ) provides communication between the axial conduit ( 414 ) and the first pump ( 280 ). The radial conduit ( 414 b ) provides communication between the axial conduit ( 414 ) and the first pump inlet ( 312 ).
[0221] In the exemplary embodiment, the first pump ( 280 ) is a double acting pump, so that both sides ( 346 , 348 ) of the first pump piston ( 288 ) are used to pump fluids from the lower wellbore section ( 94 ). As a result, in the exemplary embodiment, the radial conduit ( 412 a ) more particularly provides communication between the axial conduit ( 412 ) and the first side ( 346 ) of the first pump piston ( 288 ), and the radial conduit ( 414 a ) more particularly provides communication between the axial conduit ( 414 ) and the second side ( 348 ) of the first pump piston ( 288 ).
[0222] In the exemplary embodiment, a first pump check valve ( 364 ) is provided in the axial conduits ( 412 , 414 ) on both sides of the junctions between the axial conduits ( 412 , 414 ) and the radial conduits ( 412 a , 414 a ) respectively, to facilitate pumping by the first pump ( 280 ) from the upper wellbore section ( 92 ) as the first pump piston ( 288 ) reciprocates.
[0223] In the exemplary embodiment, a first pump outlet check valve ( 366 ) is provided in the axial conduit ( 406 ) adjacent to the first pump outlet ( 84 ), for preventing fluids from passing from the upper wellbore section ( 92 ) through the axial conduit ( 406 ). In the exemplary embodiment, the junction between the axial conduit ( 406 ) and the radial conduit ( 406 a ) is between the first pump outlet ( 84 ) and the first pump outlet check valve ( 366 ) and the pressure relief device ( 362 ) is configured to pressure in the axial conduit ( 406 ) before damage due to over-pressurization is caused to the first pump outlet check valve ( 366 ).
[0224] The method of the invention may be performed using any suitable apparatus or combination of apparatus, including an apparatus ( 10 ) within the scope of the invention. In some applications, the method of the invention may be performed using the exemplary embodiment of the apparatus ( 10 ) of the invention, as described above.
[0225] An exemplary embodiment of the method of the invention using the exemplary embodiment of the apparatus ( 10 ) of the invention may be performed as follows, with reference to FIGS. 1-3 .
[0226] First, the apparatus ( 10 ) may be inserted in the wellbore ( 16 ). The apparatus ( 10 ) may be lowered into the wellbore ( 16 ) in any suitable manner, including on a pipe string, on coiled tubing, on a wireline, on a slickline, or on any other suitable running string and/or using any suitable running tool. In some applications, the apparatus ( 10 ) may be lowered into the wellbore ( 16 ) on jointed or coiled production tubing (not shown) and may remain attached to the production tubing during use of the apparatus ( 10 ).
[0227] Second, the wellbore ( 16 ) may be sealed by actuating the packer ( 90 ) as a sealing device to provide the upper wellbore section ( 92 ) and the lower wellbore section ( 94 ). The wellbore ( 16 ) may include a single producing interval or a plurality of producing intervals. If the wellbore ( 16 ) includes a single producing interval, the wellbore ( 16 ) is preferably sealed above the single producing interval. If the wellbore ( 16 ) includes a plurality of producing intervals, the wellbore ( 16 ) is preferably sealed above the highest (most proximal) producing interval if all producing intervals produce significant liquid, and is preferably sealed above the lowest (most distal) producing interval if the lowest producing interval produces gas and the upper producing intervals produce a low percentage of the total liquid production from the wellbore ( 16 ).
[0228] Third, the lower wellbore gas phase may be supplied to the pump drive ( 220 ) by allowing the lower wellbore gas phase to enter the apparatus ( 10 ) from the lower wellbore section ( 94 ) at the gas inlet ( 100 ). If the lower wellbore gas pressure is below a threshold gas pressure, all of the lower wellbore gas phase which enters the apparatus ( 10 ) at the gas inlet ( 100 ) will be available to power the pump drive. If the lower wellbore gas pressure is above the threshold gas pressure, a vented portion of the lower wellbore gas phase may be vented to the upper wellbore section ( 92 ) so that the vented portion of the lower wellbore gas phase bypasses the pump drive ( 220 ).
[0229] Fourth, the first pump ( 280 ) may be driven by the pump drive ( 220 ) to pump fluids from the lower wellbore section ( 94 ) and the second pump ( 260 ) may be driven by the pump drive ( 220 ) to pump fluids from the upper wellbore section ( 92 ) into the lower wellbore section.
[0230] Apparatus and methods within the scope of the invention may be suitable for use in many applications in which reservoir gas and reservoir gas pressure is available to power the pump drive. In many applications, no external power is required in order to power an apparatus within the scope of the invention, with the result that the invention may be used in remote locations with little or no surface equipment being required. The potential for little or no surface equipment can result in very little noise being present at the ground surface during use of the invention.
[0231] Apparatus and methods within the scope of the invention may also be suitable for use in a wide range of reservoir conditions and wellbore configurations. In many applications, little or no wellbore modification may be required to facilitate use of apparatus and methods within the scope of the invention.
[0232] Apparatus and methods within the scope of the invention may be particularly suited for use in gas wells and in high gas-to-oil ratio (GOR) oil wells, and/or wells which may experience issues relating to liquid loading.
[0233] Apparatus and methods within the scope of the invention may be used in vertical wellbores and/or in deviated wellbores. For best results in highly deviated wellbores (having deviation angles greater than ninety degrees), the sealing device is preferably positioned in the wellbore at a location which is above or proximal to the point where the wellbore first experiences a ninety degree deviation angle (i.e., a horizontal orientation).
[0234] Apparatus and methods within the scope of the invention may be used in wellbores having a wide range of liquid loading and/or liquid production rates, in wellbores having a wide range of reservoir gas volumes and/or gas production rates, and in wellbores having a wide range of reservoir gas pressures, by varying the design parameters of the apparatus.
[0235] Apparatus and methods within the scope of the invention which include the second pump ( 260 ) facilitate the pumping from the upper wellbore section ( 92 ) to the lower wellbore section ( 94 ) of various fluids, including liquid which accumulates in the upper wellbore section ( 92 ) during use of the apparatus, wellbore or reservoir treatment fluids, and/or fluids which may be used to initiate the operation of the apparatus in the event of stalling of the apparatus during use or in the event of insufficient lower wellbore gas pressure being available to overcome friction and inertia in order to initiate operation of the apparatus.
[0236] The practicality of pumping fluids from the upper wellbore section ( 92 ) to the lower wellbore section ( 94 ) with the second pump ( 260 ) can be enhanced by the inclusion of the first pump outlet check valve ( 366 ), the pressure relief port ( 360 ) and the pressure relief device ( 362 ), which can reduce the likelihood of damage to the first pump ( 280 ) or other components of the apparatus ( 10 ) if fluids are introduced into the upper wellbore section ( 92 ) under pressure to facilitate their passing through the second pump ( 260 ).
[0237] In this document, the word “comprising” is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the elements is present, unless the context clearly requires that there be one and only one of the elements.
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An apparatus including a sealing device for sealing a wellbore, a first pump for pumping fluids from a lower wellbore section, a pump drive powered using wellbore gas, a gas inlet for supplying the pump drive with wellbore gas, and a gas outlet for exhausting wellbore gas to an upper wellbore section from the pump drive. The apparatus may further include a second pump for pumping fluids from the upper wellbore section into the lower wellbore section, a vent for venting wellbore gas to the upper wellbore section, and a switch for controlling the pump drive. A method for moving fluids in a wellbore including sealing the wellbore, supplying wellbore gas to a pump drive and driving a first pump with the pump drive. The method may further include driving a second pump with the pump drive and venting the wellbore gas to an upper wellbore section.
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FIELD OF ART
[0001] The present disclosure generally relates to catheter devices and more particularly to catheter devices having securing mechanisms and related methods.
BACKGROUND
[0002] After successful catheterization of an indwelling catheter to a patient, the access site where the catheter tube enters the skin is secured to prevent the catheter from moving or inadvertently withdrawing from the vessel of the patient. To secure the catheter to the patient, a practitioner typically uses tape or other catheter stabilization devices. These catheter stabilization devices are usually separate products that come in their own packaging.
SUMMARY
[0003] The various embodiments of a catheter device having a securing mechanism have several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of the present embodiments as set forth in the claims that follow, their more prominent features now will be discussed briefly.
[0004] Aspects of the present disclosure include a catheter assembly with securing mechanisms which includes a catheter hub unit comprising a catheter hub, a catheter tube extending distally from the catheter hub, and two wings each extending laterally of the catheter hub, a needle hub unit comprising a needle hub and a needle extending distally from the catheter hub and projecting through the catheter tube in a ready position, an anchor sheet located on each of the wings, each anchor sheet comprising a top side facing away from a corresponding wing and a bottom side facing the corresponding wing in the ready position, an adhesive layer provided on the top side of each anchor sheet, and a release liner covering the adhesive layer on each anchor sheet in the ready position. Each anchor sheet can be pivotably connected to the corresponding wing.
[0005] Each anchor sheet can be pivotably connected to the corresponding wing in a different direction from each other.
[0006] Each wing can be shaped differently from the other wing. A recessed space can be formed in each wing, the recessed space being configured for securing the anchor sheet in the ready position.
[0007] A tab can extend from each anchor sheet, the tab being configured for pulling the anchor sheet from the recessed space.
[0008] A release liner tab can extend from the release liner.
[0009] Each anchor sheet can be pivotably connected to the respective wing by adhesive along a pivoting edge on the anchor sheet. The pivoting edge for each wing can differ in location from the other or be the same.
[0010] An anchor sheet can be provided on a bottom exterior surface of the catheter hub in addition to the anchor sheets on the wings.
[0011] Each anchor sheet can be pivotably connected to the respective wing by a living hinge.
[0012] The living hinge can be located at a proximal end of the wing.
[0013] The release liner can be attached to the needle hub unit, such that withdrawing the needle hub unit from the catheter hub unit rotates the anchor sheet and removes the release liner.
[0014] The anchor sheets can include a plurality of connected subsections folded upon each other in an accordion fashion to form folded anchor sheets.
[0015] The needle hub unit can further comprise a pair of tethers attached to a free end of the folded anchor sheets.
[0016] The folded anchor sheets can be stored in a storage space in the wing. The folded anchor sheets can be tucked under the wing. The folded anchor sheets can unfold to extend in a same first direction.
[0017] One of the two folded anchor sheets can unfold to extend in a distal direction with the adhesive facing down, and the other of the two anchor sheets can unfold to extend in a proximal direction with the adhesive facing down.
[0018] Because the anchor sheets are accessible once applied to a patient, they can easily be lifted and removed to facilitate removing the catheter hub from the patient. For example, the anchor sheets can be lifted directly using fingers or other means to remove the catheter hub from the patient. Anchor sheets that are not directly accessible, such as being located only on lower surfaces of the wings or the catheter hub, can be difficult to remove.
[0019] Another aspect of the present disclosure includes a method of manufacturing a catheter assembly which includes extending a catheter tube distally from a catheter hub, a left wing laterally from a left side of the catheter hub, and a right wing laterally from a right side of the catheter hub, extending a needle from a needle hub unit through the catheter tube in a ready position, pivotably connecting an anchor sheet to the left wing and another anchor sheet to the right wing, each anchor sheet comprising a top side facing away from a corresponding wing and a bottom side facing the corresponding wing in the ready position, the top side having an adhesive layer, and covering the adhesive layer on each anchor sheet with a release liner.
[0020] Each anchor sheet can be pivotably connected to the corresponding wing in a different direction from each other.
[0021] A recessed space can be formed in each wing, the recessed space securing the anchor sheet in the ready position.
[0022] The method can further include pulling the anchor sheet from the recessed space.
[0023] Each anchor sheet can be pivotably connected to the corresponding wing by a living hinge.
[0024] The living hinge can be located at a proximal end of the wing.
[0025] The method can further include withdrawing the needle hub from the catheter hub thereby rotating the anchor sheet and removing the release liner, wherein the release liner is attached to the needle hub.
[0026] The method can further include folding the anchor sheets into a plurality of connected subsections folded upon each other in an accordion fashion.
[0027] The method can further include unfolding the anchor sheets by pulling a free end of the folded anchor sheets with tethers attached to the needle hub.
[0028] The method can further include storing the anchor sheets in a storage space in the wing.
[0029] The method can further include tucking the folded anchor sheets under the wing.
[0030] The method can further include folding the anchor sheets over the wings towards a distal direction after unfolding the anchor sheets.
[0031] The method can further include unfolding the anchor sheets in different directions.
[0032] The method can further comprise providing direct access to the anchor sheets so that they can be gripped, such as by an instrument or by fingers.
[0033] The method can further comprise the step of applying the anchor sheets to a patient.
[0034] The method can further comprise the step of directly gripping the anchor sheets and lifting the anchor sheets away from the patient.
[0035] Each anchor sheet can be removed from the skin of the patient with or without tabs for easy removal of the catheter.
DESCRIPTION OF DRAWINGS
[0036] These and other features and advantages of the present device, system, and method will become appreciated as the same becomes better understood with reference to the specification, claims and appended drawings wherein:
[0037] FIG. 1 shows one embodiment of a catheter assembly, the catheter assembly including a catheter hub unit and a needle hub unit;
[0038] FIG. 2 shows the catheter assembly of FIG. 1 with release liners of the catheter hub unit being removed;
[0039] FIG. 3 shows the catheter assembly of FIG. 1 with anchor sheets of the catheter hub unit pivoted from the wings;
[0040] FIG. 4 shows another embodiment of a catheter assembly;
[0041] FIG. 5 shows an enlarged view of the circular portion 5 - 5 of FIG. 4 ;
[0042] FIGS. 6-9 show various stages of separating a needle hub unit from a catheter hub unit of yet another embodiment of a catheter assembly, the catheter hub unit including wings and anchor sheets attached to the wings, and the needle assembly tethered to the anchor sheets;
[0043] FIG. 10 shows one embodiment of wings of the catheter assembly of FIG. 6 ;
[0044] FIG. 11 shows another embodiment of wings of the catheter assembly of FIG. 6 ; and
[0045] FIG. 12 shows a front view of the catheter assembly of FIG. 11 .
DETAILED DESCRIPTION
[0046] The detailed description set forth below in connection with the appended drawings is intended as a description of the presently preferred embodiments of catheter assemblies for use in various applications provided in accordance with aspects of the present devices, systems, and methods and is not intended to represent the only forms in which the present devices, systems, and methods may be constructed or utilized. The description sets forth the features and the steps for constructing and using the embodiments of the present devices, systems, and methods in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and structures may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the present disclosure. As denoted elsewhere herein, like element numbers are intended to indicate like or similar elements or features.
[0047] FIG. 1 illustrates one embodiment of a catheter assembly 100 , which includes a catheter hub unit 101 and a needle hub unit (conventional and shown in FIG. 4 ). The catheter hub unit 101 includes a catheter hub 102 , a catheter tube 104 connected to a distal end of the catheter hub 102 , and a pair of wings 106 a, 106 b extending laterally from the catheter hub 102 . For example, a first or left wing 106 a extends from a left side of the catheter hub 102 , and a second or right wing 106 b extends from a right side of the catheter hub 102 .
[0048] A proximal end opening 44 of the catheter hub 102 may include a female Luer fitting (not shown) having a female Luer taper and/or female Luer lock threads. The female Luer fitting is thus configured to matingly receive a male Luer connector, such as used in connection with an IV line, a Luer access connector, a needle hub, a syringe tip, a vent plug, or another known or future-developed IV devices. Each of these components can be sized and configured in conformity with at least some of the International Standards Organization (ISO) standards for female and male Luer connections under current or future standards.
[0049] The catheter tube 104 is shown penetrated under the skin into the vein of a patient at an access site 108 . Typically, a needle tip of a needle extends through a hollow interior cavity of the catheter hub 102 from a distal end of the needle hub and out the distal opening of the catheter tube 104 , prior to insertion into the patient at the access site 108 . The needle tip can also extend through various components such as a valve, a valve actuator, and a needle guard, positioned in the hollow interior cavity of the catheter hub 102 , the examples of which can be found in U.S. Pat. No. 8,333,735, the contents of which are expressly incorporated herein by reference. The needle guard may also be located outside of the catheter hub as disclosed in U.S. Pat. No. 8,597,249, the contents of which are expressly incorporated herein by reference.
[0050] A distal portion of the catheter tube 140 can taper inwardly or the distal opening can have a size smaller than an outer diameter of the needle to form a seal around the opening of the catheter tube 103 with the needle to prevent fluid from entering the annular space between the catheter tube 102 and the needle when the needle tip pierces the skin of the patient. After verification of proper needle and catheter tube placement, retraction of the needle tip in a proximal direction will allow fluid or blood to flow into the annular space between the needle and the interior of the catheter tube 102 , known as secondary blood flashback. After the needle tip and distal end of the catheter tube 104 has penetrated and accessed the vein, the needle hub is then withdrawn from the catheter hub unit 101 to remove the needle from the catheter hub 102 . When incorporated, a needle guard will activate to cover the needle tip to prevent inadvertent needle stick.
[0051] In the example shown, an anchor sheet 110 is provided on each wing 106 a, 106 b. The anchor sheet 110 is configured to secure the catheter hub unit 101 to the patient and prevent the catheter hub unit 101 , including the catheter tube 104 , from shifting in and out, or around the access site 108 , where the catheter tube penetrates the skin. Each anchor sheet 110 has a top side and an opposed bottom side facing the respective wing 106 a, 106 b. The top side of each anchor sheet 110 is provided with an adhesive, such as a hypoallergenic adhesive or a pressure-sensitive adhesive, and a release liner 112 for covering the adhesive until use. In one embodiment, each anchor sheet 110 is securely attached to the respective wing 106 a, 106 b along a pivoting edge 116 . In another embodiment, each anchor sheet 110 is securely attached to the respective wing 106 a, 106 b along a pivoting edge 116 and wedged in a recessed space 124 defined by a perimeter lip 50 of the respective wing 106 a, 106 b to hold the anchor sheet 110 in place prior to use. The pivoting edge 116 of the two anchor sheets can be located at any edge of the wings 106 a, 106 b . In one embodiment, the location of the two pivoting edges 116 of the two anchor sheets 110 are reversed. For example, the pivoting edge 116 at the left wing 106 a is on the distal side 118 of the left wing 106 a while the pivoting edge 116 at the right wing 106 b is on the proximal side 120 of the right wing 106 b. In another embodiment, the location of the two pivoting edges 116 can also be located on the same side such as the distal side 118 or the proximal side 120 of the wings 106 a, 106 b. In yet another embodiment, the location of the two pivoting edges 116 are at the edges furthest away from the catheter hub 102 . The wings 106 a, 106 b can be symmetrically identical or different from each other. In the illustrated embodiment, the wings 106 a, 106 b are shaped such that the pivoting edge 116 is sufficiently long enough to adequately secure the catheter hub unit 101 to the patient and provide a minimum rotation or movement at the pivoting edge 116 . A tab 114 extends outwardly from each anchor sheet 110 to allow a user to pull the anchor sheet 110 , such as from the recessed space 124 of the respective wing 106 a, 106 b, or the surface of the respective wings 106 a, 106 b if no recessed space 124 is provided. In a particular example, each pivoting edge 116 comprises a band of permanently bonded anchor sheet layer, bonded to the surface of the respective wing 106 a, 106 b, with a folded line along or adjacent the band to form a fold for pivoting.
[0052] FIG. 2 shows the release liner 112 being removed from the top side of each anchor sheet 110 and the anchor sheet 110 lifted from the recessed space 124 of the respective wing 106 a , 106 b by pulling up on the tab 114 or by removal of the release liner 112 from a different gripping process or location of the release liner. A tab liner 115 , which may also be called a release liner tab, can extend from the release liner 112 to help separate the release liner 112 from the anchor sheet 110 . For example, if there is no adhesive on the tab 114 and the tab liner 115 overlaps the tab 114 of the anchor sheet, a user can easily grip the tab liner 115 to pull off the release liner 112 . No adhesive on the tab 114 also allows a user to easily remove the anchor sheet 110 from the patient when removing the catheter hub unit 101 from the patient, by gripping and pulling the anchor sheet 110 from the tab 114 . In another example, the anchor sheet 110 does not have a tab 114 and the anchor sheet 110 is lifted from the recessed space 124 of the respective wing 106 a, 106 b by pulling on the release liner tab 115 or gripping one of the edges of the anchor sheet.
[0053] FIG. 3 shows the two anchor sheets 110 rotated along the pivoting edge 116 so that the top side of each anchor sheet 110 , which is provided with adhesive, can be pressed against the skin of the patient to secure the catheter hub unit 101 and the catheter tube 104 to the access site 108 . After the release liner 112 is removed from the anchor sheet 110 to expose the adhesive on the top side of the respective anchor sheet 110 , the anchor sheet 110 is removably fixed to the skin of the patient by pressing against the bottom side 122 of the anchor sheet 110 to press the now exposed adhesive layer on the top side against the skin of the patient. In some examples, the recessed space 124 of each wing 106 a, 106 b may be provided with a testing device or instrument, such as a glucose strip, which is only exposed after the anchor sheets 110 are pivoted and bonded to the patient.
[0054] FIG. 4 shows another embodiment of a catheter assembly 200 which includes a catheter hub unit 201 and a needle hub unit 209 attached to a proximal end of the catheter hub unit 201 . The catheter hub unit 201 includes a catheter hub 202 , a catheter tube 203 extending distally from the catheter hub 202 , and a pair of wings 208 extending laterally from the catheter hub 202 . In the example shown, an anchor sheet 210 is provided with each wing 208 and each anchor sheet 210 has an adhesive layer or coat covered by a release liner 220 . The needle hub unit 209 shown includes a needle hub 204 attached to the proximal end of the catheter hub 202 , and a needle 205 extending distally from the needle hub 204 and through the catheter hub 202 and the catheter tube 203 . The catheter assembly 200 is similar to the catheter assembly 100 of FIG. 1 , except that the anchor sheet 210 is integrally formed with the wing 208 , as further discussed below.
[0055] With reference now to FIG. 5 , which is an enlarged view of one of the wings of FIG. 4 , the anchor sheet 210 is shown attached to the wing 208 along a hinge 212 . In the illustrated embodiment, the hinge 212 is located at a proximal side of the wing 208 . However, the location of the hinge 212 is not limited and can be located at any of the various sides of the wing 208 . In the example shown, the anchor sheet 210 is unitarily formed with the wing 208 and the hinge 212 is a living hinge. Thus, the anchor sheet 210 is made from the same thermoplastic material as the wing 208 . When in the ready to use position as shown in FIG. 4 , the anchor sheet 210 has a top side 214 facing away from the wing 208 and a bottom side 216 facing the wing 208 . To temporarily secure the anchor sheet 210 to the wing 208 in the ready to use position, detents or a weak adhesive can be used.
[0056] Hypoallergenic adhesive or pressure-sensitive adhesive may be provided on the top side 214 of each anchor sheet 210 and is protected by a release liner 220 . FIG. 5 shows the anchor sheet 210 pivoted away at the hinge 212 from the wing 208 with the release liner 220 in the process of being removed from the top side 214 of the anchor sheet 210 . In one embodiment, the two release liners 220 are secured to the needle hub 204 so that upon retraction of the needle hub unit 209 away from the catheter hub unit 201 following successful catheterization, the anchor sheets 210 are pulled by the retracting needle hub unit 209 and automatically rotated about the hinge 212 . Concurrently therewith, the release liners 220 are automatically removed from the anchor sheets 210 thereby exposing the adhesive for attaching to the patient. In another embodiment, the two release liners 220 are not attached to the needle hub unit 209 and can be removed from the anchor sheets 210 manually by the user. Once the release liner 220 is completely removed from the anchor sheet 210 , force is applied to the bottom side 216 , now rotated to face up with respect to the wing 208 as shown in FIG. 5 , to press the adhesive against the skin, thus securing the catheter hub 202 and the catheter tube 203 to secure the access site from unwanted or from excessive movement.
[0057] With reference now to FIG. 6 , yet another embodiment of a catheter assembly 300 is shown partially inserted into an access site 108 . The catheter assembly 300 includes a catheter hub unit 301 and a needle hub unit 309 attached to a proximal end of the catheter hub unit 301 . The catheter hub unit 301 includes a catheter hub 302 , a catheter tube 303 extending distally from the catheter hub 302 , and a pair of wings 306 a, 306 b extending laterally of the catheter hub 302 . An anchor sheet 310 a, 310 b ( FIG. 7A ) is provided with each corresponding wing 306 a , 306 b, and each has an adhesive layer or coat, as further discussed below. The needle hub unit 309 includes a needle hub 304 attached to the proximal end of the catheter hub 202 , and a needle 305 with a sharpened distal tip extending distally from the needle hub 304 and through the catheter hub 302 and the catheter tube 303 . The catheter assembly 300 is similar to the catheter assembly of FIG. 1 except that the anchor sheets 310 a, 310 b are folded upon each other in an accordion fashion, with or without a separate release liner. In the illustrated embodiment, a pair of tethers 308 a, 308 b are connected to the needle hub 304 and to the folded anchor sheets 310 a , 310 b, and the folded anchor sheets 310 a, 310 b have ends that are connected to the catheter hub 202 . In an alternative embodiment, the tethers 308 a, 308 b are omitted and the two folded anchors sheets 310 a, 310 b are to be activated or deployed when a user grips and manipulates them.
[0058] FIG. 7A shows the needle hub 304 retracted away from the catheter hub 302 , such as following successful catheterization. Referring also to FIG. 7B , the folded anchor sheets 310 a , 310 b each includes a plurality of connected subsections 311 stacked upon each other. The length and width of the connected subsections 311 can vary depending on the design. In addition, the shape of the connected subsections is not limited to square or rectangular, but can be any regular or irregular shape. In the process of retracting the needle hub unit 309 from the catheter hub unit 301 , such as following successful venipuncture, the tethers 308 a, 308 b, which are attached to the two folded anchors sheets 310 a, 310 b, pull the two folded anchor sheets 310 a, 310 b away from the two wings 306 a, 306 b. When pulled, the folded and connected subsections 311 of the anchor sheets 310 a, 310 b are unfolded and lengthen. Each unfolded anchor sheet 310 a, 310 b comprises a top side 312 and a bottom side 315 opposite the top side. The anchor sheets 310 a, 310 b are provided with hypoallergenic adhesive or pressure-sensitive adhesive on at least some portions or substantially all along the top side 312 . In one example, the adhesive is only on the top side 312 of every other connected subsection 311 , such that the adhesive will be protected by an adjacent subsection 311 without the adhesive, which acts as a release liner. In another example, the adhesive is on substantially the entire top side 312 of the anchor sheet 310 a, 310 b. In yet another example, a separate release liner is provided to cover the adhesive on the top side 312 of the anchor sheet 310 a, 310 b. The connected subsections 311 can be formed by simple folds, double folds, or various fold patterns from an elongated sheet with uniform or non-uniform outer edges to form a sufficiently compact configuration for storage under the wings in a ready to use position.
[0059] FIG. 8 shows the needle hub unit 309 completely separated from the catheter hub unit 301 . The two tethers 308 a, 308 b are separated from the two folded anchor sheets 310 a, 310 b . Perforations or weakened sections may be provided at attachment points between the tethers 308 a, 308 b and the anchor sheets 310 a, 310 b to facilitate separation. In one example, the tethers 308 a, 308 b are lightly attached to at least one connected subsection 311 of the anchor sheets 310 a, 310 b and detach from the anchor sheets 310 a, 310 b when the anchor sheets 310 a, 310 b are fully extended. In another example, if a separate release liner is provided, the release liner is also attached to the tethers 308 a, 308 b and removed from the anchor sheets 310 a, 310 b when the tethers 308 a, 308 b are separated from the two folded anchor sheets 310 a, 310 b.
[0060] Referring to FIG. 9 , the two folded anchor sheets 310 a, 310 b are folded over the two wings 306 a, 306 b with a plurality of straightened connected subsections 311 extending beyond the wings 306 a, 306 b. The bottom sides 314 of the anchor sheets 310 a, 310 b are pressed against the skin to adhere the anchor sheets 310 a, 310 b to the skin to secure the catheter hub 302 and the catheter tube 303 to the access site 108 . In some examples, surfaces on an underside 54 of the wings are also provided with adhesive to further secure the wings to the skin of the patient.
[0061] FIG. 10 shows one configuration for storing the folded anchor sheets 310 a, 310 b underneath the wings 306 a, 306 b. In the illustrated embodiment, the anchor sheets 310 a, 310 b are folded and attached to the exterior underside 54 of the wings in the ready to use position of FIG. 6 , which is the side that faces the patient when pressed against the patient. Each tether 308 a, 308 b (not shown) is attached to a respective free end of the anchor sheet 310 a, 310 b, or possibly even near the respective free end if not right at the free end.
[0062] FIG. 11 shows a second configuration for storing the folded anchor sheets 310 a, 310 b underneath the wings 306 a, 306 b. In the present embodiment, the anchor sheets 310 a, 310 b are folded and attached to a hollow space or a storage space 314 a, 314 b inside each respective wing 310 a, 310 b. FIG. 12 shows each wing 306 a, 306 b having the storage space 314 a, 314 b. The folded anchor sheets 310 a, 310 b are tucked away inside the storage space 314 a, 314 b in the ready to use position. The tethers 308 a, 308 b (not shown) attach to the free ends of the anchor sheets 310 a, 310 b. The location of the folded anchor sheets 310 a, 310 b is not limited and can be stored anywhere on the wing such as underneath the wings 306 a, 306 b as discussed above for FIGS. 6-12 or above the wings 306 a, 306 b. For example, the anchor sheets 310 a, 310 b can be folded and attached at a top of the wings in the ready to use position of FIG. 6 .
[0063] It is also understood that the top or bottom sides 312 , 315 of the anchor sheets 310 a, 310 b having the adhesive could be applied to the skin in any direction such as in a direction towards the access site 108 or away from the access site 108 , depending which of the top or bottom sides 312 , 315 the adhesive is located. Thus, both anchor sheets 310 a, 310 b can be applied to the skin of the patient in a direction toward the access site 108 , or away from the access site 108 . In another embodiment, the adhesive is applied to the bottom side 315 of one anchor sheet and to the top side of one anchor sheet, such that one anchor sheet 310 a is applied to the skin of the patient in one direction, and the other anchor sheet 310 b is applied to the skin of the patient in the other opposite direction.
[0064] Methods of making and of using the catheter assemblies with securing mechanisms and their components as discussed elsewhere herein are within the scope of the present invention.
[0065] Although limited embodiments of various catheter assemblies having a securing mechanism of the anchor sheets have been specifically described and illustrated herein, many modifications and variations will be apparent to those skilled in the art. For example, any over the catheter assemblies can benefit by using the securing mechanism disclosed herein to provide quicker attachment to the patient. Furthermore, it is understood and contemplated that features specifically discussed for one catheter assemblies with securing mechanisms may be adopted for inclusion with another catheter assembly provided the functions are compatible. Accordingly, it is to be understood that the catheter assemblies with securing mechanisms and their components constructed according to principles of the disclosed devices, systems, and methods may be embodied other than as specifically described herein. The disclosure is also defined in the following claims.
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Catheter securement devices are generally described for securing the catheter hub to the access site following successful catheterization. Examples of catheter assemblies with integrated securing mechanisms and related methods are disclosed. The integrated device provides convenience and easy to use access to securing devices that are integrated to the wings of the catheter assemblies.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to provisional application Ser. No. 60/227,561, “Continuous Cooking Apparatus and Method Employing Hydrostatic Pressure,” filed Aug. 23, 2000.
FIELD OF INVENTION
[0002] The present invention relates to the substantially continuous cooking of food products and, in particular, to cooking under hydrostatic pressure of a liquid for improving cooking temperatures and cooking times.
BACKGROUND OF THE INVENTION
[0003] Cooking of foods in a heated liquid typically requires the liquid within which the food is being cooked to combine with the food as well as provide a cooking temperature sufficient for completing the cooking process. By way of example, when cooking food products such as pasta, rice, legumes, or vegetables, large amounts of water are absorbed during the cooking process, with the weight of the cooked food generally increasing to 250% of the original dry weight for pasta, for instance. Further, it is known to cook food products within enclosed containers such as cans to provide for cooking under pressure developed within the can. However, the amount of liquid that can be absorbed by the food product is limited to that carried within the can. The cooked food contained within the can and the can are cooled, labeled, packaged, and prepared for delivery to a point of sale. However, while the cooking process may be enhanced by the pressure-style cooking within an enclosed can, it is not practical to remove the cooked food from the can for further preparation such as in a frozen entree. As a result, cooking within a can has typically only been used when no subsequent food preparation process is needed or desired.
[0004] Continuous cooking processes are known in the art. For example, Spiel et al. (U.S. Pat. No. 4,155,293 disclose cooking under atmospheric pressure in hot water to hydrate the food. Hickey (U.S. Pat. No. 3,614,924) teaches a conveyor and discharge chute for conveying a food product through a cooking bath comprising cooking fat. Williams (U.S. Pat. No. 4,582,047) discloses a high-humidity steam cooker including a continuously running conveyor for processing large volumes of food products passed through an energy-efficient steam cooker that preserves the product's humidity, flavor, and appearance with water temperatures disclosed at essentially atmospheric pressures. Mette (U.S. Pat. No. 4,787,300) teaches an apparatus for continuously cooking and dehydrating foodstuffs, the apparatus including a multizone installation for preheating, boiling, and recooling through which the foodstuffs are passed. Larsen (U.S. Pat. No. 5,493,956) discloses a tank apparatus having movable rollers for receiving a pasta strand and routing the strand around rollers, including floatable rollers, for passing the pasta strand through the water bath to an exit conveyor. Depending on the blanching time required, movable rollers are repositioned to a desired elevation within the tank for blanching or cooking the pasta as it is transported through the water within the tank. D'Alterio et al. (U.S. Pat. No. 4,752,491) disclose the cooking of pasta ribbons on a zigzag conveyor passing through water carried within a tank.
SUMMARY OF THE INVENTION
[0005] It is an object of the present invention to provide an apparatus and method for cooking a foodstuff in a fluid cooking medium.
[0006] It is also an object to provide such an apparatus and method for reducing cooking time.
[0007] It is an additional object to provide such an apparatus and method that achieve a substantially continuous cooking process.
[0008] It is a further object to provide such an apparatus that has a smaller footprint than known previously in the art.
[0009] It is another object to provide such an apparatus and method that permit the absorption of cooking medium into the foodstuff.
[0010] An additional object is to provide such an apparatus and method that requires less cooking medium.
[0011] A further object is to provide such an apparatus and method that reduces a production of waste fluid.
[0012] Another object is to provide such an apparatus and method that reduces an amount of added “makeup” cooking fluid and waste fluid.
[0013] It is yet an additional object is to provide such an apparatus and method that assist in reducing potential microbial contamination.
[0014] It is yet a further object to provide such an apparatus and method for improving a quality of the cooked foodstuff.
[0015] It is yet another object to provide an apparatus and method for sterilization.
[0016] These and other objects are achieved by the present invention, one aspect of which is a method for cooking food. The method comprises the steps of heating a liquid cooking medium in a cooking vessel. The vessel has an open top, a bottom, and a wall having a vertical height. The height is sufficient, and there is sufficient medium added, so as to attain a hydrostatic pressure in the cooking medium at a predetermined lower depth that is substantially greater than ambient atmospheric pressure.
[0017] The next step comprises downwardly conveying food to be cooked from an entry area at a surface of the cooking medium to the lower depth. The hydrostatic pressure thus facilitates a cooking of the food at a rate substantially greater than a rate at ambient pressure.
[0018] Another aspect of the present invention is for enhancing a food cooking process using increased hydrostatic pressure. The method comprises the steps of placing a predetermined quantity of food into a container and conveying the container on a pathway having a downward component through a heated cooking medium. The heated cooking medium has a sufficient depth so as to increase hydrostatic pressure along the column to at least about 1.25 atmospheres, that is, 0.25 atmospheres above ambient pressure at sea level. In order to obtain such a pressure level at sea level, for example, a pathway would comprise at least 4-5 feet downward.
[0019] Yet another aspect of the present invention is an apparatus for cooking food that comprises a cooking vessel as above. Means are also provided for heating the cooking medium and for downwardly conveying food to be cooked from an entry area along the predetermined level to the lower depth. As above, this is for permitting the hydrostatic pressure to facilitate cooking the food at a rate substantially greater than a rate at ambient pressure.
[0020] A further aspect of the present invention is a method for reducing wastewater output and makeup water usage by a cooking process for a food comprising a complex carbohydrate. This method comprises the steps of heating water in a cooking vessel as above and downwardly conveying the food to be cooked to the lower depth, also as above. This method further causes released complex carbohydrate from the cooking food to cause a lower viscosity increase than a viscosity increase at ambient pressure, thereby increasing a cooking effectiveness of the water and reducing a need for adding makeup water and disposing of wastewater. In addition, the more rapid cooking times of the present invention also decrease complex carbohydrate leaching from the food being cooked, again increasing cooking effectiveness and reducing a need for adding makeup water and wastewater disposal.
BRIEF DESCRIPTION OF DRAWING
[0021] Embodiments of the invention are described, by way of example, with reference to the accompanying drawings in which:
[0022] [0022]FIG. 1 is a partial cross-sectional side elevational view of a first embodiment of the present invention;
[0023] [0023]FIG. 2 is a partial cross-sectional end view of a cooking container portion of FIG. 1;
[0024] [0024]FIG. 3 is a partial top view of FIG. 1;
[0025] [0025]FIGS. 4A and 4B are partial side and end views of a food basket of FIG. 1;
[0026] [0026]FIG. 5 is a partial cross-sectional elevation view of a second embodiment of the present invention;
[0027] [0027]FIG. 6 is a partial cross-sectional elevation view of an alternate conveyor mechanism of the present invention for transferring cooked product to a cooling section;
[0028] [0028]FIG. 7 is a partial cross-sectional elevation view of a third embodiment of the present invention; and
[0029] [0029]FIG. 8 is a partial cross-sectional side elevational view of a fourth embodiment of the present invention.
[0030] [0030]FIG. 9 is a cross-sectional side elevational view of a fifth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] The present invention will now be described more fully with reference to FIGS. 1 - 9 . This invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided to convey a scope of the invention to those skilled in the art.
[0032] As illustrated with reference to FIGS. 1 - 4 B, one embodiment 10 of the apparatus of the present invention includes a cooking vessel 11 having a generally “U”-shaped cross section for holding a column of cooking medium, such as, but not intended to be limited to, water 12 . The cooking vessel 11 has two separate vertical columns 13 , 14 , each of which extends upwardly from and is in fluid communication with a common bottom leg 15 . The vessel 11 has a length 150 , a width 16 , and a vertical height 17 . Each column 13 , 14 also has an open top 18 , 19 and a substantially rectangular enclosing wall 20 (FIGS. 2 and 3). The height 17 is sufficient for holding the cooking liquid, such as water, 12 to a predetermined level 21 for attaining a hydrostatic pressure in the water 12 at a predetermined lower depth 22 in the vessel 11 . As stated above, the hydrostatic pressure is substantially greater than ambient atmospheric pressure, and is typically in a range of 1.25-2.0 atmospheres, that is, 0.25-1 atmosphere above the ambient pressure at sea level. The vertical height 17 , which in a preferred embodiment would comprise a range of approximately 8-30 feet at sea level, provides increased pressure with increasing water depth and thus an increased temperature at the bottom portion of the vessel 11 is possible resulting from the columns 13 , 14 of water 12 above the bottom leg 15 .
[0033] An entry area 23 is along a top sector 24 of the first vertical column 13 , and an exit area 25 is along a top sector 26 of the second vertical column 14 . The entry 23 and exit 25 areas are for the entry and exit of a conveyor for downwardly and upwardly conveying the food to be cooked to and from the lower depth 22 . The conveyor comprises in a preferred embodiment a pair of parallel sprocket chains 27 engageable at each of four corners by sprockets 28 - 31 , one of which 28 comprises the drive sprocket. The chains 27 form a continuous loop through the first column 13 , the bottom leg 15 , the second column 14 , and across the space between the columns 13 , 14 .
[0034] A plurality of containers 32 (FIGS. 4A and 4B) are affixed for free rotation in spaced relation from each other via a pivot 33 on each side attachable to the chains 27 . Each container 32 is adapted to hold a discrete quantity of the food 34 to be cooked therein. Each container 32 comprises a perforated metal basket in a preferred embodiment. The pivotability about pivot 33 permits that, when the chains 27 rotate about the closed loop, the containers 32 always remain substantially upright unless affected by a force in another direction, not unlike a Ferris wheel.
[0035] As shown in FIG. 1, food to be cooked 34 , such as, for example, pasta for blanching, is delivered to the apparatus 10 via a conveyor belt 35 that terminates at a location 36 above the conveyor. As a container 32 goes by the conveyor belt 35 at discrete intervals, a mechanism such as is known in the art is provided for coordinating an activation of the belt 35 when a container 32 is beneath the belt 35 , with gravity permitting the food 34 to drop from the belt 35 into a container 32 . The speed of sprocket rotation is preferably variable, for adjusting cooking time depending upon such factors as type of food to be cooked, cooking medium, and ambient altitude.
[0036] The water 12 is heated with a steam injector in fluid communication with an interior 37 of the vessel 11 along the vessel bottom leg 15 . The steam injector in this embodiment comprises a steam inlet 38 and a steam manifold 39 having a plurality of steam nozzles 40 . The steam manifold 39 is in fluid communication with the steam inlet 38 . This is not intended as a limitation, as other heating methods may well be envisioned by one of skill in the art, such as, but not intended to be limited to, electrical resistance-type heat production (see, for example, FIG. 7). It will also be obvious to one of skill in the art that the heating means need not necessarily be at the bottom leg 15 , and that they may be positioned anywhere along the water column, although at or adjacent the bottom leg 15 is believed to represent a preferred embodiment.
[0037] Means are also provided for cooling the cooked food 34 ′ and for transferring food 34 ′ from the containers 32 to the cooling system. As shown in FIGS. 4A and 4B, each container 32 also has on each side a second pivot 41 . As the container emerges from the exit area 25 and rounds the corner at sprocket 28 , the second pivot 41 is engaged by a lifting arm 42 , which tilts the container 32 to empty the cooked food 34 ′ into a chute 43 , which in turn leads via a serpentine pathway 44 to a cooling water bath 45 . Another conveyor belt 46 takes the cooled food 34 ″ out of the bath 45 and drops it onto an outbound conveyor 47 , which leads, for example, to a packaging area.
[0038] It may also be desired to pretreat the food 34 to be cooked with steam prior to entry into the vessel 11 , which is represented in FIG. 1 by nozzle 48 .
[0039] One feature of the present invention includes cooking of the food within free water as opposed to within closed containers such as the cans earlier described. For the present invention, cooking includes not only heating the food, but allowing it to absorb the free liquid to combine with the food being cooked and complete the cooking process as desired. As described, products such as pasta absorb large amounts of water during cooking, and typically such foods as pasta can increase in weight by approximately 250%.
[0040] As illustrated with reference to FIGS. 5 - 8 , alternate embodiments 10 ′, 10 ″, 10 ′″, 10 ″″ of the apparatus described are presented with reference to FIGS. 1 - 4 B, wherein like elements are indicated by the same reference numeral with the commensurate number of primes.
[0041] A second embodiment 10 ′ (FIG. 5) includes an arcuate-shaped bottom section 15 ′ for the vessel 11 ′ with the cooling bath 45 ′ delivering cooked food product 34 ′ that has settled to the bottom of the cooling bath 45 ′ to a water lock for discharging onto the discharge conveyor 47 ′.
[0042] In the embodiments of FIGS. 5 and 6, the food 34 , 34 ′ is carried on substantially flat carriers 32 ′, 32 ″ that are carried by a chain 27 ′, 27 ″ and disgorge the cooked food 34 ′ when the carrier 32 ′, 32 ″ is tilted upon proceeding toward the top of a unitary sprocket 28 ′ in the case of FIG. 5 and a first of a pair of sprockets 28 ″, 29 ″ in the case of FIG. 6.
[0043] Yet a further embodiment includes the cooling bath 45 ′, 45 ″, 45 ′″ carried at various locations (FIGS. 5 and 6) or integrally formed (FIG. 7) within a housing that includes the vessel 11 ′″ and the cooling bath 45 ′″. In the embodiment 45 ′″ of FIG. 7, three pairs of sprockets 28 ′″- 30 ′″ are required to maintain a level attitude of the carriers 32 ′″ through the water bath 45 ′″ after exiting the second column 14 ′″.
[0044] In an additional embodiment 10 ″″ (FIG. 8), the vessel comprises a unitary, substantially rectangular cooking vessel 11 ″″, the chains 27 ″″ and containers 32 ″″ traveling along the sides 13 ″″, 14 ″″ and bottom 15 ″″ for cooking, and disgorged in like manner to the first embodiment 10 , the movement of the output conveyor 47 ″″ in this case perpendicular to the plane of the drawing.
[0045] A fifth embodiment 10 (5) (FIG. 9) comprises a substantially rectangular cooking vessel 11 (5) comprising a unitary tower. A flexible carrying member such as a wire or chain 27 (5) carrying at least one container 32 (5) is affixed to a vertical transport means, which may comprise, for example, a mechanism such as a mechanical crank 30 (5) , not unlike a well and bucket arrangement, for lowering and raising the container 32 (5) to and from a cooking level adjacent the bottom 15 (5) of the vessel 11 (5) . In this embodiment 10 (5) the food to be cooked would be placed into the container 32 (5) , lowered to the vessel bottom 15 (5) , where it would remain for a time sufficient to achieve a desired cooking level, and then raised (shown as a dotted container 32 (5) ) to the vessel top 18 (5) , where the cooked food 34 ′ may then be post-treated as desired.
[0046] The apparatus herein described with reference to the attached drawings are directed for use in blanching and cooking foods such as pasta, rice, beans, meat, and vegetables in a cooking fluid, such as water or oil, and cooking and cooling such foods within cooling baths if desired. However, it will be appreciated by one skilled in the art that the hydrostatic cooking herein described by way of example for the present invention may include cooking other foods within other liquids or other mixtures without departing from the intent and teachings of the invention.
[0047] In operation, and by way of example with reference to cooking of pasta, with an approximately 15-foot-high container, there is approximately one-half an atmosphere increase in pressure that can be used to achieve cooking temperatures of 224° F., 12° F. above the normal boiling point of water. With such, pasta will cook in 30% less time. Depending on the shapes of the pasta, the reduction in cooking time will be from 10 to 7 minutes with no breakage of the pasta due to handling and minimal starch loss in the cooking water. If the container is increased in height to approximately 30 feet, the pressure increase is close to one atmosphere and results in temperatures of approximately 240° F. With such an increase in temperature, the cooking time for the pasta is reduced by 50% of the normal cooking time while including similar benefits. The apparatus of the present invention may additionally be used for noncooking applications such as a continuous autoclave for sterilization of items such as medical implements or for pasteurization of food that does not require cooking.
[0048] The present invention permits food products to be cooked at temperatures higher than normal boiling point temperatures (212° F.) by cooking under hydrostatic pressure higher than atmospheric pressure typically used for the continuous cooking and conveying of pasta. The food cooks faster, is more efficiently cooked, and in certain cases retains and/or enhances desirable properties of the food products that can be degraded by longer cooking times.
[0049] The present invention permits continuous cooking of food products in large quantities of free liquid such that the food is in direct contact with a cooking fluid bath rather than being enclosed in a vessel for pressure cooking, such as a can. Further, water can be added as desired/needed during the cooking process. The hydrostatic column of water generates sufficient pressure increases to enhance the cooking process while permitting the continuous processing of the food from an input side to an exit side which are at atmospheric pressure. No pressure locks or pressure vessels, as defined by ASTME Codes, are required.
[0050] As earlier described with reference to the attached drawings, the apparatus of the present invention conveys food through the cooking fluid in containers made of perforated metal or other porous material. Preferably the material in contact with cooking fluid comprises food-quality stainless steel, although this is not intended as a limitation. This provides gentle treatment of the food, which prevents damage to delicate food products. A conveying mechanism for the basket may be a bucket elevator mechanism, by way of example. The bucket may be enclosed, if desired, to prevent food from escaping, which top can be opened during the loading and unloading of the food product from the cooking cycle. The “U”-shaped design, herein described for a preferred embodiment, occupies a very small amount of floor space (footprint), which is desirable in a food plant that typically has available vertical space, but limited floor space. Again, as herein described, a cooling section can be placed within the “U”-shaped space.
[0051] Because of the decreased cooking time and higher temperatures achieved, a reduction in the starch leaching into the cooking water can be achieved, and the starch that does escape from the food is less viscous in the cooking water, making the cooking process more efficient. Suspended starches cause loss in weight and throughput of food product and cause significant cost for wastewater treatment of the processing water. Because of the “U”-shaped design herein described, the amount of water used for processing and cleaning is significantly reduced in comparison to conventional cookers and blanchers, which use vat-styled containers. The efficient cooking process, as well as the efficient use of floor space, are desirable features made available by embodiments of the present invention, and are believed to confer significant environmental benefit. Further, the increased pressure and temperature experienced by the food assist in a reduction of microbial contamination, thereby improving sanitization and sterilization of the food. Pretreatment with steam is also believed to confer a toughening of the product, so that an effect of starch in the cooking water is not as deleterious, nor is as much starch released by the cooking food. In addition, the increased pressure conferred by the present invention is useful in “locking in” beneficial food characteristics such as nutrients and flavor.
[0052] Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing description and drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed.
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A method for cooking food includes heating a liquid cooking medium in a cooking vessel having a “U”-shaped structure having a height is sufficient, with sufficient medium added, to attain a hydrostatic pressure at a predetermined lower depth that is substantially greater than ambient atmospheric pressure. The food is conveyed through the vessel, mostly cooking at the bottom, where the hydrostatic pressure facilitates a cooking of the food at a rate substantially greater than a rate at ambient pressure. A further aspect of the invention is a method for reducing wastewater output and makeup water usage when cooking a food containing a complex carbohydrate. This method causes released complex carbohydrate to cause a lower viscosity increase than at ambient pressure, thereby increasing a cooking effectiveness of the water and reducing a need for adding makeup water and disposing of wastewater.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a lens barrel, particularly to a lens barrel using a piezoelectric actuator for moving optical elements such as lens sets or reflecting mirrors constituting an optical system and particularly to the structure of the actuator.
2. Description of the Prior Art
A conventional zoom lens is constituted by lens sets exclusive for zooming and lens sets exclusive for focusing. However, in recent years a zoom lens referred to as "vari-focal optical system" in which the functions of lens sets are not classified such as exclusive for zooming or exclusive for focusing and lens sets for zooming are also used for focusing by which the zoom ratio can be increased and the closest photographing distance can be decreased, has been developed.
FIG. 24 illustrates a conventional zoom lens of the vari-focal optical system indicating a sectional view taken along the optical axis direction. In FIG. 24, numeral 101 designates an outer lens tube, numeral 102 designates a zoom ring that is rotatable on the outer lens tube 101 and numeral 103 designates an inner fixed tube that is fixed to the outer lens tube 101. A zoom cam ring 104 is fitted on the outer side of the inner fixed tube 103. An annular groove 104a is formed at the vicinity of an end of the zoom cam ring 104, the annular groove 104a is engaged with an annular protrusion 103a that is formed on the outer side of the inner fixed tube 103 and the zoom cam ring 104 is supported on the outer side of the inner fixed tube 103 rotatably and unmovably in the optical axis direction.
The zoom lens is constituted by four lens sets where a first lens set L1 is held by a lens holder 105, a second lens set L2 is held by a lens holder 106, a third lens set L3 is held by a lens holder 107 and a fourth lens set L4 is held by a lens holder 108, respectively.
A pin 104p is provided at the vicinity of an end of the zoom cam ring 104 and the pin 104p is engaged with the zoom ring 102 by which the rotational operation of the zoom ring 102 is transmitted to the zoom cam ring 104. A pin 105p provided at the lens holder 105 for the first lens set L1, is disposed at an intersection of a cam groove 104c of the zoom cam ring 104 and an axial groove 103b of the inner fixed tube 103, penetrates through the cam groove 104c of the zoom cam ring 104 and is engaged with the axial groove 103b of the inner fixed tube 103. Under this construction the rotation of the zoom cam ring 104 by the rotational operation of the zoom ring 102, moves the pin 105p along the axial groove 103b of the inner fixed tube 103 and moves the first lens set L1 held by the lens holder 105 in the optical axis direction.
A pin 107p is provided at the lens holder 107 of the third lens set L3, penetrates through an axial groove 103d of the inner fixed tube 103 and is engaged with a cam groove 104d of the zoom cam ring 104. Under this construction the rotation of the zoom cam ring 104, moves the pin 107p along the axial groove 103d of the inner fixed tube 103 and moves the third lens set L3 held by the lens holder 107.
Further, a zoom cam ring 109 is fitted on the outer side of the lens holder 107 for the third lens set L3. An annular protrusion 109a is formed at the vicinity of an end of the zoom cam ring 109, the annular protrusion 109a is engaged with an annular groove 107a that is formed on the outer side of the lens holder 107 and the zoom cam ring 109 is supported on the outer side of the lens holder 107 rotatably and movably in the optical axis direction together with the lens holder 107.
A pin 104q provided at the vicinity of an end of the zoom cam ring 104 is engaged with an axial groove 109b of the zoom cam ring 109 and the rotation of the zoom cam ring 104 is transmitted to the zoom cam ring 109 whereby the zoom cam ring 109 is rotated. A pin 108p is provided at the lens holder 108 for the fourth lens set L4, penetrates through an axial groove 107b of the lens holder 107 for the third lens set L3 and is engaged with a cam groove 109c of the zoom cam ring 109. Under this construction the rotation of the zoom cam ring 104 is transmitted to the zoom cam ring 109 via the pin 104q, the rotation of the zoom cam ring 109, linearly moves the pin 108p of the lens holder 108 for the fourth lens set L4 along the axial groove 107b of the lens holder 107 and moves the fourth lens set L4 with respect to the lens holder 107.
A mounting unit 110 for mounting the lens barrel to the camera body is formed and a coupler 111 for connecting the lens barrel to a drive mechanism that is arranged on the camera body side for driving the lens sets to an in-focus position based on the defocus value detected by a focus detecting device on the camera body side, are arranged at the right end of the outer lens tube 101. A pinion 111a of the coupler 111 is in mesh with a gear formed on the outer side of a helicoidal ring 112 having a helicoidal screw 112a on its inner face whereby the rotation of the coupler 111 rotates the helicoidal ring 112. Also, an end 113b of a manual operation ring 113 arranged on the inner side of the outer lens tube 101, is engaged with a pin 112b that is implanted on the helicoidal ring 112 whereby the helicoidal ring 112 can be rotated by rotating the manual operation ring 113.
A focus cam ring 114 is inserted onto the inner side of the inner fixed tube 103 and a helicoidal screw 114a is formed at an end thereof and the helicoidal screw 114a is in mesh with the helicoidal screw 112a of the helicoidal ring 112.
A pin 106p is provided at the lens holder 106 for the second lens set L2, penetrates through a cam groove 114p of the focus cam ring 114 and an axial groove 103e of the inner fixed tube 103 and is engaged with a cam groove 104e of the zoom cam ring 104.
According to the above-mentioned constitution, when the helicoidal ring 112 is rotated by rotating the coupler 111, the focus cam ring 114 that is connected to the helicoidal ring 112 via the helicoidal screws and the lens holder 106 that is connected to the focus cam ring 114 via the pin 106p, can be moved in the optical axis direction by which the second lens set L2 can be moved in the optical axis direction. The lens holder 106 that is connected to the zoom cam ring 104 via the pin 106p can be moved in the optical axis direction by which the second lens set L2 can be moved in the optical axis direction, also by the rotation of the zoom cam ring 104.
FIG. 25 is a sectional view of a conventional lens barrel of a reflecting telescopic lens capable of focusing automatically. In FIG. 25, numeral 201 designates a first lens, numeral 221 designates a primary mirror, notation 221a designates a reflecting face formed at the back face of the primary mirror 221, numeral 202 designates a secondary mirror, notation 202a designates a reflecting face formed at the back face of the secondary mirror 202, numeral 222 designates a second lens and numeral 223 designates a third lens. A focusing lens set 203 including the first lens 201 and the secondary mirror 202, is held by a helicoidal ring 204. A gear is installed at the outside of the optical axis to be in mesh with a pinion gear 212 of a reduction gear mechanism 207 that is connected to a AF coupler 208 receiving a driving force from the camera body side, not shown, for transmitting rotation via a focusing-driven ring 205 and a distance scale ring 206.
The reduction gear mechanism 207 is constituted by a coupler gear 210 installed on a drive shaft 209, an intermediate gear 211 and the pinion gear 212.
Bearings for the pinion gear 212 and the intermediate gear 211 are installed in a primary mirror holder 215 and a bearing portion receiving the distance scale ring 206 is also provided therein. Other bearings supporting axes of the pinion gear 212 and the intermediate gear 211 are provided at a gear base plate 213 by which they are fixed to the lens barrel.
The driving force from the camera body side is transmitted to the reduction gear mechanism 207 via the AF coupler 208, the drive shaft 209 and the coupler gear 210, rotates the helicoidal ring 204 via the focusing-driven ring 205 and moves the focusing lens set 203 in the optical axis direction whereby the focusing operation is conducted.
As has been explained, according to the zoom lens in the conventional vari-focal optical system or the reflecting telescopic lens of the automatic focusing system, the coupler for connecting the lens barrel to a motor that is driven by a defocus signal detected by the focus detecting device on the camera body side, is installed on the lens barrel side and the helicoidal ring is rotated by the rotation of the coupler by which predetermined lens sets are moved to the in-focus positions.
However, according to such a constitution, the rotational motion of the helicoidal ring is converted into a linear motion of the focus cam ring in the optical axis direction by the helicoidal screws and accordingly, the constitution is complicated which, as a result, gives rise to the inconvenience of an increase in the number of parts and an increase in weight etc. and improvement therefor has been requested.
Further, for example, with respect to a telescopic lens barrel of a reflecting type, in the case where an actuator is used for moving lens sets contributing to focusing such as a secondary mirror, for the purpose of the focusing, the actuator must be arranged in the vicinity of an optical path that is incident on or reflected by the lens sets due to structural restriction. Therefore, the optical path that is incident on or reflected by the lens sets may be blocked depending on the constitution of the actuator.
Furthermore, when an actuator that is arranged in a lens barrel is used for moving lens sets contributing to focusing, it is requested that a drive circuit for driving the actuator is arranged in the lens barrel without enlarging outer dimensions of the lens barrel.
Also, when an actuator that is arranged in a lens barrel is used for moving lens sets contributing to focusing, it is requested that a drive circuit for driving the actuator is arranged in the lens barrel and electric wiring for connecting the actuator to the drive circuit does not influence an optical path passing through the lens barrel.
SUMMARY OF THE INVENTION
It is a main object of the present invention to provide a lens barrel having an improved drive mechanism for an optical system.
It is another object of the present invention to provide a small-sized and light-weighted lens barrel having an optical system drive mechanism using a small-sized and light-weighted actuator.
It is another object of the present invention to provide a lens barrel having a novel optical system drive mechanism in which a linear driving actuator using a piezoelectric element and its drive circuit are arranged inside of the lens barrel whereby an optical system is driven.
The above-mentioned and other objects and novel characteristics of the present invention will be clarified by the following detailed explanation in reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view showing the constitution of a zoom lens barrel of a first embodiment according to the present invention;
FIG. 2 is a perspective view enlarging a drive mechanism of the lens barrel in FIG. 1;
FIG. 3 is a diagram showing an example of a waveform of drive pulses applied on a piezoelectric actuator;
FIG. 4 is a diagram explaining movement loci of lens sets constituting a zoom lens barrel;
FIG. 5 is a diagram explaining a relation among a focal length, an object distance and an amount of displacement which are set at a second lens set;
FIG. 6 is a diagram explaining a relation between a focus cam and a zoom cam of the second lens set;
FIG. 7 is an explanatory view of a position detector of a ferromagnetic thin-film magnetic resistance type position detector (MR sensor);
FIG. 8 illustrates the specific arrangement of a pole spacing of a magnetized rod and a magnetic resistance element constituting the MR sensor and its output signal;
FIG. 9 is a diagram explaining a signal processing circuit of the MR sensor;
FIG. 10 is a developing diagram of encoder patterns provided on a manual focus ring;
FIG. 11 is a circuit diagram of a logical processing circuit discriminating encoder output of the manual focus ring;
FIG. 12 illustrates diagrams explaining output waveforms from the logical processing circuit in FIG. 11;
FIG. 13 is a block diagram of a lens barrel control circuit;
FIG. 14 is a sectional view showing the constitution of a reflecting telescopic lens barrel according to a second embodiment;
FIG. 15 is a sectional view showing the constitution of a reflecting telescopic lens barrel according to a third embodiment;
FIG. 16 is a sectional view showing the constitution of a reflecting telescopic lens barrel according to a fourth embodiment;
FIG. 17 is a sectional view showing the constitution of a reflecting telescopic lens barrel according to a fifth embodiment;
FIG. 18 is a sectional view showing the constitution of a reflecting telescopic lens barrel according to a sixth embodiment;
FIG. 19 is a perspective view showing an exploded state of a piezoelectric actuator suitable for the second embodiment through the sixth embodiment;
FIG. 20 is a perspective view showing an integrated state of the piezoelectric actuator in FIG. 19;
FIG. 21 is a perspective view showing a modified example of the piezoelectric actuator in FIG. 20;
FIG. 22 is a perspective view showing another modified example of the piezoelectric actuator in FIG. 20;
FIG. 23 is a diagram explaining an optical path passing range in a lens corresponding to a photographic field of view of a camera;
FIG. 24 is a sectional view showing the constitution of a conventional zoom lens barrel; and
FIG. 25 is a sectional view showing the constitution of a conventional reflecting telescopic lens barrel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An explanation will be given of embodiments of the present invention as follows.
(1) General Construction
FIG. 1 and FIG. 2 show the zoom lens barrel based on the first embodiment of this invention, of which FIG. 1 is a cross-sectional view taken along the optical axis of the lens barrel, and FIG. 2 is a perspective view of the drive mechanism which is based on a piezoelectric actuator.
In FIG. 1, indicated by 1 is an outer lens tube, 2 is a zoom ring which is fitted rotatably around the outer lens tube 1, and 3 is an inner fixed tube which is fixed to the tube 1. A zoom cam ring 4 is fitted around the inner fixed tube 3. Formed at one end of the zoom cam ring 4 is an annular groove 4a, which engages with an annular protrusion 3a formed around the inner fixed tube 3 so that the zoom cam 4 is supported only rotatably around the inner fixed tube 3, and it is not moved in the optical axis direction.
The zoom lens consists of first through fourth lens sets L1, L2, L3 and L4, which are held by lens holders 5, 6, 7 and 8, respectively. Provided at one end of the zoom cam ring 4 is a pin 4p, which engages with the zoom ring 2, and the rotation of the zoom ring 2 is transmitted to the zoom cam ring 4. A pin 5p, which is provided on the holder 5 of the first lens set L1 by being located at the intersection of the cam groove 4c of the zoom cam ring 4 and the axial groove 3b of the inner fixed tube 3, runs through the zoom cam ring 4 and engages with the axial groove 3b of the inner fixed tube 3. Based on this arrangement, the turning zoom cam ring 4, which is driven by the operation of the zoom ring 2, moves the pin 5p along the axial groove 3b of the inner fixed tube 3, and the first lens set L1 held by the holder 5 is moved in the axial direction.
The holder 7 of the third lens set L3 has a pin 7p, which runs through a groove 13e of focus cam ring 13 (will be explained shortly), further runs through an axial groove 3d of the inner fixed tube 3, and engages with a cam groove 4d of the zoom cam ring 4. Based on this arrangement, the turning zoom cam ring 4 moves the pin 7p along the axial groove 3d of the inner fixed tube 3, and the third lens set L3 held by the holder 7 is moved in the axial direction.
A zoom cam ring 9 is fitted around the holder 7 of the third lens set L3. Formed at one end of the zoom cam ring 9 is an annular protrusion 9a, which engages with an annular groove 7a formed around the holder 7 so that the zoom cam ring 9 is supported rotatably around the holder 7 and movable together with the holder 7 in the axial direction.
A pin 4q, which is provided at one end of the zoom cam ring 4, runs through a slit 3s of the inner fixed tube 3 and engages with an axial groove 9b of the zoom cam ring 9, and consequently the rotation of the zoom cam ring 4 is transmitted to the zoom cam ring 9 to turn it. The holder 8 of the fourth lens set L4 has a pin 8b, which runs through an axial groove 7c of the holder 7 of L3 and engages with a cam groove 9c of the zoom cam ring 9.
Based on this arrangement, the rotation of the zoom cam ring 4 is transmitted to the zoom cam ring 9 through the pin 4q, and the rotation of the zoom cam ring 9 moves the pin 8p of the holder 8 of L4 along the axial groove 7c. Consequently, the fourth lens set L4 is moved in the axial direction with respect to the holder 7. The rotation of the zoom cam ring 4 also moves the third lens set L3 held by the holder 7 in the axial direction as mentioned previously.
A piezoelectric actuator 12, which drives the focus cam ring 13, is disposed at one end of the inner fixed tube 3. The arrangement of the piezoelectric actuator 12 will be explained with reference to FIG. 1 and FIG. 2. The inner fixed tube 3 has in it two support members 3f and 3g, which supports a drive shaft 12b movably in the axial direction. A piezoelectric element 12a has its one end glued to the end of the drive shaft 12b and another end glued to a flange 3h of the inner fixed tube 3. A variation of thickness of the piezoelectric element 12a cause the drive shaft 12b to have a displacement in the axial direction.
The focus cam ring 13 has the formation of a cutout portion 13g in its right-hand section, and a contactor 13a through which the drive shaft 12b runs is formed near the center of the cutout portion 13g as shown in FIG. 2. The contactor 13a has the formation of a cut 13b through which the drive shaft 12b is exposed, and a flat spring 13c is disposed to bridge the cut 13b over the drive shaft 12b. The drive shaft 12b and flat spring 13c are in press contact and the drive shaft 12b and contactor 13a are also in press contact so that these members are joined to each other based on the friction.
The piezoelectric element 12a is supplied with electric drive pulses having a moderate rising edge and a sharp falling edge as shown in FIG. 3, and a resulting increase of thickness causes the drive shaft 12b to have a displacement in the axial direction. Consequently, the focus cam ring 13 which is joined by friction at the contactor 13a to the drive shaft 12b, is moved in the axial direction as shown by the arrow mark a. The focus cam ring 13 is moved in the opposite direction when drive pulses having a sharp rising edge and a moderate falling edge are supplied to the piezoelectric element 12a.
The holder 6 of the second lens set L2 has a pin 6p, which runs through a cam groove 13d of the focus cam ring 13, further runs through an axial groove 3j of the inner fixed tube 3, and engages with a cam groove 4j of the zoom cam ring 4.
The piezoelectric actuator 12 is activated in response to the defocus value detected by the focus detecting device on the part of the camera body or the operation value of the manual focus ring 14 to move the focus cam ring 13 in the axial direction. Consequently the pin 6p, which runs through the cam groove 13d of the focus cam ring 13, moves the lens holder 6 in the axial direction, causing the second lens set L2 to move in the axial direction by a distance corresponding to the detected defocus value, and it is brought to the infocus position.
The lens holder 6, which is linked to the zoom cam ring 4 by the pin 6p, also moves in the axial direction, and the second lens set L2 can be moved in the axial direction also by the rotation of the zoom cam ring 4 in response to the zooming operation.
The zoom lens barrel based on this embodiment will further be explained in the following.
(2) Adjustment of Focusing
FIG. 4 shows the loci of movement of the first through fourth lens sets L1-L4 during the zooming operation. Each lens set moves in response to the variation of the setup focal length f from the wide-angle extreme f1 to the telephoto extreme f2 as shown.
The adjustment of focusing is achieved by varying the amount of displacement of second lens set L2 in nonlinear fashion during the zooming operation in accordance with the focal length f and the object distance D that are set for the lens.
FIG. 5 shows the relationship among the setup focal length f and object distance D and the displacement d of the second lens set L2. The closer the object distance to the closest setup position and the closer the setup focal length f to the telephoto position, the greater is the displacement d. Specifically, with the object distance being at the closest position (D=Da), when the focal length f is set to the wide-angle extreme f1, the displacement d is equal to d1, or when the f is set to the telephoto extreme f2, the displacement d is equal to d2.
The shape of the cam groove 4j of the zoom cam ring 4 and the shape of the cam groove 13d of the focus cam ring 13 which move the second lens set L2, and the movement of the pin 6p which is located at the intersection of the grooves 4j and 13d will be explained in connection with the developing diagram of FIG. 6.
In FIG. 6, the solid line shows the position 4j-1 of the cam groove 4j of the zoom cam ring 4 and the position 13d-1 of the cam groove 13d of the focus cam ring 13 when focal length f is set to the wide-angle extreme f1 and the object distance D is set to the infinity position (D=∞). The dash-dot line shows the position 4j-2 of the cam groove 4j of the zoom cam ring 4 and the position 13d-2 of the cam groove 13d of the focus cam ring 13 when focal length f is set to the telephoto extreme f2 and the object distance D is set to the closest position (D=Da).
Namely, in the zooming operation, with the object distance D being set to the infinity position (D=∞) and the focal length f being set to the wide-angle extreme f1, the operation of the zoom cam ring 4 toward the telephoto position causes the cam groove 4j of the zoom cam ring 4 to move from position 4j-1 to position 4j-2 (rightward in FIG. 6). The focus cam ring 13 does not move at this time, and the pin 6p moves from position 6p-1 to position 6p-2 to implement the zooming.
In the focusing operation, with the focal length f being set to the wide-angle extreme f1 and the object distance D being set to the infinity position (D=∞), the operation of the focus cam ring 13 toward the closer distance causes the cam groove 13d of the focus cam ring 13 to move from position 13d-1 to position 13d-2 (upward in FIG. 6). The focus cam ring 4 does not move at this time, and the pin 6p moves from position 6p-1 to position 6p-3 (displacement d=d1) to implement the intended focusing.
With the focal length f being set to the telephoto extreme f2 and the object distance D being set to the infinity position (D=∞), the operation of the focus cam ring 13 toward the closer distance causes the cam groove 13d of the focus cam ring 13 to move from position 13d-1 to position 13d-2 (upward in FIG. 6). The zoom cam ring 4 does not move at this time, and the pin 6p moves from position 6p-2 to position 6p-4 (displacement d=d2) to implement the intended focusing.
Although the amount of movement of the focus cam ring 13 from the infinity position (D=∞) to the closest position (D=Da) is constant, the amount of displacement of the pin 6p, i.e., the second lens set L2, is d=d1 for the focal length f set to the wide-angle extreme, or it is d=d2 for the f set to the telephoto extreme f2, and accordingly the amount of displacement of the second lens set L2 is modified depending on the object distance.
For example, with the object distance D being set to the closest position (D=Da), when the zoom cam ring 4 is turned from the wide-angle extreme f1 to the telephoto extreme f2, the pin 6p moves from position 6p-3 to 6p-4 to provide a displacement of d=d2 for the second lens set L2, and consequently the infocus condition is not disturbed by the zooming operation.
As described above, the inventive zoom lens, although it is based on the vari-focal optical system, implements the focus modification by operating on the focus cam to move the focus-related lens sets during the zooming operation, and therefore it can be used in completely the same manner as usual zoom lenses.
The focus modification function of the inventive zoom lens, which has been explained for the cases of the focal length f set to the wide-angle extreme f1 or telephoto extreme f2 and the object distance D set to the infinity or closest position Da, is equally applied to the modification of displacement of the second lens set L2 when the f and D are set to intermediate values.
(3) Detection of lens position with MR sensor
For the detection of position of the second lens set L2 which is moved during the focusing operation, a position detector based on the ferromagnetic thin-film magnetic resistance (which will be termed "MR sensor" hereinafter) is attached on the focus cam ring 13 and a magnetized rod 22 having N and S poles at a certain spacing is attached on the inner fixed tube 3.
The MR sensor is a non-contact position detector used for the measurement of a relatively long traveling distance or the position of an object, and it consists of a magnetized rod 22 and a magnetic resistance element 21. The principle of the MR sensor will be explained with reference to FIG. 7.
Over a magnetized rod 22 having N and S poles aligned at a certain spacing along the measuring direction, a magnetic resistance element 21 is disposed such that the axis of current is at right angles with the magnetic pole alignment and the element face is in parallel and close to the surface of the magnetized rod. The leakage magnetic flux emerging between each pair of magnetic poles acts on the magnetic resistance element 21, which then exhibits the magnetic resistance effect as follows.
When the magnetic resistance element 21 is located between two poles of the magnetized rod 22, its resistance value decreases due to the magnetic resistance effect attributable to the horizontal component of the leakage magnetic flux, whereas when it is located right above a pole, the resistance value is the same as the case of no magnetic field because of the absence of horizontal component of the leakage magnetic flux over the magnetic pole. The relative movement between the magnetic resistance element 21 and magnetized rod 22 creates a periodic variation of resistance of the magnetic resistance element 21, and accordingly the distance of movement and thus the position of the element 21 can be known by counting resistance variation cycles.
FIG. 8 explains the positional relation between the magnetic resistance element 21 and magnetic poles of the magnetized rod 22, and the output signals. Magnetic poles N and S of the magnetized rod 22 have a constant spacing λ as shown by (a) and (b) of FIG. 8, and the resolution of measurement is determined from the dimension of spacing λ between adjacent N and S poles.
The magnetic resistance element 21 is made up of an a-group element pair MRa1 and MRa2 spaced out by λ/2 and a b-group element pair MRb1 and MRb2 spaced out by λ/2, with these element pairs being phased spatially by d (d=λ/4) as shown by (c) of FIG. 8.
The a-group element pair MRa1 and MRa2 and b-group element pair MRb1 and MRb2 produce output signals Va and Vb which are out of phase by d as shown by (d) of FIG. 8. By processing these signals to discriminate the phase relationship with a signal processing circuit as shown in FIG. 9 for example, the moving direction can be known.
The output signals Va and Vb are shaped into pulse signals as shown by (e) and (f) of FIG. 8, and then merged into a pulse train having a pitch of λ/4 as shown by (g) of FIG. 8, and by counting the pulses, the distance of movement can be measured at a resolution of a quarter of the pole spacing λ.
(4) Manual focusing mechanism
This zoom lens barrel employs a power-assisted focusing mechanism in which the rotational angle of the manual focus ring 14 (shown in FIG. 1) is detected electrically also in the manual focusing operation and the piezoelectric actuator 12 is energized to move the focus cam ring 13 in the axial direction.
Specifically, for the detection of rotational angle of the manual focus ring 14, a pattern encoder 14a is attached on the outer lens tube 1 and a brush 14b in contact with the encoder 14a (hatched pattern is conductive part) is attached on the ring 14. The use of a pattern encoder as shown in FIG. 10, for example, enables the detection of rotational angle in the form of a 4-bit pulse signal. The produced 4-bit pulse signal is processed by a logical processing circuit shown in FIG. 11, and the circuit yields signals indicative of the rotational direction and rotational angle of the manual focus ring.
FIG. 12 shows the signal waveforms resulting from the process by the logical processing circuit of FIG. 11. The signals include the output signals A1, B1, A2 and B2 of the four brushes 14b that are in contact with the pattern encoder, the output signals A1, B1, A2 and B2 of the inverter gate IV, the output signals A, A, B and B of the chattering preventive circuit CH consisting of two flip-flops, the output signals X and Y of the logic circuit consisting of AND gates, OR gates and a flip-flop, and the output signals CW and INT indicative of the rotational direction and rotational angle of each of clockwise rotation (CW) and counterclockwise rotation (CCW).
(5) Lens barrel control circuit and control operation
FIG. 13 is a block diagram of the lens barrel control circuit. The circuit includes a controller 51 formed of a CPU device, an MR sensor amplifier 52, a pulse signal converter 53 which shapes the output signal of the amplifier, an A/D converter 54, a manual focus ring detector 56 and a pulse signal discriminator 55 which processes the output signal of the detector 56, all connected to the input ports of the controller 51, and a piezoelectric actuator driver 57 connected to the output port of the controller 51. An AF/MF switch 61 for selecting the auto-focus or manual focus mode and a focal point detection circuit 62, both included on the part of the camera body (not shown), are also connected to the input ports of the controller 51.
Next, the operation of the control circuit for focusing the zoom lens to a photographic object will be explained with reference to FIG. 13, FIG. 1. and FIG. 2.
Initially, the controller 51 receives the signal from the AF/MF switch 61 on the camera body, and detects that the switch is set to the AF position for auto-focusing, for example. The controller 51 also receives the defocus signal for the object sent from the focal point detecting circuit 62 in the camera body.
The controller 51 discriminates the defocus signal, and upon detecting that the lens set L2, i.e., the focus cam ring 13, needs to be moved forward (indicated by the arrow mark "a" in FIG. 1), it operates on the piezoelectric actuator driver 57 to generate drive pulses having a moderate rising edge and a sharp falling edge as shown in FIG. 3 thereby to energize the piezoelectric element 12a.
The piezoelectric element 12a extends moderately in its thickness direction during the period of the moderate rising edge of the drive pulse, causing the drive shaft 12b to move forward as shown by the arrow mark "a" in FIG. 2. Consequently, the focus cam ring 13, which is in friction-fitting on the drive shaft 12b by means of the contactor 13a, moves in the direction "a" to move the lens set L2 forward.
The piezoelectric element 12a contracts quickly in its thickness direction during the period of the sharp falling edge of the drive pulse, causing the drive shaft 12b to move backward. In this case, the focus cam ring 13 has the inertia that is large enough to defeat the frictional force on the drive shaft 12b and it is virtually stationary at its position, and the focus cam ring 13 does not move. The expression of the "virtually stationary" focus cam ring 13 mentioned here disregards a momentary slip movement between the contactor 13a and drive shaft 12b in both directions, and the focus cam ring 13 is moved forward throughout the period of drive pulse application to the piezoelectric element 12a.
The focus cam ring 13 is moved backward by the the application of drive pulses having a sharp rising edge and a moderate falling edge to the piezoelectric element 12a.
As the focus cam ring 13 moves, the magnetic resistance element 21 of the MR sensor attached on the focus cam ring 13 is sensitive to the magnetic poles of the magnetic rod 22 attached on the inner fixed tube 3. The detected signals are amplified by the MR sensor amplifier 52, converted into pulse signals by the pulse signal converter 53, and fed to the controller 51. The amplified signals are also delivered to the A/D converter 54, by which the signals are converted into digital data and fed to the controllers 51. The controller 51 implements the calculation of interpolation for the digital data to evaluate the cam position between adjacent magnetic poles, thereby determining the position of the focus cam ring 13 precisely over the entire moving range.
The focus detecting circuit 62 in the camera body detects the in-focus state and sends a signal to the controller 51. In response to the signal, the controller 51 operates on the piezoelectric actuator driver 57 to cease the output of drive pulses, and the focus cam ring 13 stops.
Next, the control operation when the AF/MF switch 61 on the camera body is set to the MF position for manual focusing will be explained. When the manual focus ring 14 is operated, the rotation is detected by the manual focus ring detector 56 made up of the pattern encoder 14a and brush 14b. The resulting pulse signals are processed by the pulse signal discriminator 55, which then produces the signals CW and INT indicative of the direction of operation and the amount of operation of the manual focus ring 14.
Based on these signals, the controller 51 operates on the piezoelectric actuator driver 57 to generate drive pulses having a moderate rising edge and a sharp falling edge, or drive pulses having a sharp rising edge and a moderate falling edge, thereby energizing the piezoelectric actuator.
(6) General construction of a reflecting telescopic lens barrel
Next, an explanation will be given of a reflecting telescopic lens barrel of an automatic focusing type using a piezoelectric actuator in accordance with the present invention.
FIG. 14 is a sectional view taken along the optical axis of a reflecting telescopic lens barrel of a second embodiment according to the present invention in which numeral 71 designates a fixed tube, numeral 72 designates a first lens and numeral 73 designates a first lens holder holding the first lens, which is fixed to the fixed tube 71. Numeral 74 designates a primary mirror having a primary mirror reflecting face 74a (constituting a concave mirror) for reflecting light from an object that is incident on the primary mirror after passing through the first lens 72. Numeral 75 designates a primary mirror holder for holding the primary mirror 74 and a rear extended portion thereof, is fixed to the fixed tube 71 and also to a lens mounting unit 76.
Numeral 81 designates a secondary mirror having a secondary mirror reflecting face 81a (constituting a convex mirror) for reflecting light from object that is reflected from the main mirror 74, which is held by a secondary mirror holder 84. The secondary mirror holder 84 is driven by a piezoelectric actuator, mentioned later, where focusing (in-focus operation) is performed.
Numeral 77 designates a second lens, numeral 78 designates a third lens arranged on the image plane side, numeral 95 designates a drive circuit driving the piezoelectric element 82a and numeral 96 designates an electric wiring between the piezoelectric element 82a and the drive circuit 95.
Numeral 82 designates a piezoelectric actuator moving the secondary mirror holder 84 of which construction and operation are similar to those explained in FIG. 1 and FIG. 2. In FIG. 14, notation 82a designates a piezoelectric element, notation 82b designates a drive shaft, notation 82c designates a frame and notation 83a designates a moving member to which the secondary mirror holder 84 is fixed by pertinent means, not shown. The frame 82c is fixed to a supporting member 79 provided at the back side of the first lens 72 by pertinent means. An explanation will be given later of a detailed structure of the piezoelectric actuator.
FIG. 15 is a sectional view of a third embodiment of the present invention that is taken along the optical axis of a reflecting telescopic lens barrel. The difference thereof from the second embodiment resides in that the direction of the piezoelectric actuator 82 for moving the secondary mirror 81 is reversed and the piezoelectric element 82a is arranged on the side of the first lens 72. The structure of the piezoelectric actuator 82 and the structure of the lens barrel are not different from those in the second embodiment and accordingly, the same portions are attached with the same notations and their explanation will be omitted.
FIG. 16 is a sectional view of a fourth embodiment of the present invention that is taken along the optical axis of a reflecting telescopic lens barrel. The difference thereof from the second embodiment resides in that the central portion of the first lens 72 is hollowed-out and the secondary mirror 81 and the piezoelectric actuator 82 for moving the secondary mirror 81 are arranged at the central portion of the hollowed-out first lens 72. The structure of the piezoelectric actuator 82 and the structure of the lens barrel are not different from those in the second embodiment and accordingly, the same portions are attached with the same notations and their explanation will be omitted.
FIG. 17 is a sectional view of a fifth embodiment of the present invention that is taken along the optical axis of a reflecting telescopic lens barrel. The difference thereof from the second embodiment resides in that the focusing (in-focus operation) is conducted by driving a lens holder 85 of the third lens 78 that is arranged on the image plane side by the piezoelectric actuator 82. The frame 82c of the piezoelectric actuator 82 is fixed to the main mirror holder 75. The secondary mirror 81 is fixed to the supporting member 79 provided at the back side of the first lens 72. The structure of the piezoelectric actuator 82 and the structure of the lens barrel except the above-mentioned are not different from those in the second embodiment and accordingly, the same portions are attached with the same notations and their explanation will be omitted.
FIG. 18 is a sectional view of a sixth embodiment of the present invention that is taken along the optical axis of a reflecting telescopic lens barrel. The difference thereof from the second embodiment resides in that the focusing (in-focus operation) is conducted by driving the first lens 72 on the object side and the secondary mirror 81 that is fixed to the supporting member 79 provided at the back side of the first lens 72 by means of the piezoelectric actuator 82.
The frame 82c of the piezoelectric actuator 82 is fixed to an extended portion 75a of the main mirror holder 75 that is extended along the optical axis direction and the lens holder 73 of the first lens 72 is fixed to an extended portion of the moving member 83a of the piezoelectric actuator 82. The structure of the piezoelectric actuator 82 and the structure of the lens barrel except the above-mentioned are not different from those in the second embodiment and accordingly, the same portions are attached with the same notations and their explanation will be omitted.
An explanation will be given of a detailed structure of the piezoelectric actuator that is suitable for the reflecting telescopic lens barrels in the second embodiment through the sixth embodiment in reference to FIG. 19 and FIG. 20 through FIG. 22.
FIG. 19 is a perspective view showing an exploded state of the piezoelectric actuator 82. In FIG. 19 the frame 82c is provided with supporting members 82f, 82g and 82h and the drive shaft 82b is supported by the supporting members 82f and 82g movably in the axial direction. An end of the piezoelectric element 82a is fixedly adhered to an end of the drive shaft 82b via a member 82d, the other end of the piezoelectric element 82a is fixedly adhered to a member 82e and the member 82e is fixed to the supporting member 82h by small screws 82j.
The moving member 83a is provided with left and right rise portions 83g and a contact portion 83h of which central section has a semicircular groove and the drive shaft 82b penetrates the rise portions 83g and the lower half of the drive shaft 82b is brought into contact with the semicircular groove of the contact portion 83h. Further, a pad 83b is arranged on the upper side of the contact portion 83h and is brought into contact with the upper half of the drive shaft 82b. An elastic member 83c which is fixed to the moving member 83a by small screws 83d is arranged above the pad 83b, the pad 83b is pressed to contact the drive shaft 82b by an urging force of the elastic member 83c whereby the drive shaft 82b, the moving member 83a and the pad 83b are brought into contact by generating a pertinent frictional force among them.
In the cases of the second embodiment as illustrated in FIG. 14, the third embodiment as illustrated in FIG. 15 and the fourth embodiment as illustrated in FIG. 16, the secondary mirror holder 84 is fixed to the moving member 83a by the small screws 83d for fixing the elastic member 83c or by pertinent means, not shown. Further, in the case of the fifth embodiment as illustrated in FIG. 17, the third lens holder 85 is fixed to the moving member 83a by the small screws 83d for fixing the elastic member 83c or pertinent means, not shown.
Also, a magnetic resistance element 91 of a MR sensor for detecting the position of the moving member 83a is fixed to the back face of the moving member 83a, a magnetizing rod 92 is fixed to the frame 82c of the actuator whereby the position of the secondary mirror or the lens is detected by the MR sensor constituted by the magnetic resistance element 91 and the magnetizing rod 92.
FIG. 20 through FIG. 22 are perspective views showing outlook of integrated state of actuators illustrated in FIG. 19 where more or less modification is applied to the shape of the supporting member 82f on the frame 82c.
With respect to the actuator as illustrated in FIG. 20 the supporting member 82f on the frame 82c comprises a rectangular block. This actuator is suitable for the second embodiment illustrated in FIG. 14 and the supporting member 82f is provided with an external end face having a wide area that is suitable for fixing to the supporting member 79 installed at the back side of the first lens 72. Also, this actuator is suitable for the fifth embodiment illustrated in FIG. 17 and the sixth embodiment illustrated in FIG. 18.
With respect to the actuator illustrated in FIG. 21 the difference thereof from the actuator illustrated in FIG. 20 resides in that the external end face of the supporting member 82f is formed in a step-like shape. When this actuator is arranged such that the supporting member 82f of the actuator 82 is disposed on the side of the primary mirror 74 as in the third embodiment illustrated in FIG. 15 and the fourth embodiment illustrated in FIG. 16, a range by which optical path reflected by the primary mirror 74 and is incident on the secondary mirror 81 is blocked (kicked) can be reduced.
With respect to the actuator illustrated in FIG. 22 the difference thereof from the actuator illustrated in FIG. 20 resides in that the external end face of the supporting member 82f is formed in an approximately semicircular shape. When the actuator is arranged such that the supporting member 82f of the actuator 82 is disposed on the side of the primary mirror 74 as in the third embodiment illustrated in FIG. 15 and the fourth embodiment illustrated in FIG. 16, a range by which optical path reflected by the primary mirror 74 and is incident on the secondary mirror 81 is blocked can be reduced.
Although the external end face of the supporting member 82f is formed in a step-like shape or an approximately semicircular shape in the actuators in FIG. 21 and FIG. 22, the supporting member 82h may be formed in a step-like shape or an approximately semicircular shape. In this constitution, when the supporting member 82h of the actuator 82 is arranged to dispose on the side of the primary mirror 74 as in the second embodiment in FIG. 14, a range by which optical path reflected by the primary mirror 74 and incident on the secondary mirror 81 is blocked can be reduced.
Further, other than the actuators in which the supporting member 82f on the frame 82c is formed in a step-like shape or an approximately semicircular shape as shown by FIG. 21 and FIG. 22, the range by which optical path reflected by the primary mirror 74 and incident on the secondary mirror 81 is blocked can be reduced by rendering the height of the supporting member 82f or the supporting member 82h disposed on the side of the primary mirror 74, in the actuator arranged inside of the lens barrel, gradually lower toward the external side of the frame 82c, or rendering a total thereof as low as possible and the area thereof as small as possible.
Concerning the second embodiment in FIG. 14 through the fourth embodiment in FIG. 16, it is possible that optical path reflected by the primary mirror 74 and incident on the secondary mirror 81 is not blocked by the actuator 82 by arranging the actuator 82 to dispose at an external side FX with regards to a frame (vision field frame) FM indicating a range for passing optical path in the lens corresponding to the photographic field of view of a camera as shown by FIG. 23. Incidentally, it is preferable to place the actuator 82 on the short side of the above-mentioned frame FM since vacant space is larger on the short side than on the long side.
Next, an explanation will be given of the arrangement of the drive circuit driving the actuator in the lens barrel and the arrangement of an electric wiring between the drive circuit and the piezoelectric element of the actuator.
In the conventional reflecting telescopic lens barrel the reduction gear mechanism 207 is provided in the vicinity of the lens mounting unit as shown by FIG. 25. In this invention such a reduction gear mechanism is not necessary and accordingly, the drive circuit driving the actuator is arranged at a space portion where the reduction gear mechanism has been removed.
Furthermore, the actuator 82 is arranged to dispose at the external side FX from the frame (vision field frame) FM indicating a range for passing optical path in the lens corresponding to the photographic field of vision in a camera as illustrated in FIG. 23, in the second embodiment of FIG. 14 through the fourth embodiment of FIG. 16 and accordingly, the electric wiring 96 between the drive circuit 95 and the piezoelectric element 82a is connected to the drive circuit 95 via the external side of the frame and via the inner face of the fixed tube 71.
The electric wiring 96 is formed by a flexible printed board in which transparent leads are printed on a flexible transparent film and of which surface is subjected to a reflection preventive treatment, or a flexible printed board in which leads are printed on a flexible film and of which surface is subjected to a black color reflection preventive treatment etc.
Moreover, when the electric wiring 96 is disposed at a position crossing optical path in the lens barrel, the film face on which the electric wiring is formed is arranged to be in parallel with optical path by which the optical path blocked by the electric wiring 96 is minimized.
The control circuit and the control operation focusing the lens to the object are the same as those in the first embodiment which has been explained previously in reference to FIG. 13 and therefore, the explanation will be omitted here. However, the focus cam ring 13 in FIG. 13 corresponds to the secondary mirror holder 84 in the second embodiment through the fourth embodiment, the lens holder 85 of the third lens 78 in the fifth embodiment and the lens frame 73 of the first lens 72 in the sixth embodiment and accordingly, this portion of the lens barrel must be interpreted by such substitution.
As has been explained, according to the present invention, in a lens barrel conducting focusing operation by moving in the optical axis direction lenses contributing to the focusing operation among lenses constituted by a plurality of lens sets by means of an actuator arranged in the lens barrel, the actuator is constituted by a piezoelectric element, a drive member arranged along the optical axis direction and connected to the piezoelectric element for displacing together with the piezoelectric element, a moving member connected with a support frame of the lens sets contributing to the focusing operation and friction-coupled to the drive member and a supporting member supporting the drive member movably in the optical axis direction.
The supporting member for supporting the drive member is constituted such that the height in the direction intersecting with the optical axis direction is lowered toward the exterior side of the actuator, or a section thereof orthogonal to the axial direction of the drive member is made approximately semicircular. Also, when the actuator is arranged in the lens barrel, it is arranged such that the piezoelectric element is disposed on the object side and the drive member is disposed on the image plane side and further arranged at the external side of a range for passing optical path in the lens corresponding to the photographic field of view. Additionally, the drive member is preferably arranged at the external side on the short side of the range for passing optical path.
Thereby, not only there is no concern of blocking optical path incident on (or reflected by) the lens by the actuator, but also effects in which the drive mechanism of the lens sets can be simplified without using the complicated construction in which the rotational motion of a helicoidal ring etc. is converted into the motion in the optical axis direction by helicoidal screws as in the conventional lens, a number of parts is reduced and the weight is reduced, can be provided.
According to the present invention, a gear drive mechanism arranged at the rear portion of the lens barrel occupying a large space in the conventional lens barrel can be dispensed with and therefore, the actuator drive circuit can be arranged at the space portion whereby the actuator drive circuit can be accommodated without enlarging the outer dimensions of the lens barrel.
Additionally, the electric wiring connecting the actuator with a drive circuit is a flexible printed board which is formed by printing leads on a transparent film and accordingly, when it is disposed at a position crossing optical path at the inside of the lens barrel, the range of blocked optical path can be minimized by arranging the film face in parallel with the optical path.
It is further understood by those skilled in the art that the foregoing description is a preferred embodiment of the disclosed device and that various changes and modifications may be made in the invention without departing from the spirit and scope thereof.
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The present invention discloses a lens barrel moving an optical system by a linear actuator using a piezoelectric element. The actuator is provided with the constitution whereby a driving member is driven by an extension displacement and a contraction displacement having different velocities caused by applying drive pluses to the piezoelectric element and a driven member frictionally connected to the driving member is linearly moved. The focusing operation is conducted by moving the optical system directly in the optical axis direction by the linear actuator.
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RELATED APPLICATIONS
The present application claims the benefit of priority to U.S. Provisional Application No. 61/801,493, filed on Mar. 15, 2013, which is hereby incorporated by reference in its entirety.
FIELD
This disclosure relates to photoluminescence wavelength conversion components for use with solid-state light emitting devices to generate a desired color of light.
BACKGROUND
White light emitting LEDs (“white LEDs”) are known and are a relatively recent innovation. It was not until LEDs emitting in the blue/ultraviolet part of the electromagnetic spectrum were developed that it became practical to develop white light sources based on LEDs. As taught, for example in U.S. Pat. No. 5,998,925, white LEDs include one or more one or more photoluminescent materials (e.g., phosphor materials), which absorb a portion of the radiation emitted by the LED and re-emit light of a different color (wavelength). Typically, the LED chip or die generates blue light and the phosphor(s) absorbs a percentage of the blue light and re-emits yellow light or a combination of green and red light, green and yellow light, green and orange or yellow and red light. The portion of the blue light generated by the LED that is not absorbed by the phosphor material combined with the light emitted by the phosphor provides light which appears to the eye as being nearly white in color. Alternatively, the LED chip or die may generate ultraviolet (UV) light, in which phosphor(s) to absorb the UV light to re-emit a combination of different colors of photoluminescent light that appear white to the human eye.
Due to their long operating life expectancy (>50,000 hours) and high luminous efficacy (70 lumens per watt and higher) high brightness white LEDs are increasingly being used to replace conventional fluorescent, compact fluorescent and incandescent light sources.
Typically the phosphor material is mixed with light transmissive materials, such as silicone or epoxy material, and the mixture applied to the light emitting surface of the LED die. It is also known to provide the phosphor material as a layer on, or incorporate the phosphor material within, an optical component, a phosphor wavelength conversion component, that is located remotely to the LED die (“remote phosphor” LED devices).
FIG. 1 shows one possible approach that can be taken to implement a lighting device 100 when using a wavelength conversion component 102 . The wavelength conversion component 102 includes a photoluminescence layer 106 having phosphor materials that are deposited onto an optically transparent substrate layer 104 . The phosphor materials within the photoluminescence layer 106 generate photoluminescence light in response to excitation light emitted by an LED die 110 . The LED die 110 is attached to a MCPCB 160 . The wavelength conversion component 102 and the MCPCB 160 are both mounted onto a thermally conductive base 112 .
The wavelength conversion component 102 is manufactured to include a protruding portion 108 along the bottom. During assembly of the lighting device 100 , the protruding portion 108 acts as an attachment point that fits within a recess formed by mounting portion 116 of the thermally conductive base 112 .
To increase the light emission efficiency of the lighting device 100 , a reflective material 114 is placed onto the thermally conductive base 112 . Since the light emitted by the phosphor materials in the photoluminescence layer 106 is isotropic, this means that much of the emitted light from this component is projected in a downwards direction. As a result, the reflective material 114 is necessary to make sure that the light emitted in the downwards direction is not wasted, but is instead reflected to be emitted outwardly to contribute the overall light output of the lighting device 100 .
One problem with this approach is that adding the reflective material 114 to the base 112 requires an additional assembly step during manufacture of the lighting device. Moreover, significant material costs are required to purchase the reflective material 114 for the light assembly. In addition, it is possible that the reflective surface of the reflective material 114 may end up damaged during shipping or assembly, thereby reducing the reflective efficiencies of the material. An organization may also incur additional administrative costs to identify and source the reflective materials.
Another problem with this type of configuration is that light emitted from the lower levels of the photoluminescence layer 106 can be blocked by the mounting portion 116 on the base 112 . This effectively reduces the lighting efficiency of the lighting device 100 . Since phosphor materials are a relatively expensive proportion of the cost of the lighting device, this wastage of the light from the lower portions of the wavelength conversion component 102 means that an excessive amount of costs was required to manufacture the phosphor portion of the product without receiving corresponding amounts of lighting benefits.
SUMMARY OF THE INVENTION
Embodiments of the invention concern an integrated lighting component that includes both a wavelength conversion portion and a reflector portion and may optionally further include a third optical portion which can include a light diffusive material.
According to one embodiment a photoluminescence wavelength conversion component comprises: a first portion having at least one photoluminescence material; and a second portion comprising light reflective material, wherein the first portion is integrated with the second portion to form the photoluminescence wavelength conversion component. In some embodiments the component further comprises a third optical portion. The third optical portion can comprise a lens. Alternatively, and or in addition, the third optical portion can comprise a light diffusive material. In preferred embodiments the light diffusive material comprises nano-particles.
Preferably the first portion, second portion and or third portions have matching indices of refraction and each can be manufactured from the same base material.
The component having the first portion, the second portion and/or third portion can be co-extruded. For example, where the component has a constant cross section the first portion, the second portion and/or third portion can be co-extruded.
In some embodiments the at least one photoluminescence material is incorporated in and homogeneously distributed throughout the volume of the first portion.
The second portion can comprise an angled slope. To reduce light loss the angled slope extends from a base of the first portion to a top of an attachment portion of the component.
According to another embodiment, a method of manufacturing a lamp, comprises: receiving an integrated photoluminescence wavelength conversion component, wherein the photoluminescence wavelength conversion component comprises a first portion having at least one photoluminescence material and a second portion comprising light reflective material, wherein the first portion is integrated with the second portion to form the photoluminescence lighting component; and assembling the lamp by attaching the integrated photoluminescence wavelength conversion component to a base component, such that the integrated photoluminescence wavelength conversion component is attached to the base portion without separately attaching the first portion and the second portion to the base portion.
According to an embodiment of the invention a method of manufacturing a photoluminescence wavelength conversion component, comprises: extruding a first portion having at least one photoluminescence material; and co-extruding a second portion comprising light reflective material, wherein the first portion is integrated with the second portion to form the photoluminescence wavelength conversion component. Advantageously the method further comprises co-extruding a third optical portion.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the present invention is better understood LED-based light emitting devices and photoluminescence wavelength conversion components in accordance with the invention will now be described, by way of example only, with reference to the accompanying drawings in which like reference numerals are used to denote like parts, and in which:
FIG. 1 shows an end view of a linear lamp as previously described;
FIG. 2 is a schematic end view of an integrated photoluminescence wavelength conversion component in accordance with an embodiment of the invention;
FIG. 3 is a perspective view of the component of FIG. 2 ;
FIG. 4 is a schematic sectional view of an integrated photoluminescence wavelength conversion component in accordance with an embodiment of the invention;
FIG. 5 is a schematic end view of an LED-based linear lamp utilizing the photoluminescence wavelength conversion component of FIGS. 2 and 3 ;
FIG. 6 is a schematic end view of an integrated photoluminescence wavelength conversion component in accordance with an embodiment of the invention;
FIG. 7 is a schematic sectional view of an integrated photoluminescence wavelength conversion component in accordance with an embodiment of the invention;
FIG. 8 is a schematic sectional view of an integrated photoluminescence wavelength conversion component in accordance with an embodiment of the invention; and
FIG. 9 is a schematic end view of an LED-based reflector lamp utilizing the photoluminescence wavelength conversion component of FIG. 8 .
DETAILED DESCRIPTION OF THE INVENTION
Some embodiments of the invention are directed to an integrated lighting component that includes both a wavelength conversion portion and a reflector portion. FIG. 2 illustrates an end view of an integrated component 10 that includes both a wavelength conversion layer 20 , a an optical component portion 22 and a reflector portion 25 . The optical component portion 22 can be implemented as an optically transparent substrate or lens upon which the materials of the wavelength conversion layer 20 have been deposited. The integrated component 10 also includes feet/extended portions 15 . These extended portions 15 are to assemble component 10 to a base, by inserting the extended portions 15 within a matching recess on the base portion.
By integrating both the wavelength conversion portion 20 and the reflector portion 25 into a unitary component, this avoids many of the problems associated with having them as separate components. Recall that the alternative approach of having separate components requires a step to assemble the reflective component onto a base, followed by an entirely separate step to then place the wavelength conversion component onto the exact same base. With the present invention, the integrated component can be assembled to the base without requiring separate actions for the reflective component and the wavelength conversion component. Instead, both are assembled to the base in the present approach by assembly the single integrated component 10 to the base.
In addition, significant material cost savings can be achieved with the present invention. The overall cost of the integrated component is generally less expensive to manufacture as compared to the combined costs of having a separate wavelength conversion component and a separate reflector component. A separate reflector component (such as a light reflective tape) typically includes, for example, a substrate for the reflective materials (e.g., paper materials) and an adhesive portion on the underside to form the adhesive tape properties, with these costs passed on to the purchaser of the reflector product. In addition, separate packaging costs would also exist for the separate reflector component, which would likewise be passed onto the purchaser of the product. Moreover, an organization may incur additional administrative costs to identify and source the separate reflective component. By providing an integrated component that integrates the reflector portion with the wavelength conversion portion, many of these additional costs can be avoided.
Furthermore, it can be seen that the reflective surface of the reflector portion 25 is within the interior of the component 10 . This makes it less likely that the reflective properties of the reflector portion 25 could be accidentally damaged, e.g., during assembly or shipping. In contrast, a separate reflector component has its reflective portion exposed, creating a greater risk that the reflective surface may end up damaged during shipping or assembly. Any damage to the reflective surface could reduce the reflective efficiencies of the material, which may consequently reduce the overall lighting efficiency of the lighting device that uses the separate reflector component.
The present invention also provides better light conversion efficiencies for the phosphor materials of the wavelength conversion layer 20 . As previously discussed, one problem with the configuration of FIG. 1 that has feet/extended portions 108 is that light emitted from the lower levels of the wavelength conversion layer can be blocked by the mounting portion 116 on base 112 . This effectively reduces the lighting efficiency of the lighting device 100 . Since phosphor materials are a relatively expensive proportion of the cost of the lighting device, this wastage of the light from the lower portions of the wavelength conversion component 102 means that an excessive amount of costs was required to manufacture the phosphor portion of the product without receiving corresponding amounts of lighting benefits.
In the present invention, the integrated nature of the component 10 allows the reflector portion 25 to assume any appropriate configuration relative to the rest of the component 10 . As shown in FIG. 2 , this embodiment has the reflector portion 25 configured such that it slopes upward from the bottom of the wavelength conversion layer 20 up towards the upper height of the feet 15 . This angled implementation of the reflector portion 25 means that light produced by the bottom portion of the wavelength conversion layer 20 will tend to reflect outwards from the bottom of the light, rather than towards the sides of the light. Therefore, less of the phosphor-generated light will be blocked by the mounting portion 116 or within the recess created by mounting portion 116 . As a result, greater lighting emission efficiencies can be achieved, which means that less phosphor materials are required to otherwise achieve the same relative light output as the prior art lighting products.
Lighting products and lamps that employ the present invention can be configured to have any suitable shape or form. In general, lamps (light bulbs) are available in a number of forms, and are often standardly referenced by a combination of letters and numbers. The letter designation of a lamp typically refers to the particular shape of type of that lamp, such as General Service (A, mushroom), High Wattage General Service (PS—pear shaped), Decorative (B—candle, CA—twisted candle, BA—bent-tip candle, F—flame, P—fancy round, G—globe), Reflector (R), Parabolic aluminized reflector (PAR) and Multifaceted reflector (MR). The number designation refers to the size of a lamp, often by indicating the diameter of a lamp in units of eighths of an inch. Thus, an A- 19 type lamp refers to a general service lamp (bulb) whose shape is referred to by the letter “A” and has a maximum diameter two and three eights of an inch. As of the time of filing of this patent document, the most commonly used household “light bulb” is the lamp having the A- 19 envelope, which in the United States is commonly sold with an E 26 screw base.
FIGS. 3 and 4 illustrate two example different lamps that can be implemented using the integrated component of the present invention.
FIG. 3 illustrates an integrated component 10 for a linear lamp. This version of the integrated component 10 has a body that is extended in a lengthwise direction, with the same cross-sectional profile shown in FIG. 2 running throughout the length of the body. To assemble a linear lamp, the component 10 of FIG. 3 is mounted onto a base, where an array of LEDs is placed at spaced intervals within/under the interior of the component 10 .
FIG. 4 illustrates a cross sectional view of an integrated component having a shape that is generally a dome. In this approach, the feet 15 extend in either a full or partial circular pattern around the base of the component 10 . The reflector 25 has an annular profile that forms the base of the component 10 .
FIG. 5 illustrates an LED-based linear lamp 50 in accordance with embodiments of the invention, where the integrated component 10 (i.e. the component of FIG. 2 ) is mounted to a base 40 . The base 40 is made of a material with a high thermal conductivity (typically ≧150 Wm −1 K −1 , preferably ≧200 Wm −1 K −1 ) such as for example aluminum (≈250 Wm −1 K −1 ), an alloy of aluminum, a magnesium alloy, a metal loaded plastics material such as a polymer, for example an epoxy. Conveniently the base 40 can be extruded, die cast (e.g., when it comprises a metal alloy) and/or molded, by for example injection molding (e.g., when it comprises a metal loaded polymer).
One or more solid-state light emitter 110 is/are mounted on a substrate 160 . In some embodiments, the substrate 160 comprises a circular MCPCB (Metal Core Printed Circuit Board). As is known a MCPCB comprises a layered structure composed of a metal core base, typically aluminum, a thermally conducting/electrically insulating dielectric layer and a copper circuit layer for electrically connecting electrical components in a desired circuit configuration. The metal core base of the MCPCB 160 is mounted in thermal communication with the upper surface of the base 40 , e.g., with the aid of a thermally conducting compound such as for example a material containing a standard heat sink compound containing beryllium oxide or aluminum nitride. A light reflective mask can be provided overlaying the MCPCB that includes apertures corresponding to each LED 110 to maximize light emission from the lamp.
Each solid-state light emitter 110 can comprise a gallium nitride-based blue light emitting LED operable to generate blue light with a dominant wavelength of 455 nm-465 nm. The LEDs 110 can be configured as an array, e.g., in a linear array and/or oriented such that their principle emission axis is parallel with the projection axis of the lamp.
The wavelength conversion layer 20 of lamp 50 includes one or more photoluminescence materials. In some embodiments, the photoluminescence materials comprise phosphors. For the purposes of illustration only, the following description is made with reference to photoluminescence materials embodied specifically as phosphor materials. However, the invention is applicable to any type of photoluminescence material, such as either phosphor materials or quantum dots. A quantum dot is a portion of matter (e.g. semiconductor) whose excitons are confined in all three spatial dimensions that may be excited by radiation energy to emit light of a particular wavelength or range of wavelengths.
The one or more phosphor materials can include an inorganic or organic phosphor such as for example silicate-based phosphor of a general composition A 3 Si(O,D) 5 or A 2 Si(O,D) 4 in which Si is silicon, O is oxygen, A includes strontium (Sr), barium (Ba), magnesium (Mg) or calcium (Ca) and D includes chlorine (Cl), fluorine (F), nitrogen (N) or sulfur (S). Examples of silicate-based phosphors are disclosed in U.S. Pat. No. 7,575,697 B2 “Silicate-based green phosphors”, U.S. Pat. No. 7,601,276 B2 “Two phase silicate-based yellow phosphors”, U.S. Pat. No. 7,655,156 B2 “Silicate-based orange phosphors” and U.S. Pat. No. 7,311,858 B2 “Silicate-based yellow-green phosphors”. The phosphor can also include an aluminate-based material such as is taught in co-pending patent application US2006/0158090 A1 “Novel aluminate-based green phosphors” and patent U.S. Pat. No. 7,390,437 B2 “Aluminate-based blue phosphors”, an aluminum-silicate phosphor as taught in co-pending application US2008/0111472 A1 “Aluminum-silicate orange-red phosphor” or a nitride-based red phosphor material such as is taught in co-pending United States patent application US2009/0283721 A1 “Nitride-based red phosphors” and International patent application WO2010/074963 A1 “Nitride-based red-emitting in RGB (red-green-blue) lighting systems”. It will be appreciated that the phosphor material is not limited to the examples described and can include any phosphor material including nitride and/or sulfate phosphor materials, oxy-nitrides and oxy-sulfate phosphors or garnet materials (YAG).
Quantum dots can comprise different materials, for example cadmium selenide (CdSe). The color of light generated by a quantum dot is enabled by the quantum confinement effect associated with the nano-crystal structure of the quantum dots. The energy level of each quantum dot relates directly to the size of the quantum dot. For example, the larger quantum dots, such as red quantum dots, can absorb and emit photons having a relatively lower energy (i.e. a relatively longer wavelength). On the other hand, orange quantum dots, which are smaller in size can absorb and emit photons of a relatively higher energy (shorter wavelength). Additionally, daylight panels are envisioned that use cadmium free quantum dots and rare earth (RE) doped oxide colloidal phosphor nano-particles, in order to avoid the toxicity of the cadmium in the quantum dots.
Examples of suitable quantum dots include: CdZnSeS (cadmium zinc selenium sulfide), Cd x Zn 1-x Se (cadmium zinc selenide), CdSe x S 1-x (cadmim selenium sulfide), CdTe (cadmium telluride), CdTe x S 1-x (cadmium tellurium sulfide), InP (indium phosphide), In x Ga 1-x P (indium gallium phosphide), InAs (indium arsenide), CuInS 2 (copper indium sulfide), CuInSe 2 (copper indium selenide), CuInS x Se 2-x (copper indium sulfur selenide), CuIn x Ga 1-x S 2 (copper indium gallium sulfide), CuIn x Ga 1-x Se 2 (copper indium gallium selenide), CuIn x Al 1-x Se 2 (copper indium aluminum selenide), CuGaS 2 (copper gallium sulfide) and CuInS 2x ZnS 1-x (copper indium selenium zinc selenide).
The quantum dots material can comprise core/shell nano-crystals containing different materials in an onion-like structure. For example, the above described exemplary materials can be used as the core materials for the core/shell nano-crystals. The optical properties of the core nano-crystals in one material can be altered by growing an epitaxial-type shell of another material. Depending on the requirements, the core/shell nano-crystals can have a single shell or multiple shells. The shell materials can be chosen based on the band gap engineering. For example, the shell materials can have a band gap larger than the core materials so that the shell of the nano-crystals can separate the surface of the optically active core from its surrounding medium. In the case of the cadmiun-based quantum dots, e.g. CdSe quantum dots, the core/shell quantum dots can be synthesized using the formula of CdSe/ZnS, CdSe/CdS, CdSe/ZnSe, CdSe/CdS/ZnS, or CdSe/ZnSe/ZnS. Similarly, for CuInS 2 quantum dots, the core/shell nanocrystals can be synthesized using the formula of CuInS 2 /ZnS, CuInS 2 /CdS, CuInS 2 /CuGaS 2 , CuInS 2 /CuGaS 2 /ZnS and so on.
The optical component 22 can be configured to include light diffusive (scattering) material. Example of light diffusive materials include particles of Zinc Oxide (ZnO), titanium dioxide (TiO 2 ), barium sulfate (BaSO 4 ), magnesium oxide (MgO), silicon dioxide (SiO 2 ) or aluminum oxide (Al 2 O 3 ). A description of scattering particles that can be used in conjunction with the present invention is provided in U.S. Provisional Application No. 61/793,830, filed on Mar. 14, 2013, entitled “DIFFUSER COMPONENT HAVING SCATTERING PARTICLES”, which is hereby incorporated by reference in its entirety.
The reflector portion 25 can comprise a light reflective material, e.g., an injection molded part composed of a light reflective plastics material. Alternatively the reflector can comprise a metallic component or a component with a metallization surface.
In operation, the LEDs 110 generate blue excitation light a portion of which excite the photoluminescence material within the wavelength conversion layer 20 which in response generates by a process of photoluminescence light of another wavelength (color) typically yellow, yellow/green, orange, red or a combination thereof. The portion of blue LED generated light combined with the photoluminescence material generated light gives the lamp an emission product that is white in color.
FIG. 6 is a schematic partial sectional view of an integrated component 10 intended for a reflector lamp, e.g., such as an MR 16 lamp. In this embodiment the photoluminescence wavelength conversion portion 20 comprises dome-shape in the center of the component. The reflector portion 25 comprises a light reflective material on its inner surface. The wavelength conversion portion 20 of the component 10 is located at or near the focal point of reflector portion 25 . An optical component portion 22 is disposed at the projecting end of the component 10 . The optical component portion 22 may be configured as a lens in some embodiments. The optical component portion 22 may be configured to include light diffusive materials.
The interior of the component 10 may include a solid fill material. In some embodiments, the solid fill material has a matching index of refraction to the material of the wavelength conversion portion 20 . In some embodiments, the same base material is used to manufacture both the wavelength conversion portion 20 and the solid fill, with the exception that the solid fill does not include photoluminescence materials.
FIG. 7 illustrates that the component 10 can have a generally frusto-conical shape. FIG. 8 illustrates that the reflector portion 25 of the component may include multi-faceted reflector configuration within the interior surface of the component. FIG. 9 shows a reflector lamp product that includes the integrated component, e.g., such as an MR 16 lamp product. The lamp product includes one or more LEDs 110 and an electrical connector 180 .
In embodiments where the integrated component has a constant cross section, it can be readily manufactured using an extrusion method. Some or all of the integrated component can be formed using a light transmissive thermoplastics (thermosoftening) material such as polycarbonate, acrylic or a low temperature glass using a hot extrusion process. Alternatively some or all of the component can comprise a thermosetting or UV curable material such as a silicone or epoxy material and be formed using a cold extrusion method. A benefit of extrusion is that it is relatively inexpensive method of manufacture. It is noted that the integrated component can be co-extruded in some embodiments even if it includes a non-constant cross-section.
A co-extrusion approach can be employed to manufacture the integrated component. Each of the reflector 25 , wavelength conversion 20 , and optical 22 portions are co-extruded using respective materials appropriate for that portion of the integrated component. For example, the wavelength conversion portion 20 is extruded using a base material having photoluminescence materials embedded therein. The reflector portion 25 can be co-extruded such that is entirely manufactured with light reflective plastics, and/or where only the interface between the reflector portion 25 and the wavelength conversion portion 20 is co-extruded with the light reflective plastics and the rest of the reflector portion 25 is extruded using other appropriate materials. The optical component portion 22 can be co-extruded using any suitable material, e.g., a light transmissive thermoplastics by itself or thermoplastics that includes light diffusive materials embedded therein.
Alternatively, some or all of the component can be formed by injection molding though such a method tends to be more expensive than extrusion. If the component has a constant cross section, it can be formed using injection molding without the need to use an expensive collapsible former. In other embodiments the component can be formed by casting.
In some embodiments, some or all of the different reflector 25 , wavelength conversion 20 , and optical 22 portions of the integrated component are manufactured with base materials having matching indices of refraction. This approach tends to reduce light losses at the interfaces between the different portions, increasing the emission efficiencies of the overall lighting product.
It will be appreciated that the invention is not limited to the exemplary embodiments described and that variations can be made within the scope of the invention.
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A photoluminescence wavelength conversion component comprises a first portion having at least one photoluminescence material; and a second portion comprising light reflective material, wherein the first portion is integrated with the second portion to form the photoluminescence wavelength conversion component.
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This application claims priority of provisional application serial No. 60/255,550, filed Dec. 14, 2000.
FIELD OF THE INVENTION
This invention relates to the cleaning of textiles generally, and is more specifically related to a process of wet-cleaning textiles that were heretofore cleaned by chemical dry-cleaning processes.
BACKGROUND OF THE INVENTION
The cleaning of textiles has been necessary for as long as humans have worn clothing. Textiles are commonly cleaned with water. To reduce the surface tension of water, and increase the effectiveness of the water cleaning process, surfactants are commonly added to the water. Further, to remove oil-based dirt and stains, emulsifiers are commonly added to the water to assist in removing oil from stains.
The use of water to clean textiles is almost always associated with substantial mechanical action, whether or not agents such as surfactants and emulsifiers are added to the water. Historically, this has included beating the textile with a rock in the presence of water, and in more recent times, is associated with washing machines having electric motors, which are designed to substantially agitate the textile in the presence of water and detergents.
Textiles are damaged by substantial mechanical action in the presence of water. Commonly used textile materials such as silks and wools may be ruined by machine washing with water. Wet-washing with detergents and mechanical action can damage fibers, cause shrinkage and remove dye from the fabric. This damage is further enhanced by elevated temperatures and harsh detergents.
Accordingly, many textiles are intended to be dry cleaned and are specifically labeled as “dry clean only”. Dry cleaning processes are well known, but in summary, dry cleaning processes may be more accurately described as non-aqueous cleaning, rather than “dry” cleaning. Textiles are introduced into a solvent, and are agitated in the presence of the dry cleaning chemical solvent. This solvent removes dirt and stains by solubilizing or emulsifying the dirt and stains. The materials removed from the garments, which are suspended or dissolved in the dry clearing fluid, are carried away with the fluid, which is filtered to remove particles.
The solvents that are typically used in dry cleaning processes will remove both oil based stains and dirt, and with added soaps stains and dirt that are otherwise water-soluble. Dry cleaning solvents are typically organic. The solvents which have been in primary use in dry-cleaning are perchloroethylene based dry cleaning fluids.
Most dry cleaning fluids in common use, particularly including those which include perchloroethtylene, are toxic. They are both an environmental hazard and a health hazard. Disposal of used perchloroethylene based dry cleaning fluids, as well as other known dry cleaning fluids, has become a substantial health and environmental problem
The use of water to clean textiles is preferred, since the associated environmental and health problems are reduced. Heretofore, textiles that are labeled dry clean only could not be commercially cleaned using a water based process.
Any cleaning process that involves water is dependent on four factors: time, temperature, chemicals and mechanical action. According to the International Fabricare Institute, most wet cleaning cycle times range from 13-19 minutes, at a temperature of 80-89° F. The chemical agents used in most commercial processes are neutral to slightly acidic, and have a pH in the range of 6.5-7. Mechanical action is substantial, lifting the clothing to the 10 o'clock position of the cylinder, and reversing to the 2 o'clock position in most machines, although some lift to the 9 o'clock and 3 o'clock positions. The clothing lifts and falls within the cylinder to mechanically agitate and achieve cleaning. Most washers apply a G-force of 0.6 to 0.7 G during the wash cycle, which is increased upon water extraction to 250-460 G. 1 The time, temperature, chemicals and mechanical action that are used in commercial wet cleaning processes, as described, will damage textiles that are labeled “dry clean only”.
1 Source: International Fabricare Institute
SUMMARY OF THE INVENTION
The present invention is a process of cleaning textiles, including textiles that are labeled dry clean only, without the use of large quantities of environmentally hazardous dry cleaning fluids, such as those containing perchloroethylene or petroleum. The textile, such as a garment that is labeled dry clean only, is treated by hand, applying at least one cleaning agent to at least one soiled area of the garment which is labeled for dry cleaning. The garment is washed in water to partially remove the cleaning agent, and to remove soil from the garment, including soil loosed or emulsified by the cleaning agent. Chilled ozonated water is used to further remove the cleaning agent, and to remove the water from the garment. The garment is the dried at a temperature imparted to the garment of not more than 55 degrees Celsius.
The garment is primarily cleaned by the hand application of the cleaning agent, which does not damage the dry clean only fabric. The use of the ozonated water removes the cleaning agent and the water. Ozonated water dries faster than water, and is more effective than water at removing the cleaning agent, so that the dry clean only garment does not materially shrink or deform. The garment is dried without exposing the garment to heat at the levels normally used by commercial laundry dryers.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart demonstrating the process of an embodiment of the invention.
FIG. 2 is an elevation of a device for practicing wet cleaning according to an embodiment of the invention.
FIG. 3 is an elevation of a device for vacuum drying textiles according to an embodiment of the invention.
FIG. 4 is a side elevation of a restorer/refinisher.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The process of the present invention is intended to replace, or to reduce the use of, known commercial dry cleaning processes. Accordingly, the description herein is very typical of a preferred embodiment of the process, as it would be used by a commercial laundry or textile cleaner.
Refer to FIG. 1, which is a flow chart of the process (“O3RM Process”). It is preferred that garments are sorted by care labels and fabric content. Like fabrics should be matched with like fabrics. Fabrics are matched according to a percentage of a particular fiber. Fabrics which can be cleaned with the process of the present invention include, but are not limited to, silks, wools, acetates, polyesters, nylons, rayons, cotton, angora, cashmere (and other animal hair), animal hides, metals, and glass.
Empirical observation will permit the process described herein to be refined so that each fabric type may be optimally cleaned. Accordingly, sorting of the fabrics is for the purpose of optimal cleaning of the fabrics and not because the mixing of fabrics will cause, or result in, damage to the fabric if various fabrics or colors are mixed within the process. The variables, which may be changed according to the fabric, include cycle times, water temperatures, load sizes, drum rotation, particular surfactants and sizings and conditioners to be used.
Either before or after the fabrics are sorted, but preferably after, the garment is inspected for soiled areas and fabric stains, and are cleaned by hand with one or more cleaning agents. The cleaning agents may be acid-based or alkaline-based products with surfactants and emulsifiers. Removal agents, which include enzymes and oxygen bleach, may also be used.
After the garments are separated, and hand cleaned, the textiles are introduced into a compatible laundry machine 2 . An example of a laundry machine to be used is a MARVEL AQUADRY. This cleaning machine should not be overloaded, since a low level of rotation for water circulation is desired. Overloading may prevent a proper level of water circulation, or cause excessive mechanical interaction between the garments.
Water is introduced into the machine to an appropriate level. The type of garment determines the water level and type of water. It is preferred that dechlorinated, filtered, and softened water be used. Water temperatures should not be greater than room temperature, and room temperature is preferred not to exceed 80° F. Chilled water or ozonated water is optimal, and will produce superior results.
The cleaning machine is the actuated. An example of a cleaning machine that may be used in the process is a front-loading, wet cleaning laundry machine having a rotating drum with multiple spines or paddles in the drum. These spines and paddles are intended to provide agitation for prior art laundry processes, which impart substantial mechanical action and kinetic energy to the textiles. However, when the machine is used with the present process, it is placed on a low RPM setting, and usually the lowest setting available. It is imperative that a slow rotational speed for the drum be used, so that very minimal agitation of the clothing occurs. For most laundry machines with a motor controlled by a inverter, the lowest setting for the rotational speed of the drum should be used, along with a relatively high level of water, so that there is no material lifting of individual textile objects above the water line, nor is there the associated falling of the textile. The rotation of the drum should not cause the spines to lift the garment or other object materially above the level of the water, when the machine is ¾ full of water. In a preferred embodiment of the device, the rotational speed of the drum is 11 revolutions per minute or less.
A surfactant is introduced into the water. The surfactant should be pH neutral. To achieve the results required by the process, the process uses little mechanical agitation in combination with mild surfactants. The use of a surfactant that is highly alkaline is detrimental to the fabric, just as too much mechanical energy and heat energy is detrimental to fabric.
The time of continued operation of the machine is determined by the fabric to be cleaned and the level of foreign materials and stains in the fabric. Typically the time of operation of the machine for this step ranges from 2 to 20 minutes. This initial cycle removes at least some of the cleaning agent and the soil from the garment by means of the water, and if used, the surfactant. Cleaning during this cycle, as well as during all other steps of the process, does not occur as a result of kinetic energy imparted to the clothing by the cleaning machine, as is true in prior art processes. The operation of the machine mixes the water with the textile, but it does not clean by beating or pounding the textile, or by lifting the garment materially above the water line in the cleaning machine and dropping it, which is what is meant herein when it is stated that the cleaning machine does not remove soil by imparting kinetic energy to the garment or textile.
After the machine is operated for the appropriate time, water is removed from the machine. Optionally, a cylinder stop or medium drum rotation can take place at this time to prevent agitation of garments during drain. A fan or blower may be operated to assist in water removal from the machine and the textiles.
The machine is then filled to ¾ of the maximum water level with ozonated water. Ozonated water is produced by dissolving ozone (0 3 ) in the water. The ozone of a concentration within the water is preferred to be 1.5-2.5 parts per million (ppm). The ozone level is appropriate if a reading of 900 to 950 millivolts is obtained, as measured by a gauge, which indicates oxidation-reduction potential or other known instrumentation. An example of a device for producing ozonated water is the TECH 2 OZONE™ system manufactured by AJT.
As shown in the drawings, water flows from the ozone generator 4 through a line 6 and into the machine. An additional line 8 may be provided. “City” water may be provided to the machine though a valve 9 as desired.
The ozonated water is preferred to be chilled. Superior results are achieved if the water has a temperature of 10-18° F. Just as mechanical agitation and harsh soaps or other chemicals are detrimental to fabrics, and particularly, dry clean only fabrics, heated water is detrimental to fabrics, and should be avoided. The use of chilled water produces superior results as compared to the use of water that is at room temperature. Chilled water more readily accepts the introduction of ozone.
The ozonated water is constantly circulated within the system, so that ozone is continuously introduced into the water as needed to maintain the appropriate level of ozone in the water that is present in the machine. A recirculation line 10 to the ozone generator 4 is provided. By monitoring the water, an appropriate level of ozone can be maintained with a 1.5 to 2.5 ppm indication maintained on the gauge. An ozone probe can be installed in a machine overflow or bypass to indicate garment cleaning. As the ozone eliminates foreign organic materials that were present in the textile, ozone is maintained at higher levels within the water indicating that the cleaning process is near completion, or is completed. An ozone concentration of more than 3.0 ppm will degrade many textile dyes, and must be avoided when used to clean dry clean only garments.
As the ozonated water is slowly agitated in the machine, ambient gasses will dissolve in the water, making it difficult to maintain the desired level of ozone in the water. It is preferred to remove these gasses from the water after the water exits the machine and prior to entering the ozone generator during the recirculation process. A gas removal device 12 is preferred to be used during recirculation.
The ozone removes the remaining cleaning agents. The ozonated water also removes the water. Ozonated water dries faster than water that is not ozonated, so that shrinking and deformation of the dry clean only garment is reduced or eliminated, which is a key to the efficacy of this process of wet cleaning of dry clean only garments.
Optionally, an additional wash cycle may be used. This wash cycle may use a combination of ozonated water and filtered or softened water. If this additional step is used, it is preferred that the machine is partially filled, such as to ¼ of the maximum level, with softened or filtered water. Sizing and/or conditioner may be introduced at this time. The fill may then be completed using ozonated water. Typically, the ozonated water will not be recirculated during this step. Again, slow rotation is provided by means of a machine for a period of three (3) to five (5) minutes.
The water is removed from the machine upon completion of the cycle. The optional cylinder stop, medium drum rotation or blower or fan may be introduced. Excess water is then removed from the garment with the use of the extract cycle on the machine, although imparting significant kinetic energy to the garment is undesirable.
After the extract cycle is completed, the clothing is removed from the machine. The clothes are then dried. It is important that excess heat or mechanical action not be introduced to the textiles. However, commercial processes demand that drying of the textiles take place as quickly as possible.
In the present process, a vacuum dryer 20 and/or a refinisher/restorer device are preferred to be used. The vacuum dryer operates at 28 inches of vacuum or less within a sealed chamber with heated infrared lights. The infrared lights should not impart more than 55° C. to the garments, and it is preferred that not more than 120° F. (49° C.) be imparted to the fabric. The combination of vacuum and infrared lights expedites the drying of the garments, without heat buildup, due to an evaporation effect. Tumbling the garment is not needed, thereby meeting a goal of the invention of not imparting impact energy to the garment during processing.
The vacuum dryer of the preferred embodiment is used by opening the door of the device, and pulling a rack out of the interior of the device. The wet garment is positioned so that it is flat on the rack, in as natural a position as possible. The rack is placed into the device and the door is closed. The drying time and temperature are set, taking into consideration garment color, fabric type, and thickness. The device is actuated, and vacuum is applied, along with infrared lights for infrared heat, until the garment is dry. The garment is then removed from the device. To expedite water vapor removal, airflow to the vacuum pump may be provided.
A restorer/refinisher 30 may be used to reshape garments. Garments are staged on the refinisher/restorer according to the type of garment. Openings on garments are substantially closed with buttons, clips or clamps. Pressurized hot, or ambient, air and steam are introduced into the inside of the garment. Weights may be attached to lower portions of the garment. This process relaxes fibers and conditions the garments prior to finishing.
The restorer/refinisher is designed to condition garments before finishing. The restorer/refinisher will process long and short garments; both tops halves and bottom halves, such as shirts and pants, or jackets and skirts).
The garment is staged by positioning the garment on the device, then closing, such as by clamping or buttoning, all openings, such as pant cuffs, skirt hem, or skirt. The restorer/refinisher has adjustments for air temperature, blower forced pressurized air, time, dry steam time, dry steam, ambient air time, amount of air pressure, waist size, auto cycle and manual cycle. With these controls, an operator will accomplish conditioning of almost any wet garment to its intended shape.
The operator stages garment on restorer/refinisher, sets dry steam injection time, hot air temperature, air pressure, hot air pressure time, ambient air pressure time, height, and cycle. Steam pressure to the restorer/refinisher is preferred to be at about 80-90 psi. The device is actuated. Dry steam is injected into garment via an expander 32 supplied by a steam line 34 . This controllable level of steam will relax the fibers of the garment. Hot pressurized air is then blown into the garment tot the point of garment pillowing out (balloon like), but within preset limits so to prevent exceeding the garments design and manufactured strength. The process dries the garment from wet to dry, removes wrinkles, and stretches fibers if needed back to their intended shape per manufacturing. Ambient air is then blown into the garment through an air duct 36 to cool down the garment so to prevent shocking of fibers (yielding possible garment distortion if not evenly cooled) and operator comfort when removing the garment form machine. When the cycle stops, the operator inspects and removes the garment.
Performance time of drying and reshaping is relative to the fabric weave thickness and layers of fiber bearing a saturation percentage of water in the garment. The tightness or looseness of the fibers, which allows the air to escape the inner cavity of a garment, is also a factor. If a loose weave in the fibers, then more air flow is used to increase evaporation.
The restorer/refinisher operates through a combination of:
1) Dry steam
2) Adjustable blower yielding forced, steam heated air, and forced ambient air, either together, or separately
3) Gravity
4) Forced Air Pressure
The present invention demonstrates that immersing garments in water and drying without mechanical action with limited heat can successfully clean and condition “dry clean only” garments. However, dry clean only garments cannot be cleaned in the presence of water if substantial mechanical action along with heat that is materially above ambient temperatures, or harsh alkaline detergents, are used. The present process will effectively clean dry clean only garments without damage to the garment, and minimal shrinking or fading of dyes or pigments, which are used to color the textiles. The process uses water, substantially neutral surfactants, and low energy imparted to the textile by the use of low temperatures and low mechanical action, in both the cleaning and drying cycles, to achieve the successful cleaning of dry clean only textiles.
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A process of cleaning textiles, including textiles that are labeled dry clean only, without the use of large quantities of environmentally hazardous dry cleaning fluids such as those containing perchloroethylene or petroleum. The process uses hand treatment of soiled areas with a cleaning agent, with subsequent washing in water, followed by washing in ozonated water to remove the cleaning agent and the water. The textile is dried using a process that does not depend on tumbling of the textile in the presence of heat to dry the textile.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation application under 35 U.S.C. §111(a) of PCT Application No. PCT/US2016/023686 having an international filing date of Mar. 23, 2016, which designated the United States, which PCT application claims the benefit of U.S. Application Ser. No. 62/136,978, filed on Mar. 23, 2015 and U.S. Application Ser. No. 62/292,988, filed Feb. 9, 2016, all of which are incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The invention relates to an apparatus and methods, in certain embodiments, to reduce the friction required to rotate a tubular within a single joint elevator during the process of running tubulars in an oil and gas well. The invention would eliminate the need for the elevator to have to rotate and reduce the amount of torque required to rotate the tubular on stationary elevators. This would allow most tubular connections to be started by hand with the use of a strap wrench. In particular, but not exclusively, the invention relates to a tool for, and a method of, reducing the torque required to rotate a tubular within an elevator while running and making up tubulars in the oil and gas industry. This tool may complement elevators that utilize die sets or inserts to adjust the internal diameter of the elevator to match a range of tubular sizes. This tool may be used to run any sized tubular, including tubulars from 2⅜ inches to 20 inches.
BACKGROUND AND SUMMARY OF THE INVENTION
[0003] In the oil and gas industry, wellbores are drilled into the earth using drilling rigs, where tubulars are threaded together to form long tubular strings that are inserted into the wellbore to extract the desired fluid. The tubing string is generally suspended in the borehole using a rig floor-mounted spider, such that each new tubular segment or stand may be threaded onto the end of the previous tubular just above the spider. A segment is generally considered one joint of tubing and a stand is generally considered to be two or three joints of tubing combined together. A single joint elevator is commonly used to grip and secure the segment or stand to a hoist to lift the segment or stand into position for threading the tubulars together. Sometimes compensators are used in combination with elevators to reduce the weight of the stand on the connection of the previous string. Once set into position the tubular is rotated with a power tong in the elevator or the entire elevator is allowed to rotate on a swivel with the tubular to allow the connections to be threaded.
[0004] In general, single joint elevators are specifically adapted for securing and lifting tubular segments having a conventional connection, such as an internally threaded sleeve that receives and secures an externally threaded end from each of two tubular segments to secure the segments in a generally abutting relationship. The internally threaded sleeve is first threaded onto the end of a first tubular string to form a “box-end.” The externally threaded “pin end” of a second tubular string is then threaded into the box end to complete the connection between the two strings. These elevators have a circumferential shoulder that forms a circle upon closure of the hinged body halves. The shoulder of the elevator engages the shoulder formed between the end of the sleeve and the pipe segment.
[0005] Other elevators are specifically adapted for securing and lifting tubular segments having integral connections. These integral connections are generally permanently fixed to each end of the tubular, one end having an internally threaded end or “box-end” and the other end having an externally threaded end or “pin-end”, in a generally abutting relationship. The externally threaded pin-end of the first tubular segment is then threaded into the internally threaded box-end of the tubular string. These elevators generally have a beveled or angled shoulder that forms a circle upon closure of the hinged body halves. The beveled shoulder engages the beveled end of the integral connection of the pipe segment.
[0006] At least one challenge encountered by those in the industry is maintaining proper thread integrity of the connections while making up the stand to the string of tubulars. Generally, if the threads of the two connecting tubulars are not properly aligned when the rotation with power tongs begins, the threads of both connections will usually gall or be crushed to a state of non-compliance with industry standards. Typically these connections will have to be removed from the string and discarded or sent back to the manufacturer to be re-threaded. This removal of tubulars and connections from the string can be time consuming and very costly to the rig operator.
[0007] Another such challenge to those in the industry is the ability to run segments or stands of very heavy weight tubing. Generally the face of the internally threaded sleeve of a conventional connection rests on the top of the elevator. If the weight of the tubing segment or stand is too great, the friction between the face of the sleeve and the shoulder of the elevator will cause the sleeve to “stick” and the sleeve will not rotate with the tubing. This eventually causes the sleeve to “back-off” or become disconnected from the tubing, possibly allowing the tubing segment or stand to fall to the rig floor.
[0008] Yet another challenge is the safety issue that may arise when allowing the single joint to rotate on a swivel. The possibility exists that if the swivel, or the cable holding the swivel, becomes worn or fatigued to the point of failure, the elevator and the tubing would fall to the rig floor.
[0009] Therefore, there is a need for an apparatus or system that allows the tubulars to rotate within the elevator with little required torque. This will allow the operator the ability to start the connection of the tubulars by hand with a strap wrench. Thus, the operator may determine whether or not the threads are aligned properly prior to connecting the power tongs and finishing the make-up of the connection.
[0010] An objective of the invention is to provide a system comprising multiple rollers that may be seamlessly integrated into existing elevators which encompass inserts or dies to aid in the process of running tubulars.
[0011] A further objective is to provide a means of allowing the tubulars to rotate within the elevator without the need for additional pneumatic or hydraulic control lines or actuation.
[0012] A further objective is to provide a means to rotate a stand of multiple tubulars that would have been too heavy or unsafe to rotate using conventional methods.
[0013] A further objective is to provide a means to run stands of two or three segments of heavy weight tubing instead of a single segment, significantly reducing the time required to run the tubing in the well.
[0014] An apparatus of this nature may also significantly reduce the amount of loss time and money due to galled or destroyed connections.
[0015] An apparatus of this nature may significantly reduce safety concerns by replacing the need to hang the elevator with cables and a swivel, and also to reduce the possibility of spinning off the upper collar holding the stand on the elevator.
[0016] An apparatus of this nature may comprise rollers that encompass a shaft with an arrangement of radial and/or thrust bearings contained within a cylindrical hub.
[0017] An apparatus of this nature may comprise rollers that encompass a single ball bearing fixed within a housing.
[0018] An apparatus of this nature may typically have rollers that will be oriented vertically or at a specified angle from the vertical in combination with rollers that will be aligned with the vertical or horizontal.
[0019] An apparatus of this nature may have interchangeable components that can be replaced in the field thus reducing downtime and ensure proper rotation of the tubular.
[0020] These and other advantages will be apparent from the disclosure of the invention(s) contained herein. The above-described embodiments, objectives, and configurations are neither complete nor exhaustive. The Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the invention. Moreover, references made herein to “the invention” or aspects thereof should be understood to mean certain embodiments of the invention and should not necessarily be construed as limiting all embodiments to a particular description. The invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and Detailed Description and no limitation as to the scope of the invention is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary of the Invention. Additional aspects of the invention will become more readily apparent from the Detailed Description particularly when taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate certain embodiments of the disclosure and together with the general description of the disclosure given above and the detailed description of the drawings given below, serve to explain the principles of the disclosures.
[0022] FIG. 1 a is a section view of a single upper roller block in accordance with embodiments of the invention;
[0023] FIG. 1 b is a section view of a single lower roller block in accordance with embodiments of the invention;
[0024] FIG. 2 a is a section view of a single upper roller block utilizing a cam follower roller in accordance with embodiments of the invention;
[0025] FIG. 2 b is a section view of a single lower roller block utilizing a cam follower roller in accordance with embodiments of the invention;
[0026] FIG. 3 is a top view of an elevator roller insert utilizing an arrangement of single upper and lower roller blocks in accordance with embodiments of the invention;
[0027] FIG. 4 is a top view of an elevator roller insert utilizing an arrangement of multiple roller blocks in accordance with embodiments of the invention; and
[0028] FIG. 5 is a section view of a segment of tubing having an integral (beveled) connection within the roller insert in accordance with embodiments of the invention;
[0029] FIG. 6 is a section view of a segment of tubing having a conventional (collared) connection within the roller insert in accordance with embodiments of the invention;
[0030] FIG. 7 a is a top view of a single joint elevator encompassing an elevator roller insert in a closed position in accordance with embodiments of the invention; and
[0031] FIG. 7 b is a top view of a single joint elevator encompassing an elevator roller insert in an open position in accordance with embodiments of the invention.
[0032] It should be understood that the drawings are not necessarily to scale, and various dimensions may be altered. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.
DETAILED DESCRIPTION
[0033] The invention has significant benefits across a broad spectrum of endeavors. It is the Applicant's intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed. To acquaint persons skilled in the pertinent arts most closely related to the invention, a preferred embodiment that illustrates the best mode now contemplated for putting the invention into practice is described herein by, and with reference to, the annexed drawings that form a part of the specification. The exemplary embodiment is described in detail without attempting to describe all of the various forms and modifications in which the invention might be embodied. As such, the embodiments described herein are illustrative, and as will become apparent to those skilled in the arts, and may be modified in numerous ways within the scope and spirit of the invention.
[0034] Although the following text sets forth a detailed description of numerous different embodiments, it should be understood that the detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims. To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term by limited, by implication or otherwise, to that single meaning.
[0035] Various embodiments of the invention are described herein and as depicted in the drawings. It is expressly understood that although the figures depict tubulars, inserts, and elevators, the invention is not limited to these embodiments.
[0036] Now referring to FIG. 1 a, an upper roller set 26 is provided with an upper roller 4 positioned within a recess of the upper roller block 2 , the upper roller 4 having a rotational axis 6 about which the upper roller 4 rotates to accommodate tubulars being handled by an elevator. In some embodiments, upper roller 4 may comprise a combination of axial and thrust bearings encased within a roller housing and rotating about a central shaft 8 . Also, as it can be appreciated by one skilled in the art, in certain embodiments, the types and sequence of bearings may be different than discussed herein to accommodate the different types of tubing and tubing connections being handled by an elevator. A plurality of upper roller sets 26 can form an elevator roller insert 30 (shown in FIG. 3 below) that bears the weight of a tubular yet still allows the tubular to rotate rather freely. To bear the weight of the tubular and to allow free rotation of the tubular, the upper roller 4 is configured to have a maximum operating weight and a maximum load rating. In some embodiments, the maximum operation weight for an upper roller 4 is 4,350 lbs and the maximum load rating is 6,300 lbs. It will be appreciated that in other embodiments, the maximum operation weight and the maximum load rating for an upper roller 4 may be greater or less than 4,350 lbs and 6,300 lbs, respectively.
[0037] In the embodiment shown in FIG. 1 a, the rotational axis 6 of the upper roller 4 is offset in a transverse direction from a central axis 8 of a complete elevator roller insert 22 (shown in FIGS. 3 and 4 below). Also, rotational axis 6 of the upper roller 4 may be offset from the vertical by an upper roller angle 10 . In various embodiments, the upper roller angle 10 is approximately 0, 5, 12 or 18 degrees to match common tubular connection angles. In other embodiments, the upper roller angle 10 ranges from 0 to 90 degrees.
[0038] In some embodiments, the upper roller set 26 is also comprised of a connection 12 which allows the roller block to be fixed to the elevator in some abutting fashion. In some embodiments this connection will be a dovetail type connection. In other embodiments the connection type may match that of the elevator that the inserts will be used in.
[0039] Now referring to FIG. 1 b, a lower roller set 28 is provided with a lower roller 16 positioned within a recess of the lower roller block 14 . The lower roller 16 has a rotational axis 18 about which the lower roller 16 rotates to prevent a tubular from binding against the elevator roller insert 30 should the elevator be tilted or off center. The lower roller 16 may comprise a combination of axial and thrust bearings encased within a roller housing and rotating about a central shaft 20 . Also, as it can be appreciated, in certain embodiments, the types and sequence of bearings may be different than discussed here to accommodate the different types of tubing and tubing connections being handled by an elevator. In the embodiment shown in FIG. 1 b, the rotational axis 18 of the lower roller 16 is substantially parallel with a central axis of the complete elevator roller insert 30 (shown in FIGS. 3 and 4 below), or a central axis of a roller set. However, in some embodiments, the rotational axis 18 of the lower roller 16 may form a lower roller angle similar to the upper roller angle 10 . In various embodiments, the lower roller angle may be between approximately 0 and 90 degrees.
[0040] In some embodiments, the lower roller set 28 may also be comprised of a connection 12 which allows the roller block to be fixed to the elevator in some abutting fashion. In some embodiments this connection will be a dovetail type connection. In other embodiments the connection type will match that of the elevator that the inserts will be used in.
[0041] Now referring to FIG. 2 a , some embodiments of the upper roller set 26 may utilize a cam follower roller 22 instead of an upper roller 4 with bearings as depicted in FIG. 1 a. Cam follower rollers are well known to those skilled in the art, and an exemplary cam follower roller is disclosed by U.S. Pat. No. 4,152,953, which is incorporated herein in its entirety by reference. The cam follower roller 22 would be threaded or otherwise secured into the upper roller block 2 and would bear the weight of the tubular being handled by the elevator 40 . The cam follower roller would be oriented along a rotational axis 6 similar to that of the upper roller 2 in FIG. 1 a, and its utilization would also be similar.
[0042] Now referring to FIG. 2 b , some embodiments of the lower roller block 14 may utilize a cam follower roller 24 instead of a lower roller 16 with bearings as depicted in FIG. 1 b. The cam follower roller 24 would be threaded or otherwise secured into the lower roller block 14 and rotate to prevent a tubular from binding against an insert should the elevator be tilted or off center. In some embodiments, the cam follower roller is oriented along a rotational axis 18 similar to that of the lower roller in FIG. 1 b, and its utilization would also be similar.
[0043] Now referring to FIG. 3 , a combination of upper roller sets 26 and a combination of lower roller sets 28 may be combined to form an elevator roller insert 30 . A plurality of upper roller blocks 2 are arranged about the central axis 8 of the elevator roller insert 22 to form the upper roller set 28 , and similarly, a plurality of lower roller blocks 14 are arranged about the central axis 8 of the elevator roller insert 30 to form the lower roller set 28 . The upper and lower roller sets 26 , 28 may then combine to form a complete elevator roller insert 30 . In some embodiments the upper rollers may be combined in the same block with the lower rollers (combination block 32 ) in a single or multiple block set as can be seen in FIG. 4 . In other embodiments there may be no lower roller sets 28 included in the elevator roller insert 30 .
[0044] The elevator roller insert 30 may comprise various numbers of upper roller sets 26 and lower roller sets 28 . For example, in some embodiments, the elevator roller insert 30 comprises four upper roller sets 26 and four lower roller sets 28 . It will be appreciated that in other embodiments, the number of upper roller sets 26 and/or the number of lower roller sets 28 may be greater or less than four. Further, the number of upper roller sets 26 may be distinct from the number of lower roller sets 28 . In addition, FIG. 4 depicts an elevator roller insert 30 having three combination roller sets 32 , but it will be appreciated that the elevator roller insert 30 may have more or less than three combination roller sets 32 . As stated above, the rollers may have a maximum operating load and/or a maximum load rating, and similarly, the complete elevator roller insert 30 may also have a maximum operating load and/or a maximum load rating.
[0045] Now referring to FIG. 5 , a cross section is shown comprising of a tubing 34 with an integral connection 36 being held in place by the upper rollers 4 in a generally abutting relationship. Due to the weight bearing rotational capabilities of the upper roller 4 , the tubing 34 will be allowed to rotate rather freely within the elevator roller insert 30 . The upper roller angle 10 is designed such that it will closely match the angle of the integral connection 36 . The lower rollers 16 will then hold the tubing 34 centrally within the elevator roller insert 30 and, in the same manner as the upper rollers 4 , would allow the tubular 34 to rotate rather freely. Also the upper 26 and lower roller sets 28 (or combination roller sets 32 in some embodiments) are radially aligned in a manner that the minimum internal diameter 38 of the elevator roller insert 30 is less than the greatest outer diameter of the integral connection 36 . The internal diameter 38 of the elevator roller insert 30 keeps the tubular 34 from slipping through the insert 30 and falling to the rig floor.
[0046] Now referring to FIG. 6 , a cross section is shown comprising of tubing 40 with an internally threaded sleeve 42 being held in place by the upper rollers 4 in a generally abutting relationship. Due to the weight bearing rotational capabilities of the upper roller 4 , the tubing 40 will be allowed to rotate rather freely within the elevator roller insert 30 . The lower rollers 16 will then hold the tubing 40 centrally within the elevator roller insert 30 and, in the same manner as the upper rollers 4 , would allow the tubular 40 to rotate rather freely. Also the upper 26 and lower 28 roller sets (or combination roller sets 32 in some embodiments) are radially aligned in a manner that the minimum internal diameter 38 of the elevator roller insert 30 is less than the greatest outer diameter of the sleeve 42 . The internal diameter 38 of the elevator roller insert 30 keeps the tubular 40 from slipping through the elevator roller insert 30 and falling to the rig floor.
[0047] And now referring to FIGS. 7 a and 7 b , an elevator roller insert 30 is shown within a single joint elevator 44 in the closed and opened position respectively. The elevator roller insert 30 is generally segmented to allow the elevator be opened, to accept the tubular, and closed, to contain the tubular within the elevator.
[0048] The invention has significant benefits across a broad spectrum of endeavors. It is the Applicant's intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed.
[0049] The phrases “at least one”, “one or more”, and “and/or”, as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B, and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C,” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together.
[0050] Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification, drawings, and claims are to be understood as being modified in all instances by the term “about.”
[0051] The term “a” or “an” entity, as used herein, refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein.
[0052] The use of “including,” “comprising,” or “having,” and variations thereof, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Accordingly, the terms “including,” “comprising,” or “having” and variations thereof can be used interchangeably herein.
[0053] It shall be understood that the term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C. §112(f). Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials, or acts, and the equivalents thereof, shall include all those described in the summary of the invention, brief description of the drawings, detailed description, abstract, and claims themselves.
[0054] The foregoing description of the invention has been presented for illustration and description purposes. However, the description is not intended to limit the invention to only the forms disclosed herein. In the foregoing Detailed Description for example, various features of the invention are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the invention.
[0055] Consequently, variations and modifications commensurate with the above teachings and skill and knowledge of the relevant art are within the scope of the invention. The embodiments described herein above are further intended to explain best modes of practicing the invention and to enable others skilled in the art to utilize the invention in such a manner, or include other embodiments with various modifications as required by the particular application(s) or use(s) of the invention. Thus, it is intended that the claims be construed to include alternative embodiments to the extent permitted by the prior art.
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A device, system, and/or method for reducing friction required to rotate a tubular within an elevator during the process of running tubulars in an oil and gas well are provided. An elevator roller insert may be used in conjunction with an elevator, such as a single joint elevator. Such an insert may comprise upper and lower rollers which are positioned on upper and lower roller sets or a combination roller set containing multiple upper and/or lower rollers. The result is the provision of a plurality of rollers which bear the weight of a tubular yet still allow the tubular to rotate rather freely, facilitating the maintenance of proper thread integrity of the connections while making up a stand to a string of tubulars as well as preventing the loss of resources due to galled or crushed threads or a tubing segment or stand falling to the rig floor.
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BACKGROUND OF THE INVENTION
The present invention relates to a stitch presser for knitting machines. More particularly, the present invention provides a stitch presser with a slide presser for pressing the knitwear and a supplementary means for pressing the stitches against the needle beds.
In a flat knitting machine where the needles are controlled in both oscillating movements of the carriage by lock fixed below said carriage it is known to mount a device for the control of the stitch presser directly on the carriage, so that one of the slide threads constituting the pressing member of the stitch presser operates when the carriage is moved in an opposite direction. It is also customary to assign one stitch presser device to each knitting system or to each pair of knitting systems, if the knitting is done on two needle beds. Furthermore, it is known to assign one stitch presser to each knitting system or to each pair of knitting systems when the knitting is done on two needle beds and to modify the position of the stitch presser at the end of each stroke of the carriage, so that it is possible to successively work in two opposite directions.
Stitch pressers traditionally include slide threads of different shapes and are sometimes completed by other means such as rollers, blade scrapers or brushes, all being afflicted with the disadvantage of being useable for only part of the knitting fabrics and particularly not for mixed fabrics, for example, one form of slide thread can be used only for a limited lock or mesh density and a selected fabric. The stitch pressers equipped with rollers, blade scrapers, brushes, etc., present the inconvenience of discontinuity of action on the knitwear i.e., the space between the roller, scraper, or brush, and the beginning of a slide thread is not controlled.
SUMMARY
The stitch presser of the invention includes a slide thread and a supplementary means whose field of action is at least partially superposed over the field of action of the slide thread and whose field of action starts ahead of the first point of crossing of the needles, seen in the moving direction of the carriage. Normally the field of action of the supplementary means will also end ahead of the end of the complete upward movement of the needles. The cumulative width of the field of action will ordinarily be at least equal to the spacing measured between two needle beds. The slide thread presses the knitwear and the supplementary means acts to press the stitches against the needle beds to improve on the conventional action of the slide thread which often results in irregular columns of stitches on the knitwear due to excessive friction between the slide thread and the stitch.
Preferrably, the supplementary means is a fluid, for example, compressed air or water, or an auxiliary slide including additional slide threads.
It is advantageous to mount a valve at the fluid distribution point, in order to direct it toward one or another principal slide thread depending on whether the carriage is moved in one direction or in the opposite direction. It is also advantageous for the fluid to be directed in a direction which is not perpendicular to the movement of the carriage.
Accordingly, the primary object of the invention is to provide a simple device which is easily adaptable to a stitch presser, which controls the friction between the slide thread and the knitwear. Another object is a return means for a stitch presser, acting in the space between the two needle beds, independently of the thickness of the yarn or the kind of knitwear.
The novel features which are believed to be characteristic of the invention are set forth in the appended claims. The invention itself, however, together with further objects and attendant advantages thereof, will be best understood by reference to the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a partial view of a stitch presser for a knitting machine according to the invention;
FIG. 2 is a front view of a stitch presser according to the invention;
FIG. 3 is a partial section along 3--3 of FIG. 2;
FIG. 4 is a schematic representation of the fields of action of one slide thread and of the compressed air jets in relation to the needle beds and the trajectories of the needles;
FIG. 5 is a section of the needle beds at a larger scale, just ahead of the point of intersection of the needles;
FIG. 6 is similar to FIG. 5 for a different knitwear material;
FIG. 7 is a front view of a variation according to the invention;
FIG. 8 is a view along 8 of FIG. 7; FIG. 9 is a representation similar to FIG. 4;
FIG. 10 shows a section of the needle beds on a larger scale and of the slide threads along 10 of FIG. 7; and
FIG. 11 is a section similar to FIG. 10, along 11 of FIG. 7 for another knitwear fabric.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The stitch presser 1 represented in FIG. 1 comprises two stitch pressing means 2. Each stitch pressing means 2 consists of a slide thread 3 which operates when the knitting carriage is moved from right to left on the knitting machine, and of a slide thread 4 which works when the carriage is moved in the opposite direction.
The stops 5 and 6 are used to reverse the stitch pressers after the carriage has arrived at its end of stroke.
The fixation means of the stitch pressing device on the carriage and the reversing means of the stitch pressers are known from prior art and outside the scope of this invention. They are neither described nor shown.
The slide threads 3 and 4 form one piece with a support 7 which in turn is mounted by means known and not shown, on the lever 8.
A pipe for supplying compressed air forms one piece with the support 9. It includes two pipes 11 and 12 respectively to conduct compressed air toward the slide threads 3 and 5 respectively.
The pipes 11 and 12, shown in FIG. 3, include a baffle 13, thereby separating the end of the pipes into two nozzles 14 and 15. The supply of compressed air is accomplished via the flexible pipe 16 connected on the one hand to the pipe 10 and on the other hand to a device which may or may not form one piece with a knitting machine, and capable of supplying said compressed air. This kind of device is known, it is outside the scope of the invention and thus not shown. Provisions are made to mount, at the point of distribution 17, a valve making it possible to direct compressed air toward pipe 11 or pipe 12, depending on whether the carriage is moved from the right to the left or from the left to the right, on the knitting machine.
The fields of action 18 and 19 of the nozzles 14 and 15 respectively are shown schematically in FIG. 4. The slide thread 3 will have a field of action 20 shown between the two fields of action of the nozzles.
Reference symbols 21 and 22 show the start and end, respectively of the field of action of the slide thread 3.
Reference symbols 23 and 24 show the start and end, respectively of the fields of action 18, 19 of the nozzles 14, 15.
The start of the field of action (23) of a nozzle is located ahead of the first crossing point 25 of the needles viewed in the direction of movement of the carriage, and ends ahead of the end of the complete upward movement of the needles in stitch formation. The curves 26 and 27 respectively, drawn in dots and dashes represent the trajectories of the needle hooks working on a front needle bed 28, and/or of a rear needle bed 29 of a knitting machine.
The fields of action 18, 19 of the nozzles are superposed over the field of action of the slide thread 3, so that they commence after the start 21 and terminate prior to the end 22 of the field of action 22 of the slide thread 3.
The cumulative width of the fields of action is at least equal to the distance between the two needle beds 28, 29.
During the knitting on two needle beds 28, 29, the knitwear 30 is held by the stitches 31 in the needle hook 33 and by the stitches 32 in the needle hook 34.
The arrangement shown is the one we find just prior to the needles being moved by the locks of the knitting carriage.
The slide thread 3 presses on the knitwear 30 and the compressed air spouts 35 and 36 originating from the nozzles 14 and 15 respectively press the stitches 37 and 38 against the needle beds 29 and 28 respectively. During the start of the upward movement of the needles, the stitches 31, 32 expand and the slide thread 3 along with the compressed air jets 35, 36, press the knitwear 30 downward, so as to make sure that the stitches 31, 32 remain taut. During the upward movement the compressed air spouts 35, 36 aid the stitch 31, 32, to slide along the needle body 33a, 34a.
The combination of the two elements, compressed air and slide thread, make possible the judicious dimensioning of the slide thread, to avoid excessive friction of the slide thread on the stitch, which could cause irregular columns of stitches to appear on the knitwear, that is columns which would not be strictly straight. with the knitting on one needle bed 29 only, the same device may be used. FIG. 6 is a view similar to FIG. 5, but for knitting on one needle bed only. In that case, the action of the slide thread 3 on the knitwear 39 is considerably reduced, it has a tendency to slide on the knitwear to be placed in the free space remaining between said knitwear 39 and the opposite needle bed 28. On the other hand, the compressed air spout 35 remains completely active and suffices to compensate for the lack of work furnished by the slide thread 3.
Thus it is readily understood that such an apparatus allows for the knitting on one and two needle beds in one and the same row of stitches or in different rows of stitches.
It may be advantageous to direct the fluid in a direction which is not perpendicular in relation to the movement of the carriage, so as to contribute toward a possible balancing of the stitches.
The stitch presser shown in FIGS. 7 and 8 is a variation of the additional device mentioned in the object of our invention.
It consists of the principal slide threads 40, 41 and auxiliary flexible slide threads 42, 43, 44, 45. The principal slide threads 40, 41 form one piece, by way of fixation means 46, with a support 47 which is mounted to the lever 8 by means known and not shown.
The auxiliary flexible slide threads 43, 45 are placed in grooves 48, 49 located in a slot 50. By their shapes they are positioned directly. The auxiliary flexible slide threads 42, 44 are placed in an identical manner in a crosspiece 51, all of this being fixed with the aid of a cover 52 and fixation means 53. A compression spring 54 is located on the one hand in the housing 55 of the slot 50 and on the other hand against the support 47.
The auxiliary flexible slide threads 42, 43 and 44, 45, are provided so that they can be concealed on each side of the principal slide thread 40, 41 respectively.
The fields of action of the above mentioned slide threads, in spacing of the needle beds are shown in FIG. 9.
The reference symbols 56 and 57 show the start and the end respectively of the field of action 58 of a principal slide thread 41.
The reference symbols 59 and 60 represent the start and end respectively of the fields of action 61 and 62 of the auxiliary flexible slide threads 45 and 44. The end 60 of the fields of action 61, 62 of said flexible auxiliary slide threads is located, seen in the direction of movement of the carriage, after the start 56 and prior to the end 57 of the field of action 58 of a principal slide thread 41. The fields of action 61, 62, 58 thus are partly superposed.
The curve 63 and 64, represent the trajectory of the needle hooks working on a front (28) and a rear (29) needlebed of a knitting machine.
The cumulative width of the fields of action 61, 58, 62, is at least equal to the distance separating both needle beds 28, 29.
The fields of action 61, 62 of the auxiliary flexible thread slides commence, seen in the operating direction of the knitting carriage, prior to the first crossing point 65 of the needles, and terminate prior to the complete upward movement of the needles.
During the knitting on two needle beds 28, 29 (FIG. 10), the stitches 31 and 32 are maintained in the hook 33 and 34, of the needles. The needles have not yet moved upward. The principal slide thread 41 presses on the knitwear 30. The auxiliary flexible slide threads 45 and 44 press against the needle beds 29 and 28 and on the already formed stitches 37 and 38. To arrive in this position, the auxiliary flexible slide threads 45, 44 have been compressing the compression spring 54 by the movement they have caused to the slot 50. The end of the auxiliary flexible slide threads 44, 45 is found just below the roof (or inverted "V"-shaped part) formed by the crossing of the needles. To facilitate the comprehension of the drawing, the following needles which have already started their upward movement or which have partly moved upward, are not shown.
During the knitting on one needle bed 29 only, according to FIG. 11, the auxiliary flexible slide thread 45 presses the knitwear 39 downward and against the needle bed 29, the auxiliary flexible slide thread 44, like the principal slide thread 41, are used as self-centering elements of the slide threads in the spacing of the needle beds. The slot 50 (FIG. 7) is in low position, under this action of the compression spring 54.
It thus is readily understood that with such a device it is possible to knit fabrics on one or two needle beds and even mixed fabrics in one and the same knitting row.
A mixed contexture of fabric will cause a back and forth movement of the slot 50, enabling it to assume the position according to FIG. 10 or according to FIG. 11, depending on whether the auxiliary flexible slide threads 44, 45 are located in one knitting range on two needle beds (FIG. 10) or on one needle bed (FIG. 11).
The knitter thus has in his hands a simple apparatus, enabling him to considerably increase the field of application of the stitch pressers. He has a self-adjustable system as to width which no longer is a function of the contexture of the knitwear. He has thus a device working in the entire area separating the needle beds and particularly very near the needle beds.
Of course, it should be understood that various changes and modifications in the preferred embodiments described herein will be apparent to those skilled in the art, such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. It is, therefore, intended that such changes and modifications be covered by the following claims.
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A stitch presser for a knitting machine equipped with at least two needle beds arranged in an inverted "V", and provided with needles which intersect during their upward movement, a carriage movable above the needle beds, a system for control of the needles during their displacement in alternate directions, and a means for the alternate control of the stitch presser along a row of needles and in another adequate position for the movement in the opposite direction wherein the stitch presser acts between two needle beds on the stitches held by the needles. The stitch presser includes a slide thread for pressing the knitwear and a supplementary means for pressing the stitches against the needle beds.
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CROSS REFERENCE TO RELATED PATENT APPLICATIONS
This application claims priority from U.S. Provisional Application Ser. No. 61/050,851, filed on May 6, 2008, said application being relied upon and incorporated herein by reference.
BACKGROUND OF THE INVENTION
Metal culverts have been used in building roads for a long time because metal pipe is lighter than concrete pipe and road crews needed special equipment to set heavier concrete pipes in road cuts. Metal pipes started as galvanized plates, which were bolted or riveted together. They later became rolled pipes which were fabricated at a plant and then installed in twenty-foot lengths to be jointed with a band to other twenty-foot segments to form a long culvert.
Metal pipe inverts will experience failure over time, which has been blamed on rust or corrosive soil conditions. Further analysis indicates that the failure is caused by continuous movement of sediment through the drain via drain water, effectively “sand blasting” or eroding the bottom of the pipe. Once protective elements have eroded portions of the pipe, then the pipe will rust.
Removing the metal pipes having failed inverts is an extraordinarily expensive and time consuming job. In particular, the soil must be removed to expose the pipe experiencing failure. The excavated hole must be wide enough to prevent further soil collapse. The bed must then be reworked, such as with crushed stone. The bed must be on an even stable grade to prevent pipe separation at the joints, and the replaced material must be compacted. Once that step is complete, base and pavement layers must then be replaced.
SUMMARY OF THE INVENTION
An apparatus and method for repairing failed metal pipe inverts is described herein. The apparatus includes a frame having a forward end and a rearward end. A trough is connected to the forward end, and a support arm is connected to said rearward end. One end of a chute traverses the trough, while the other is supported by the support arm. A scraper is to the chute to spread concrete distributed from the trough into the pipe invert.
In operation, the apparatus for distributing concrete that is positioned at one entrance of the metal pipe invert. The concrete is poured into the chute and distributed into the trough. The apparatus is pulled through the metal pipe invert to distribute concrete from an opening in the trough onto the metal pipe invert. The scraper engages the concrete to selectively spread the concrete on the metal pipe invert and repair the invert.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an apparatus for laying concrete on metal pipe inverts;
FIGS. 2 and 3 are side elevational view of the apparatus engaging a metal pipe invert;
FIG. 4 is a side sectional view of the metal pipe invert illustrated in FIG. 3 ;
FIG. 5 a is a cross-sectional view of the metal pipe invert;
FIG. 5 b is a cross-sectional view of the metal pipe invert treated with the apparatus;
FIG. 6 is a top plan view of the apparatus;
FIG. 7 is an elevational view of the forward end of the apparatus;
FIG. 8 is an elevational view of the rear end of the apparatus; and
FIGS. 9 and 10 is a perspective view of the apparatus engaging a metal pipe invert.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in detail to FIGS. 1-10 , an apparatus 10 to lay concrete 6 on metal pipe inverts 8 is illustrated. The apparatus 10 includes a base frame 14 , which in the illustrated embodiment includes a pair of spaced apart runners 16 that are connected to each other via one or more support arms 18 . Each runner 16 has a forward end 16 f and a rearward end 16 r , with the support arms 18 connecting the runners 16 at the rearward end 16 r . As shown in the embodiment illustrated, the support arms 18 form an A-frame between the runners 16 , although it is foreseen that the support arms 18 may be designed according to any known shape useful for the present application.
The apparatus 10 further includes a trough or receptacle 12 that is mounted between both runners 16 of the frame 14 toward the forward end 16 f of the runners 16 . The trough 12 includes a forward wall 12 f , a rearward wall 12 r , two side walls 12 s , and a floor 13 connected with the lower most edges of the walls 12 f , 12 r and 12 s . It is foreseen that various configurations of the trough 12 beyond the box-shape illustrated in the attached drawings could be implemented by one having ordinary skill in the art to achieve the desired distribution of concrete 6 described herein.
The apparatus 10 additionally includes a chute 20 , duct or other conduit having a distal end 20 d and a proximal end 20 p . In the embodiment illustrated, the chute 20 has a hollow cylindrical shape, with the proximal end 20 p intersecting or connecting with the rearward wall 12 r of the trough 12 . The distal end 20 d of the chute 20 is supported by the support arms 18 mounted on the runners 16 .
A recession 22 is defined in the distal end 20 d of the chute 20 to receive cement 6 from a concrete mixer or other source 21 (see FIG. 2 ). Furthermore, the distal end 20 d of the chute 20 is elevated by the support arms 18 above the proximal end 20 p so that cement may be dispense into the chute 20 through the recession 22 and directed by gravity into the trough 12 . The trough 12 includes an opening 11 traversing or proximate the floor 13 of the trough 12 . The opening 11 may extend from runner 20 to runner 20 , or it may have a varying shape. In addition, a supplemental plate (not shown) may be incorporated to vary the size of the opening 11 . Similarly, the floor 13 adjacent the opening 11 may be positioned at an angle to assist the flow of concrete 6 on to the invert 8 . In any case, the opening 11 is designed to allow the concrete 6 to pass through the floor 13 to the surface below the apparatus 10 , which in operation is the metal pipe 8 .
A pair of cable connectors 24 are attached to the forward wall 12 f of the trough 12 , and they may also be connected to the rearward end of the apparatus 10 , such as on the support arms 18 . A cable, chain, rope or similar embodiment may be linked to the connectors 24 to assist the user in moving the apparatus 10 back and forth in a substantially horizontal direction. In addition, a lift connector 26 is affixed to the chute 18 , such that the apparatus 10 is able to be lifted and positioned using this connector 26 .
The apparatus 10 additionally includes at least one scraping apparatus for controlling the dispersion of the concrete 6 in the metal invert. A first scraping apparatus 30 a is attached to the distal end 20 d of the chute 18 . The first scraping apparatus 30 a includes a pair of connectors, such as L-shaped arms 32 , that are securely connected to opposite sides of the chute 18 , such as by welding. A connecting aperture 34 extends through both L-shaped arms 32 , and through the use of a pin 35 , a support sleeve 36 is connected to the respective L-shaped arm 32 .
The scraping assembly 30 a additionally includes a primary flexible scraper flange or wings 38 that is connected to the support members 36 . In the embodiment shown in the figures, the scraper flange 38 has somewhat of a semi-circular or semi-ellipse shape, with the width of the primary scraper 38 being greater than the width of the trough 12 . That is, the primary scraper 38 has a contoured side edge and a substantially flat bottom edge. In this embodiment, the scraper 38 is sandwiched between two metal plates 40 that are connected with a support member 37 . The scraper 38 is made of a flexible material (such as rubber) so that it will be able to bend when in contact with the metal pipe 8 . The support member 37 will traverse or engage the support sleeve 36 so that the position of the support member 37 may be adjusted with respect to the sleeve 36 to determine the position of the scraper 38 with respect to the runners 16 and the metal invert 8 .
In addition, a pivot bar or rod 39 may be mounted to the distal end 20 d of the chute 20 to provide a supplemental means for adjusting the first scraping apparatus 30 a . That is, the first scraping apparatus 30 a may be pivotally connected to the rod 39 so that the first scraping apparatus 30 a may pivot between a lowered position (see FIG. 1 ) and a raised position (see FIG. 9 ). In the lowered position, the first scraping apparatus 30 a will engage the concrete 6 distributed in the invert 8 , whereas in the raised position, the first scraping apparatus 30 a will simply be displaced from the surface of the concrete 6 .
Continuing to view FIG. 1 , the apparatus 10 may include a supplemental scraping apparatus 30 b connected to opposite sides of the trough 12 . That is, the scraping apparatus 30 b may be affixed to opposite sides of the rearward wall 12 r of the trough 12 . The supplemental scraping apparatus 30 b includes a secondary scraper flange or wing 42 that is connected to each side of the rearward wall 12 r using a respective secondary plate 44 and bolt or screw 45 . The secondary scrapers 42 may be attached to the rearward wall 12 r such that they extend outwardly from the trough 12 in opposite directions, with the secondary scrapers 42 engaging the side walls of the metal tube 8 as necessary. Because the scrapers 42 may be made of a somewhat flexible material (such as rubber), they will be able to bend as necessary for the apparatus 10 to traverse the metal invert 8 . Furthermore, a substantially horizontal slit 33 extends through each supplemental scraping apparatus 30 b , such that the position of the supplemental scraping apparatus 30 b may be adjusted with respect to the pipe 8 as desired by simply loosening the screw or bolt 45 and adjusting the position of the secondary scraper flange 42 and secondary plate 44 .
Placing concrete 6 in the failed metal pipe inverts 8 is a much faster and less expensive process than conventional replacement of the metal pipe 8 . In operation, the concrete 6 from the mixer 21 is poured into the chute 20 through the recession 22 , and thereby distributed into trough 12 . The concrete 6 will temporarily be stored in the trough 12 , and the apparatus 10 will be pulled through the metal pipe 8 , with the forward end 16 f initially leading the way through the pipe 8 the first time. The scrapers or wings 38 of the apparatus 10 will spread the concrete 6 as the apparatus 10 is pulled through the metal pipe 8 . The concrete 6 will fill up the holes below the invert 8 as well as the lower portion of the pipe invert 8 (see FIG. 5 a ), and the concrete 6 will then be allowed to set. After the concrete 6 has set, the process will be repeated, and these steps will be followed until the complete bottom of the metal invert 8 is covered with concrete 6 , such as 3000 PSI pea gravel mix with fibermesh.
In order to fill all of the failed invert 8 at the desired distribution, the user may make multiple pulls of the apparatus 10 through the metal pipe 8 . That is, the rearward end 16 r may be pulled back through the pipe 8 , and then the forward end 16 f will be pulled through one again. The last pass is with adjusted scrapers or wings 38 so the concrete 6 can be smoothed and pulled up the walls of the metal pipe 8 . This gives a concrete bottom 6 for the water to run across during normal flow, and therefore the metal remains dry during this normal flow period. During rains or high water periods, the metal pipe 8 may fill up and carry the water load. After high flows recede, though, the water level will return to normal flow and the metal pipe 8 will dry.
The manpower needed for operation of the apparatus 10 will vary, but it is foreseen that it can be operated by two to three persons and take about one hour for typical operation in a standard pipe 8 , which would include passing the apparatus 10 down and back a pipe 8 of standard length (approximately 20 feet), with one additional pass all the way through the pipe 8 . During the first two pulls, the scrapers/wings 38 will be kept in an upright position. In the last pull through, the scrapers/wings 38 will be lowered and the user will simply pull the apparatus 10 all the way through the pipe 8 .
The apparatus 10 may operate with pipes 8 of having various lengths and widths. In addition to the standard sized pipes 8 noted above, it can be used with pipes 8 having various diameters (e.g, 54-72 inch diameters) and having lengths of 60 to 90 feet and longer according to the length of the pipe laid. These dimensions are simply examples, and it is noted that the diameters and lengths of the pipes 8 may vary with the apparatus 10 still being able to operate properly. Furthermore, the dimensions of the apparatus 10 disclosed above and in the drawings may vary as necessary for the corresponding pipe 8 .
While the invention has been shown and described in preferred forms, it will be apparent to those skilled in the art that many modifications, additions, and deletions can be made therein. For example, the footholds can be secured to the platform of the tree stand assembly. These and other changes can be made without departing from the spirit and scope of the invention as set forth in the following claims.
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An apparatus and method for repairing failed metal pipe inverts includes an apparatus for distributing concrete that is positioned at one entrance of the metal pipe invert. The apparatus includes a frame having a forward end and a rearward end. A trough is connected to the forward end, and a support arm is connected to said rearward end. One end of a chute traverses the trough, while the other is supported by the support arm. A scraper is to the chute to spread concrete distributed from the trough into the pipe invert. The concrete is poured into the chute and distributed into the trough. The apparatus is pulled through the metal pipe invert to distribute concrete from an opening in the trough onto the metal pipe invert. The scraper engages the concrete to selectively spread the concrete on the metal pipe invert and repair the invert.
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BACKGROUND OF THE INVENTION
This invention relates generally to a bearing assembly and, more particularly, to a bearing assembly having a pillow block housing for supporting a linear bearing which, in turn supports a slidable shaft.
In many applications, the slidable shaft is guided by two bearings which are housed in two axially spaced pillow blocks. In order to enable free sliding of the shaft, it is essential that the centerlines of the two bearings be in precise alignment. Such precise alignment is difficult to attain, however, because of imprecision in the structure on which the pillow blocks are mounted or because of imprecise installation of the pillow blocks. While self-aligning pillow blocks exist, they are relatively complex in structure and, in some cases, the pillow blocks themselves are so imprecise that ball bearing bushings are necessary to compensate for the loose tolerances of the pillow blocks and maintain precise centerline accuracy.
SUMMARY OF THE INVENTION
The general aim of the present invention is to provide a new and improved pillow block housing which is self-aligning and which, at the same time, is of very simple construction and establishes precise and rigid centerline accuracy.
A more detailed object of the invention is to achieve the foregoing by providing a pillow block housing having a bore which is shaped to enable the bearing to rock universally within the housing through a limited range to permit self-alignment while still maintaining precision rigidity.
In still a more detailed sense, the invention resides in forming a spherical radius at the midportion of the pillow block bore in order to permit rocking of the bearing while still providing the solid rigidity necessary to support overhung loads.
These and other objects and advantages 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
FIG. 1 is a fragmentary perspective view of a typical installation utilizing bearing assemblies having new and improved pillow block housings incorporating the unique features of the present invention.
FIGS. 2 and 3 are diagrammatic views which schematically illustrate on a greatly exaggerated scale two different conditions which can cause centerline misalignment of a pair of axially spaced bearing assemblies.
FIG. 4 is an enlarged fragmentary cross-section taken substantially along the line 4--4 of FIG. 1.
FIG. 5 is a fragmentary cross-section taken substantially along the line 5--5 of FIG. 4.
FIG. 6 is an enlarged fragmentary cross-section taken axially through the bore of the pillow block housing of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
For purposes of illustration, the invention has been shown in the drawings in conjunction with bearing assemblies 10 for linearly slidable shafts 11. In this instance, two parallel shafts have been illustrated and each is adapted to slide within a pair of axially spaced bearing assemblies. The bearing assemblies have been shown as being secured to the underside of a component 12 such as a machine tool carriage and support the carriage for movement along the shafts.
It is important that the carriage 12 be supported precisely and rigidly on the shafts 11 and to be able to move freely along the shafts with very low friction. In order to enable free sliding, it is necessary that the axes 13 (FIGS. 2 and 3) of the two bearing assemblies 10 for each shaft be in precise alignment and coincide precisely with the axis 14 of the shaft so as to prevent binding of the shaft. Precise alignment of the two axes 13, however, is difficult to achieve. For example, the carriage 12 may be bent slightly as shown in FIG. 2 thereby resulting in the axes 13 of the bearing assemblies 10 sloping in opposite directions relative to the axis 14 of the shaft 11. Or, the carriage may be torqued as shown in FIG. 3 and cause the axes 13 to slope in the same direction relative to the axis 14. Still a further misalignment condition which has not been illustrated involves the installation of one bearing assembly 10 at an angle relative to the other assembly such that the axis 13 of one assembly is inclined relative to the axis 14 of the shaft even though the axis of the other assembly might coincide with the shaft axis.
The present invention contemplates the provision of a bearing assembly 10 having a unique pillow block housing 15 which, while being simple, rigid and precise, is constructed so as to enable the axis 14 of the shaft to pivot relative to the geometric axis 13 of the overall bearing assembly and thereby enable the shaft to automatically compensate for any minor misalignment between two bearing assemblies. The pillow block housing 15 of the invention is particularly characterized by the fact that it provides self-alignment capability while holding an extremely close centerline tolerance.
More specifically, each pillow block housing 15 includes a body 16 and a mounting flange 17. A bore 18 of circular cross-section is formed longitudinally through the body 16. Housed in the bore 18 is a bearing or bushing 19 (FIG. 4) which forms part of the overall bearing assembly 10. The bushing is formed with a cylindrical bore 20 which is lined with an antifriction material to enable the shaft 11 to slide freely in that bore.
The outer surface of the bushing 19 is cylindrical and is formed with two axially spaced and circumferentially extending grooves which receive resiliently yieldable O-rings 21 (FIG. 4). The O-rings are compressed by the bore 18 of the pillow block housing 15. Two snap rings 22 fit into axially spaced annular grooves in the bore 18 and engage the ends of the bushing 19 to captivate the bushing axially.
In carrying out the invention, a portion of the bore 18 of the pillow block housing 15 is longitudinally crowned in order to enable the bushing 19 to rock universally through a limited distance and accommodate misalignment between two paired pillow block housings. Referring to FIG. 5, there is shown a radial plane P which cuts through the bore 18 substantially midway between the ends of the bushing 19. In the radial plane P, the bore 18 has a minimum diameter D which very closely approximates the outer diameter of the bushing 19. As the bore proceeds axially in opposite directions from the plane P, its diameter increases progressively and symmetrically for predetermined equal distances A. The two end portions 25 of the bore are of conventional cylindrical shape.
While the bore 18 could be defined by two oppositely tapered frustums whose small ends meet at the radial plane P, it is highly preferred that the bore be arcuately crowned (i.e., formed on a large spherical radius R (FIG. 4) struck from a center C located in the plane P). Stated differently, the bore 18 is shaped such that every possible line extending longitudinally along the surface of the bore defines a convex arc 26 having a midpoint located at the plane P and having ends each spaced a distance A from such plane. The bore may be formed in this manner by a boring tool operated by a CNC machine tool.
By virtue of the crowned bore 18, the bushing 19 of the bearing assembly 10 may rock in the pillow block housing 15 in any direction necessary to enable the axis of the bushing to move into alignment with the axis of the bushing of a paired bearing assembly 10 and thereby accommodate misalignment between the nominal axes 13 of the two bearing assemblies themselves. Importantly, the self-alignment capability afforded by the crowned bore 18 does not sacrifice precision. In one specific example, the crowned portion of a bore with a diameter D of 1.25" has a total length 2A of 2.0" and allows the bushing to pivot in any direction through an angle a of 1/2 degree. This results in an angular displacement of the bushing and shaft through 0.0087" for each inch of length from the plane P. Because of the precision fit between the inner diameter of the bore 18 and the outer diameter of the bushing 19 at the midpoint plane P, the centerline accuracy X (FIG. 5) of the bearing assembly 10 is held to within a tolerance of plus/minus 0.0010" as opposed to an industry standard of plus/minus 0.003".
From the foregoing, it will be apparent that the present invention brings to the art a new and improved pillow block housing 15 in which the specially shaped bore 18 allows universal rocking of the bushing 18 to accommodate misalignment. The resilient O-rings 21 dampen vibration and tend to keep the axis of the bushing coincident with the axis of the bore but yield as necessary to permit rocking of the bushing. Softer or harder O-rings may be used to control the lateral stiffness of the bearing assembly.
Since the bushing 19 is cylindrical and is not crowned, the same bushing may be used in the self-aligning pillow block housing 15 or in a standard precision housing. Also, the bearing 19 may be in the form of the plain bushing which has been shown or, as an alternative, a Thompson-type roller bearing may be used in the housing 15.
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A shaft is supported to slide in a linear bearing which, in turn, is supported within a bore in a pillow block housing. To enable the bearing to self-align with a bearing in a paired pillow block housing, the bore of the housing is longitudinally crowned and permits the bearing to rock universally within a limited range while still maintaining rigidity and precise centerline accuracy.
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CROSS-REFERENCE TO PRIORITY APPLICATION
This application hereby claims the benefit of the commonly assigned German Patent Application Serial No. 10 2007 030 425.2 (filed Jun. 29, 2007), which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to a forwardly movable vehicle seat assembly and seat that is particularly suited for front seats of motor vehicles equipped with only one side door on each vehicle side.
BACKGROUND
In known vehicle seats, access to the rear row of seats may be eased by moving the front vehicle seat forward. Typically, a user manually moves the front seat forward, and later backward. In other words, the user introduces the forces necessary to move the motor vehicle seat forward and backward. Specifically the user grasps the upper part of the seat back and pushes the seat back together with the entire motor vehicle seat into the forwardly moved position. Thereafter, the user pushes the entire motor vehicle seat backward from a forwardly moved position to a position of use (i.e., position of utilization) wherein the user may sit and drive the vehicle. For ease of use, it is preferable for the seat to readily move forward and backward with as little force as possible applied by the user. As necessary, a motor may partially assist the forward and/or backward movement of the vehicle seat. It will be understood that in general configurations the user typically tilts the seat back rearward in a manual fashion.
Known configurations for movable vehicle seats are described in DE 10 2004 061 139 A1. Further, known forwardly movable vehicle seats are described in DE 101 51 762 A1 and to U.S. Pat. No. 5,352,019.
Known forwardly movable motor vehicle seats are typically equipped with a memory unit. The memory unit stores a position of utilization and facilitates movement of the seat to a previously adopted position of utilization when the vehicle seat is moved backward from a forwardly moved position.
A vehicle seat frame is connected to an underbody of a motor vehicle. Suited means are provided for this purpose. The invention relates to motor vehicle seat frames that are equipped with a longitudinal adjustment device comprising two pairs of rails that are lockable through a locking unit, and to motor vehicle seat frames that move forward through hinge arms articulated between the seat pan and an underbody. The invention further relates to other constructions for a longitudinal adjustment device.
As disclosed in previously cited DE 101 51 762 A1, a forwardly movable vehicle seat may include a stopper device used in connection with a seat back hinge. In a first stop position, the stopper device retains the seat back in the normal position of utilization. In a second stop position, the stopper device retains the seat back in a forwardly pivoted position. Through a special transmission means as disclosed, the stopper device is restricted to a second stop position wherein the seat back is in a front or forward portion of travel, and not in a rear portion. The disclosure contained in DE 101 51 762 A1 is incorporated in the present application.
Known forwardly movable vehicle seats to include the vehicle seat disclosed in DE 10 2004 061 139 A1 have yet to overcome one particular problem associated therewith. When known vehicle seats are moved backward from a forwardly moved position, a certain actuation force is required. The actuation force is usually applied by the user to the seat back. Upon application, the actuation force translates to and acts against the stopper device. By doing so, the actuation force advances the stopper device into the stop position in a manner more forcefully than without said actuation force. The disclosed vehicle seat incorporates two parts for ensuring that the seat back is retained in the second or forward stop position, namely a blocking cam and a limit stop. During actuation to release the seat back from the forward position, the blocking cam and limit stop are pushed against each other, such that the lever arm formed by the seat back transmits the actuation force thereby increasing the contact force between the blocking cam and limit stop. As a result, it is much more difficult to release the stopper device (i.e., separating the blocking cam and limit stop) during backward movement. Accordingly, actuation and release of the stopper device during backward movement requires a considerable release force.
SUMMARY OF THE INVENTION
It is one object of the present invention to further develop the forwardly movable motor vehicle seat according to DE 10 2004 061 139 A1 in such a manner that the stopper device can be released with less force applied to the seat back, in particular during backward movement of the motor vehicle seat. This object is solved by the features of patent claim 1 .
As contrasted to the forwardly movable vehicle seat according to DE 10 2004 061 139 A1 there is now provided at least one transmission means between the blocking cam and the release device. This transmission means increases the force assisting the separation of the blocking cam and limit stop at the expense of the travel. It is preferably configured to be a lever transmission but may also be formed otherwise, in particular as a block and tackle. These configurations may also be combined. As a result, the forces which are available when the motor vehicle seat is being moved backward manually will suffice to release the stopper device.
The transmission means is defined in that it increases the force at the expense of the travel. The travel increases to the same extent as the force transmitted by the transmission means. Accordingly, the release device must travel a longer distance than in prior art, which results in an increased actuation force at the blocking cam. The force transmission of the transmission means is at least 20%, preferably at least 50% and more specifically at least 100%. With a 100% force transmission, meaning when the force is doubled, the actuation travel is also doubled.
Preferably, the stopper device is actuated and controlled such that it retains the seat back in the forward tilted position as long as the seat frame is located in a front portion of its travel. The stopper device enables the seat back to be tilted upward into the normal position of utilization if the seat frame is located in a rear portion of the travel.
The release device typically includes at least one transmission means. In one embodiment, the transmission means may include any type of flexible cable used to transmit mechanical force by the movement of an inner cable relative to a hollow outer cable housing. One such embodiment of the transmission means is commonly referred to as a “Bowden cable.” In one embodiment a Bowden cable is connected to a region of the seat frame where a relative movement of parts occurs during movement of the vehicle seat (e.g., between the rails of a longitudinal adjustment device or between a hinge arm and the underbody of the vehicle). Incorporation of such a transmission means results in a desired amount of controllable force that is available and transmittable to other elements of the invention. It will be understood that the available force provided by the transmission means originates indirectly from the actuation force applied by a user. By virtue of the transmission of the actuation force by the at least one transmission means, the force needed to release the stopper device is much less than the force needed to release the stopper devices as disclosed in prior art. Generally, the release device additionally has a device for controlling the transmission means.
Moreover, the actuation force required to manipulate the seat back may be reduced by choosing a configuration that reduces the friction affecting movement of the blocking cam and/or limit stop. For example, one embodiment of the invention may incorporate a rotatable limit stop such as a pulley. In this configuration, the pulley abuts the blocking cam when the stopper device is in the stop position. The stopper device may then be released with a minimum amount of stopping force, and at any rate with less tensile force than with a limit stop configured to be a rigid bolt. By incorporating a pulley, sliding friction between the moving parts is thus avoided. As an alternative or in addition thereto, the blocking cam may also carry a pulley at its free end.
In one embodiment of the invention, the rear portion of the travel is quite short, ranging for example from 5 to 10 millimeters (mm). It is thus ensured that the seat back may only be tilted upward into the position of utilization when backward movement of the seat frame is almost completed. A certain distance is needed for the rear portion since otherwise it cannot be made certain that the seat back will release from the stopper device and adopt the position of utilization before backward movement of the seat frame has been completed.
The foregoing and other objects and advantages of the invention and the manner in which the same are accomplished will become clearer based on the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of a first embodiment of a vehicle seat in its position of use (i.e., in a rearward position);
FIG. 2 is a schematic side view of the vehicle seat of FIG. 1 illustrating the vehicle seat in the forward position wherein the seat back is in the forward tilted position;
FIG. 3 is a partial schematic side view of a second embodiment of the vehicle seat illustrating a seat back hinge wherein the seat back hinge is in the forwardly moved position;
FIG. 4 is a partial schematic side view of the second embodiment of the vehicle seat of FIG. 3 illustrating the seat back prepared for backward movement, wherein a release device has been actuated (i.e., a blocking cam has been released from a limit stop) to facilitate backward movement of the seat back into the position of use;
FIG. 5 is a partial schematic side view of a third embodiment of the vehicle seat illustrating an additional transmission lever; and
FIG. 6 is a schematic side view of a fourth embodiment of the vehicle seat illustrating a block and tackle with a deflection pulley as a transmission means.
DETAILED DESCRIPTION
The forwardly movable vehicle seat assembly includes a seat frame having a seat back 20 and a seat carrier 22 . This seat carrier 22 has a left side part 24 and a right side part (not shown). The seat back 20 is connected to the seat carrier 22 through a seat back hinge 32 . The seat back hinge 32 is comprised of a lower mounting part 34 and an upper mounting part 38 . The lower mounting part 34 is defined by at least a portion of the left side part 24 . The upper mounting part 38 is connected to the seat back 20 . The upper mounting part 38 is also connected to the lower mounting part 34 for pivotal movement about an axis 36 providing pivotal movement of the seat back. The lower mounting part 34 is fixed to the seat carrier 22 by any known conventional means. Through actually known means that are not illustrated herein, the angular position of the seat back 20 relative to the upper mounting part may be adjusted and secured. For example, one embodiment may include a toothed quadrant positioned on the upper mounting part 38 and stopper piece positioned on the seat carrier 22 , wherein the quadrant and stopper piece correspondingly engage one another. In one embodiment, the upper mounting part 38 is an integral constituent part of at least one side frame part of the seat back 20 .
The invention further provides a stopper device 40 formed between the upper and lower mounting parts 34 , 38 . The stopper device 40 consists of several individual parts that will be discussed later. The stopper device 40 enables the fixed integration or fixed immobilization of the two mounting parts 34 , 38 in the normal position of utilization of the vehicle seat (this function is not shown in the Figs.) such that the upper and lower mounting parts 34 , 38 may operate as a single unit. Upon release of the stopper device 40 , the seat back 20 may be pivoted forward from its position of utilization whereby the two mounting parts 34 , 38 may pivot with respect to each other. By means of the stopper device 40 , the seat back 20 is retained in a forwardly pivoted position (see e.g., FIG. 2 ). The stopper device 40 secures the seat back 20 , and more specifically secures the seat back in the pivoted position (see FIG. 2 ). It will be understood that the stopper device 40 secures the seat back 20 with a forward pivotal movement of between about 40° and 50°, as measured from the position of utilization, or at an angle of about 20° to 40°, as measured from the z axis.
Via front and rear pivotal arms, the two side parts 24 of the seat carrier 22 are connected to an underframe for pivotal movement. This underframe has two pairs of rails, each pair comprising a top rail 58 and a bottom rail 60 . Each pair of top and bottom rails 58 , 60 are locked together through a locking unit 56 in a known way. In a known way, the bottom rails 60 are each connected to an underbody 62 of the motor vehicle.
Between the rails 58 , 60 of at least one pair of rails, there is disposed a memory unit 63 as disclosed in the prior art. The memory unit 63 is exemplary of a release device. The memory unit 63 is connected to the stopper device 40 via a transmission means 64 . In one embodiment, the transmission means is configured to be a Bowden cable. At an upper end region of the Bowden cable, its sheath or hollow outer housing is fixed to the seat carrier 22 or to a part connected therewith. The core or flexible cable of the Bowden cable is fixed to a first transmission lever 66 at a point of action 86 . It will be understood that the point of action may include a pin, a pintle, or any known element capable of connecting the core to the first transmission lever 66 . In the first exemplary embodiment, the lever 66 is the transmission means, as shown in the FIGS. 1 and 2 . The transmission means is associated with the stopper device 40 , which will be discussed in closer detail herein after.
The stopper device 40 has a blocking cam 70 which, in the exemplary embodiment shown, is hinged to the side part 24 for pivotal movement about a cam axis 72 . The blocking cam 70 cooperates with a limit stop 74 that is fixed to the upper mounting part 38 . In the first exemplary embodiment ( FIGS. 1 and 2 ), and in the fourth exemplary embodiment ( FIG. 6 ) as well, the blocking cam 70 is configured to be a rigid axle journal, but in the second exemplary embodiment ( FIGS. 3 and 4 ), and in the third exemplary embodiment ( FIG. 5 ), the blocking cam 70 is configured to be a pulley. The blocking cam 70 forms an inclined clamping surface by which it rests against the limit stop 74 . Beneath this inclined clamping surface, said blocking cam 70 has a projection 76 that prevents the limit stop 74 from losing contact with the blocking cam 70 .
Approximately in its center region, the first transmission lever 66 has a lever axis 78 where it is articulated to the blocking cam 70 . The lever axis 78 is hereby closer to the inclined clamping surface than to the cam axis 72 . The first transmission lever 66 has a left arm, the free end of which is located approximately in the same position as the inclined clamping surface of the blocking cam 70 . As shown in the embodiment depicted in FIG. 2 , this left arm of the first transmission lever 66 abuts the limit stop 74 . It will be understood, however, that the left arm may be located in immediate proximity to this limit stop 74 . If a downward directed force is introduced at the right arm of the first transmission lever 66 through the core of the Bowden cable 64 , the left arm abuts the limit stop 74 and the lever axis 78 is pulled downward with the transmission of force. As a result, the blocking cam 70 is also pivoted downward to form a sufficient air gap between the limit stop 74 and the inclined clamping surface. In this configuration, the vehicle seat may be moved from the forward position depicted in FIG. 2 back into the position of utilization as shown in FIG. 1 .
The second exemplary embodiment shown in the FIGS. 3 and 4 coincides with the first exemplary embodiment insofar as the transmission means is formed by a lever gear and again only comprises one transmission lever, namely the first transmission lever 66 . In contrast to the configuration shown in the first exemplary embodiment of FIG. 1 , the cam axis 72 is now offset very far towards the left or forward (with respect to the present figure) in the first transmission lever 66 so that the ratio between the right lever arm and the left lever arm amounts to approximately 2:1 on the one side; on the other side, the lever axis 78 is also disposed in another position on the blocking cam 70 , namely much closer to the inclined clamping surface, so that the lever ratio now amounts to approximately 4.5:1. As a result, the lever transmission is now greater than in the first exemplary embodiment.
In the third exemplary embodiment shown in FIG. 5 , the transmission means is formed by a lever gear; though a second transmission lever 80 is additionally provided. The blocking cam 70 corresponds to the blocking cam of the second exemplary embodiment; the first transmission lever 66 is configured similarly. The transmission means 64 now does not act onto the first transmission lever 66 in the point of action 86 for the Bowden cable, but onto the second transmission lever 80 . The second transmission lever 80 is a one-arm lever and has a lever axis 78 as its axis by which it is fixed at its right end to the lower mounting part 34 . The second transmission lever 80 also includes a long hole 84 . In the second exemplary embodiment the pin of the first transmission lever 66 to which the Bowden cable 64 is connected engages through this long hole 84 . Finally, the second transmission lever 80 has a point of action 86 for the Bowden cable. The lever ratio, meaning the distance between the second lever axis 82 and the point of action 86 as compared to the distance between the long hole 64 and the second lever axis 82 , effects a power transmission. The arrangement consisting of the first transmission lever 66 and the second transmission lever 80 forms a pair of scissors as can be seen from FIG. 5 .
In the alternative in which the limit stop 74 is configured to be a pulley, this pulley may be realized in various manners. It may be any rotatable part. The circumference of the limit stop or pulley 74 must not extend over 360°. For example a smaller angular range of approximately 90° c.is sufficient. The surface of the pulley 74 may be hard or elastic. For example, the surface of the pulley 74 may be formed by an O ring made from rubber, which is resilient. The pulley 74 may also be toothed.
The features of individual claims may be combined, even if the claims are not directly referred to each other.
In the fourth exemplary embodiment shown in FIG. 6 , the transmission means is configured to be a block and tackle. As it is obvious when viewing it, this exemplary embodiment largely corresponds to the first exemplary embodiment. The fourth embodiment of the invention does not include a first transmission lever hinged to the blocking cam 70 . Rather, the fourth embodiment provides a rotatable deflection pulley 88 located at the same position and having the same axis of rotation as the first transmission lever of the earlier embodiments. The core of the Bowden cable 64 is fastened at the point of action 86 that is positioned on the lower mounting part 34 . The core of the Bowden cable 64 surrounds the deflection pulley 88 . As a result of this configuration, the transmission force is doubled, but the travel distance is now twice the length of the travel distance in the earlier embodiments. It is possible and advantageous to position the deflection pulley 88 closer to the inclined clamping surface. It is also advantageous to provide for at least one additional deflection pulley, so that the force transmission of the block and tackle is increased.
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The forwardly movable motor vehicle seat has a seat back ( 20 ) and a seat frame with a seat pan. The motor vehicle seat may be moved between a normal position of utilization and a forwardly moved position. An immobilizing device is associated with the seat frame. In particular, the seat back ( 20 ) has a seat back hinge ( 32 ) and a stopper device ( 40 ). The stopper device ( 40 ) retains the seat back ( 20 ) in the forward tilted position as long as the seat frame is located in a front portion of the travel path. The stopper device ( 40 ) enables said seat back to tilt upward into the normal position of utilization when the seat frame is located in a rear portion ( 74 ) of the travel path. The stopper device ( 40 ) has a first limit stop and a second limit stop, one limit stop being disposed on the seat frame and the other one on the seat back ( 20 ).
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BACKGROUND OF THE INVENTION
The invention relates to a process for ventilating the interior of a motor vehicle having at least one closure, such as a roof cover or windows, which can be opened by a drive motor operated in response to outputs from a logic component or control device which includes a computer for receiving inputs from an interior temperature-setpoint value generator, at least one interior temperature sensor and at least one outside temperature sensor.
The present invention can be incorporated in all motor vehicles of the luxury class which are equipped with electric window lift mechanisms and/or an electric sliding-lifting roof and an on-board computer as well as an air conditioner.
In addition to electrically operated windows and sliding-lifting roofs, various motor vehicle auxiliary ventilation systems are well known in the art. For example, European Patent No. 256,313 and German Patent No. 3,938,259 both disclose ventilation systems which are preferably operated by solar power and include a ventilator or fan and an operating device for a roof cover.
Since the individual components are usually obtained from various suppliers, each component has its own control panel, switching logic and sensors. This compilation of components creates an undesired accumulation of parts, which causes an increase in the total price and weight of the motor vehicle. Also, the driver may become stressed and distracted by the plurality of necessary switching operations, especially since the interaction of the various components is often difficult to figure out.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a process for ventilating the interior of a motor vehicle which effectively uses individual operating components (sensors, switching logic) in such a manner to provide a variety of ventilation conditions thereby relieving the driver, as much as possible, of the manipulation of controls. The process according to the invention is suitable both for auxiliary ventilation and for air conditioning in driving operation.
This object of the present invention is achieved by a ventilating process which includes reading both an interior temperature-setpoint value and an interior temperature-setpoint value range, and measuring both the motor vehicles' interior temperature and the outside temperature. These four values are supplied to the input of a logic component having a computer portion which calculates an upper and a lower threshold temperature. An output signal from the logic component then controls the drive motor associated with one or more of the vehicle closures (e.g., roof cover, windows, etc.) to move the closure in the opening direction if: the interior temperature is no greater than the outside temperature and the interior temperature is greater than the upper threshold temperature, or if the interior temperature is less than or equal to the outside temperature and the interior temperature is less than the lower threshold temperature. The vehicle closure will be moved in the closed direction if the interior temperature is greater than the outside temperature and less than or equal to upper threshold temperature and less than the lower threshold temperature. The process may also operate to turn on the vehicle's air conditioner if the interior temperature is greater than both the outside temperature and the upper threshold temperature.
The interior temperature-setpoint value can be adjusted manually on an interior temperature-setpoint generator so that each driver can set a temperature which is comfortable for himself. Also, a manual setting of the interior temperature setpoint value range may be provided to allow the driver, based on his experience in driving the motor vehicle, to preset the setpoint value range permitting the driver to have greater control over the opening and closing of the various vehicle closures (windows, sliding-lifting roof).
Values for the atmospheric moisture and/or motor vehicle speed can be supplied to the logic component as additional parameters to be used in calculating the interior temperature-setpoint value and the interior temperature-setpoint value range. Therefore, yet additional values essential for comfort may be considered in addition to the consideration of the outside and inside temperature.
In addition, the upper threshold value and lower threshold value may be calculated taking into consideration other parameters, such as outside temperature, atmospheric moisture, motor vehicle speed, or other performance data read from a memory connected with the logic component.
The process may also include a comfort switch to be operated by the driver which is examined before all other process steps to see whether it is in the ON position. In this manner, the driver can manually override the automatic operation of the ventilation system.
To enhance the ventilation action, the process may include operating at least one ventilator or fan placed in the motor vehicle, simultaneous with the operation of the roof cover and windows. Specifically, it is especially advantageous to activate the fan to convey air from the outside into the interior when the interior temperature is less than or equal to the outside temperature and the interior temperature is less than the lower threshold temperature. The fan is preferably placed in the area of a ventilation gap that is exposed by the cover or window being operated. The fan is also preferably operated by solar power which may be generated by a solar roof cover. However, the fan or fans may be powered by the motor vehicle battery, in which case undervoltage protection should be provided.
The interior temperature of the motor vehicle, as experienced by the occupant, may be more accurately determined by using two interior temperature sensors (e.g., in the head area and on the dashboard). A weighted average value can then be calculated using both measured values indicated by the sensors. Likewise, two outside temperature sensors may be used to produced an average weighted value. As a result, more reliable conclusions can be drawn from the outside temperature.
One of the inputs of the logic component may be connected to a rain sensor for detecting precipitation. If precipitation is detected, the logic component gives off an output signal causing at least partial closing of the vehicle closure.
These and further objects, features and advantages of the present invention will become apparent from the following description and the accompanying drawings which, for purposes of illustration only, show several embodiments in accordance with the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic arrangement of the individual components of the ventilation process embodying the present invention as applied to a motor vehicle;
FIG. 2 is a block diagram illustrating the ventilation process steps according to the present invention;
FIG. 3 is a block diagram illustrating the ventilation process steps of a second embodiment of the present invention incorporating an air conditioner.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the individual components used to effectuate the ventilation process are diagrammatically represented in relation to a motor vehicle indicated generally at 10. The motor vehicle includes an electric sliding-lifting roof 12 with a solar cover 14 and a first ventilator or fan 15 placed in the vicinity of the ventilation gap that is formed by opening cover 14. The electric sliding-lifting roof (SLR) 12 is operated by a logic component or SLR control device 16 which has several inputs and outputs at its disposal. The inputs include an interior temperature sensor 1 positioned in the driver's head area of the vehicle, an interior temperature sensor 2 located in the area of the dashboard assigned to an air conditioner 18 of the motor vehicle, an outside temperature sensor 3 placed in the area of the air supply shaft in front of the windshield, an outside temperature sensor 4 placed in the area of the front bumper, a tachogenerator 20, a rain sensor 22 preferably placed in the vicinity of the rear window, an atmospheric moisture sensor 24 and a comfort switch 26.
The SLR 12 is preferably normally supplied by solar power produced by crystalline solar cover 14 with the motor vehicle battery 28 acting as an alternate power source in case of insufficient output. SLR control device 16 (which can be a logic circuit, microcomputer chip or an existing on-board computer component of the vehicle) controls the position of SLR 12 via an automatic positioner 30 capable of moving SLR 12 into a closed position, a push-open position and one or more sliding positions. SLR control device 16 also controls the position of any window lift mechanisms, the operation of first fan 15 as well as the motor vehicle's second fan 32 placed in the area of the dashboard.
The operation of the motor vehicle air conditioner 18 is controlled by its own separate control device 34 to which both an interior temperature-setpoint value generator 35 and an interior temperature-setpoint value range generator 37 are connected. In a more integrated variation, these generators may also be connected to the control device of the electric sliding-lifting roof to control the operation of the air conditioner by this control device. Alternatively, instead of using a separate SLR control device 16, an air conditioner control device may be used as a logic component to which all ventilation related sensors are connected and from which all ventilation related control functions originate.
If the motor vehicle is equipped with an on-board computer to which an outside temperature sensor is connected, the latter may be suitably used to determine the outside temperature. In addition, if the vehicle is equipped with an air conditioner, existing interior temperature sensors, interior temperature-setpoint value generators and outside temperature sensors are also advantageously used.
If the SLR 12 or any other closure that can be opened is equipped with an existing operating mechanism of its own, the latter is suitably used as a logic component. Also, a cover that can be placed in the roof of the motor vehicle and swung at least around an axis transverse to the lengthwise direction of the motor vehicle is especially suitable for use.
Referring to FIG. 2, the operational sequence of a first embodiment of the ventilation process according to the present invention will now be described. Initially, in the first process step S1, which is triggered by the operation of a preselection clock (not shown) or a remote-controlled device, the position of comfort switch 26 is examined. The comfort switch is manually operated by the driver to activate or deactivate the automatic ventilation process as desired. If the comfort switch is in the On position, an interior temperature-setpoint value T SP and an interior temperature-setpoint value range ΔT SP are read into the control device 16 in the next process step S2. Alternatively, the driver may manually input these values in corresponding setpoint value generators. In the next process step S3, an interior temperature T IN and an outside temperature T OUT are read into the logic component of SLR control device 16 directly from two corresponding sensors. However, in the preferred embodiment, interior temperature value T IN is calculated from two initial values (T1, T2) measured by two interior temperature sensors 1 and 2 while two outside temperature sensors 3 and 4 provide two initial outside temperature values (T3, T4) for calculating outside temperature T OUT . Interior temperature T IN and outside temperature T OUT are each calculated from the corresponding initial temperature values using an average weighted percentage formulation as illustrated, for example, by the following formulas:
T.sub.IN =0.7×T1+0.3×T2
T.sub.OUT =0.1×T3+0.9×T4
In the following step S4, an upper threshold value temperature T UT is calculated according to the formula T UT =(T SP +ΔT SP )/2 and a lower threshold temperature T LT is calculated according to the formula T LT =(T SP -ΔT SP )/2. In a more complex variation not described here, outside temperature T OUT , inside temperature T IN as well as an atmospheric moisture reading (obtained, e.g., from rain sensor 22) and the traveling speed of the vehicle (determined as a function of the output of the tachogenerator 20, for example) could also enter into the calculation of upper threshold temperature T UT and lower threshold temperature T LT .
In the next process step S5, measured or calculated interior temperature T IN is compared to outside temperature T OUT . If interior temperature T IN is not greater than outside temperature T OUT then, in the next process step S6, it is determined whether T IN is smaller than T LT . If this condition is not met, the sequence or path of operation leads back to process step S3. If the condition in process step S6 is met, one or both of the fans 15, 32 are turned on in the following process step S7 and SLR 12 is placed in lifting position in the process step S8. Subsequently, the sequence of operation leads back to process step S3.
If the condition T IN >T OUT , examined in process step S5, is answered in the affirmative, an examination of condition T IN >T UT follows in the next process step S9. If the condition in process step S9 is not met, the inquiry follows in the process step S10 whether T IN <T LT . If this condition is also not satisfied, the sequence of operation leads back to step S3. If the condition in step S10 is satisfied, the fan is turned off and SLR 12 is closed in the subsequent steps S11a and S11b, respectively. The sequence of operation then leads back to step S3. If condition T IN >T UT in step S9 is met, one or both of fans 15 and 32 are turned on in the next process step S12 and the sliding-lifting roof 12 is lifted in the following process step S13. The operational sequence then again leads back to process step S3.
The turning on of the fan in step S7 as well as the lifting of the SLR in step S8, when interior temperature T IN is both less than or equal to outside temperature T OUT and less than lower threshold temperature T LT , is used to convey the relatively warmer outside air into the cooler interior of the vehicle. Conversely, the operation of the fan and the opening of SLR 12 in process steps S12 and S13 serve the purpose of removing heated air from the interior of the vehicle when interior temperature T IN is greater than both outside temperature T OUT and upper threshold temperature T UT .
The turning off of the fan or fans 15, 32 in process step S11a and the closing of SLR 12 in process step S11b serve the purpose of preserving the status quo when inside temperature T IN is greater than outside temperature T OUT , less than upper threshold temperature T UT and less than lower threshold temperature T LT . The ventilation process could also include a step for turning on a fan if interior temperature T IN fell significantly below the lower threshold temperature T LT in step S11b and a motor-independent heater was available.
In the second embodiment represented in FIG. 3, process steps S1 to S13 are identical to the above-described preferred embodiment shown in FIG. 2. However, if the motor vehicle has an air conditioner, the process may use the air conditioner to improve the quality of ventilation by incorporating the process steps S14 and S15 following step S13. While the process described in FIG. 2 also operates in a turned-off motor vehicle, the operation of the air conditioner is possible only when the motor vehicle is in operation because of the increased energy consumption of the compressor. The inquiry in process step S14 is whether the motor vehicle engine is operating. If engine operation is detected (such as by the presence or absence of a signal 61 from tachogenerator 20), terminal 61 of process step S14 shows a positive signal. If the result of the inquiry in step S14 is positive, the air conditioner is turned on in a step S15. Also, from step S15, the sequence of operation leads back to step S3. The turning off of the air conditioner is not represented and takes place automatically depending on temperature (e.g., following step S11b). If the result of the inquiry in step S14 is negative, the sequence of operation leads back without action to step S3.
Although process steps S8, S11b and S13 have been described as only operating the sliding-lifting roof 12, one or more electric window lift mechanisms 36 may be activated to at least partially open or close one or more of the motor vehicle windows simultaneously with these process steps.
Referring to FIGS. 1-3, one of the inputs of the logic component may be connected to a rain sensor for detecting precipitation. If precipitation is detected, the logic component gives off an output signal causing at least partial closing of the vehicle closure. The signal which leads from rain sensor 22 represented in FIG. 1 to control device 16 may be incorporated into the operational sequence in either of two places. As shown in FIG. 2, it may tie in before process step S3 as an additional inquiry, with the result that, if precipitation is noted, stopping of the process occurs. Alternatively, the question of precipitation can be asked before each operation of SLR 12 in the opening direction in steps S8 and S13. In this case, a positive answer results in bypassing step S8 or S13 thereby preventing SLR 12 or the windows from opening.
While we have shown and described various embodiments in accordance with the present invention, it is understood that the same is not limited thereto, but is susceptible of numerous changes and modifications as known to those skilled in the art, and we, therefore, do not wish to be limited to the details shown and described herein, but intend to cover all such changes and modifications as are encompassed by the scope of the appended claims.
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A process for ventilating the interior of a motor vehicle having a closure which can be opened by a drive motor, an interior temperature-setpoint value generator, at least one interior temperature sensor, at least one outside temperature sensor and a logic component with inputs, outputs and a computer portion. Existing components (sensors, logic components) of different units are used and operatively linked so that the driver is largely relieved of the need to manipulate numerous controls.
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This is a continuation of application Ser. No. 08/264,860, filed on Jun. 23, 1994, now abandoned.
FIELD OF THE INVENTION
The present invention relates to a stereoscopic imaging system. More particularly, the present invention relates to a stereoscopic imaging system in which a convergence angle is electronically controlled according to a distance from an object to the camera.
BACKGROUND OF THE INVENTION
To achieve a good stereoscopic image, it is important to adjust the convergence angle of the cameras in accordance with the distance from an object. Referring to FIG. 6, a detailed explanation will be made. A stereoscopic imaging system typically has two cameras, namely a right camera 1 and a left camera 2, which are used to obtain a stereo-graphic image. The distance between the object A and the cameras 1 and 2 is greater than the distance between the object B and the cameras 1 and 2. When an image of the object A is focused, as shown in FIG. 7, the image of the object A should preferably be centered in both image frames 3 and 4 of the right camera 1 and the left camera 2, respectively. On the other hand, when an image of the object B is focused, as shown in FIG. 8, it is preferable that the image of the object B is centered in image frames 5 and 6 of the right camera 1 and the left camera 2, respectively. In other words, referring to FIG. 6, when object A is located further from the cameras than object B, the convergence angle θ1 for the object A is smaller than the convergence angle θ2 for the object B. As a result of the control of these convergence angles, an observer can obtain a well-defined stereoscopic view from the images of the right and left cameras 1, 2 for both distances.
However, it is difficult to control the convergence angle mechanically due to the complicated mechanical system needed for adjusting the convergence angle required to obtain a stereoscopic view. Furthermore, such a mechanical system is relatively expensive.
SUMMARY OF THE INVENTION
One object of the present invention is to provide a stereoscopic imaging system in which the convergence angle for an object is controlled according to the distance between the object and the s imaging system.
Another object of the present invention is to provide a stereoscopic imaging system in which a convergence angle for an object is electronically controlled.
These and other objects of the present invention are achieved by a stereoscopic imaging system having a first and second imaging device. The first and the second imaging devices have a predetermined convergence angle there between for a particular object. A distance detecting apparatus detects a distance from the first and the second imaging devices and to an object for imaging. A first electronic zooming apparatus receives a signal from the first imaging device and extracts an image projecting over a predetermined area of a first imaging device. A second electronic zooming apparatus receives a signal from the second imaging device and extracts an image projecting over a predetermined area of a second imaging device. A control device controls the location of the projected images on the imaging devices according to the distance information.
In accordance with one aspect of an embodiment of the present invention, the distance detecting apparatus provides a measurement of the distance between a focused object and the imaging devices. According to the the measurement, the images projected onto the imaging devices are adjusted so that the focused object is located at the center of each of the provided image frames. As a result, the convergence angle is substantially changed according to the measured distance between the object and the imaging device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an embodiment of the present invention.
FIGS. 2(a), 2(b), 2(c) and 2(d) are illustrative views showing the operation of an embodiment of the present invention.
FIG. 3(a), 3(b), 3(c) and 3(d) are illustrative views showing the operation of an embodiment of the present invention.
FIG. 4 is an explanatory view illustrating a method of an embodiment of the present invention for deciding how much to shift the imaging frame to center the projected image.
FIG. 5 is a flow chart showing the operation of an embodiment of the present invention.
FIG. 6 is an explanatory view of a convergence angle defined by two cameras focused on one image.
FIG. 7(a) and 7(b) are explanatory views in which the convergence angle of two cameras is matched to an object A shown in FIG. 6.
FIG. 8(a) and 8(b) are explanatory views in which the convergence angle of two cameras is matched to an object B located closer to the cameras than the object A shown in FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a block diagram of a preferred embodiment of the present invention. This embodiment has two circuits, one for a right camera and one for left to achieve a stereoscopic image. For convenience, the following explanation will primarily concern the circuitry for the right camera as it is understood that the circuitry for the left channel is essentially the same.
An imaging lens 102 focuses the image of an object on an imaging device 104. In this embodiment, a charge coupled device (CCD) is used as the imaging device 104 which provides an output signal corresponding to one field picture at a 60 Hz rate or 60 field pictures in one second. It will be appreciated that the standard television signal, such as, for example, an NTSC signal, provides for video images at 60 Hz. An auto focusing drive circuit 106 controls the movement of the imaging lens 102 for focusing the object's image on the imaging device 104. A signal processing circuit 108 processes an output signal from the CCD 104. The signal processing circuit 108 includes a correlation double sampling (CDS) circuit and an automatic gain control (AGC) circuit. An A/D converter 110 converts an analog signal provided by the signal processing circuit 108 into a digital signal.
A digital memory 112 receives the digital signal from the A/D converter 110. The digital memory 112 has a capacity of storing data from a digital signal corresponding to each sequential picture field. A memory control circuit 114 controls write and read operations of the digital memory 112. The movement detecting circuit 116 compares each field picture with the previous field picture to detect unintentional movement of the stereoscopic imaging system from the user holding it. A digital signal processing circuit 118 receives a digital signal provided by the digital memory 112. The digital signal processing circuit 118 processes the digital signal from the digital memory 112 to provide a standard video signal, such as, for example, an NTSC color signal. A D/A converter 120 converts the digital signal output from the digital signal processing circuit 118 into an analog video signal. An auto focus (AF) integration circuit 122 receives the digital output signal stored in the digital memory 112 and integrates the high frequency elements (components) of the digital output signal for auto focusing. In this embodiment, auto focusing is achieved by a method in which high frequency elements of the video output signal is maximized. This method is based on the principle that the high frequency elements of a video signal are greater for in-focus status than for out-of-focus status.
As discussed above the digital memory 112 stores a digital signal corresponding to each sequential field picture which is provided by the CCD 104. In one embodiment, the CCD 104 comprises an array of picture elements to define one field picture. For each writing operation controlled by the memory control circuit 114, the digital memory 112 stores digital information corresponding to one array of picture elements of the CCD 104. The digital memory 112 has a predetermined number of memory regions. The predetermined number of the memory region is at least the number of picture elements of the CCD 104. Each memory region stores the digital information of one picture element. Further, each memory region has one unique address. Specific digital information for a specific picture element of the CCD 104 can be obtained from the digital memory 112 by using the appropriate address.
The digital memory 112 defines a read-out region in memory which is smaller in size than the storage capacity of the digital memory 112. When the stored information is retrieved from the digital memory 112 for electronic zooming and convergence angle control, the memory control circuit 114 controls the digital memory 112 to read out information corresponding only to the read-out region.
Further, the information from the read-out region is compensated and converted into a full size picture corresponding to all of the CCD picture elements. A zoom ratio is changed to vary the size of the read-out region to match the full size picture. In a preferred embodiment, the position of the read-out region within the the memory of digital memory 112 may be changed to control a convergence angle of two cameras or two imaging lenses 102 and 202 with respect to an object. As described above, since each memory region in the digital memory 112 has an address, the position change is achieved by changing a start address for the read-out region. Further, the position change is achieved along a direction of the arrangement of the two images on the respective CCDs.
As described above, the numerals 102-120 denote elements for circuitry for the right eye. Numerals 202-220 denote elements for circuitry for the left eye. Explanation for the elements 202-220 is omitted because those elements are substantially the same as elements 102-120.
A micro-computer 300 controls the operation of the stereoscopic imaging system. The micro-computer 300 receives the movement detecting signal from the movement detect circuits 116 and 216. The micro-computer 300 also receives an auto focus signal from the AF integration circuits 122 and 222. Further, the micro-computer 300 provides AF control signals to AF drive circuits 106 and 206 to control focusing of the imaging lenses 102 and 202 in response to the output of the AF integration circuits 122 and 222, respectively. The micro-computer also controls the operation of the memory control circuits 114 and 214.
Referring to FIGS. 2 and 3, a convergence angle control method in accordance with one embodiment of the present invention is described. In FIGS. 2 and 3, there are a distant object A and a close object B. A direction 302 is the direction of arrangement of the cameras. In this embodiment, the direction 302 coincides with a horizontal direction of the CCD 104 and 204. The stereo-graphic apparatus has a convergence angle adjusted to the distant object A. Further, an electronic zooming ratio is selected to be 1.5 (one and half). An electronic zooming is based upon the size of the image projected onto the imaging device 104 and the size of the read-out region. This zooming ratio is selected for the convenience of explanation.
First, when focusing is made on the distant object A, as shown in FIGS. 2 (a) and (b), the distant object A is located at the center of each image 308 and 310 projected onto the CCD's 104 and 204, respectively. This is because the convergence angle is adjusted to the distant object A and focusing is made on any object located on the center region of the image in this embodiment. Therefore, in the electronic zooming operation, a predetermined area (designated by dotted lines 304 and 306) located on the center part of each of the images 308 and 310 in FIGS. 2(a) and 2(b) is extracted and enlarged. As a result, images 312 and 314 (shown in FIGS. 2(c) and 2(d) are used for a left camera image and a right camera image, respectively. In the enlarged images, as shown in FIGS. 2(c) and 2(d), the distant object A is still located on the center of each of the images. In this case, it is not necessary to correct the convergence angle.
Next, the zooming operation with respect to the close object B is described. The convergence angle of the two cameras is not matched to the close object B but to the distant object A. Therefore, if the close object B is located on a center line between the two cameras, the close object B is not located on the center parts (designated by alternate long and short dashed lines 316 and 318, respectively) of each of the images 308 and 310. It is necessary to reposition each extracting area 304 and 306 for centering the close object B in the images 308 and 310 obtained from the two cameras. The areas 304 and 306 (designated by dotted line) are extracting areas. As shown in FIGS. 3(c) and 3(d), the close object B is projected onto the center part of each of the images 312 and 314 of the right camera and the left camera, respectively. Therefore, the convergence angle of the two cameras is apparently matched to the close object B.
Referring to FIGS. 4 and 5, the convergence angle control of one embodiment is described. The optical axes of two cameras are in parallel with each other therefore the actual convergence angle of the two cameras is 0 degrees. No mechanical convergence system is required. Instead, the position of the image is centered on the extracting area of the CCD.
In FIG. 4, the center of the left camera (or the imaging lens 204) is located on a point L, and the center of the right camera (or the imaging lens 104) is located on a point R. The distance between points L and R, which is the distance between the optical axis of the left camera and the optical axis of the right camera, equals a length 2A 0 . The length 2A 0 is preferably about 65 millimeters(mm) which that is nearly the average distance between the human eyes. Let us suppose that the horizontal length of CCD 204 is 3W 0 , the number of the picture elements along the horizontal direction 302 is 3X 0 , the focal length of the two imaging lenses of the left and right camera is L 0 , a maximum imaging range is Z, and the electronic zooming ratio is set at 1.5. The length of an imaging area on the CCD determined by the maximum imaging range is 2W 0 (3W 0 /1.5).
The close object B is located from imaging lenses L and R a distance l. When the system focuses on close object B, as described above, the image of the object B does not project onto the center o of the CCD 204, but onto a point 402 which is separated from the center o by a distance W. The distance W corresponds to a number X of picture elements of the CCD 204 along the direction 302. In the extracting operation for electronic zooming, the extracting area is shifted by the number X to the left (in FIG. 4). As a result, the image of the object B is centered on the image 312 in FIG. 3 (c). In the case of the right camera, the extracting area is shifted by the number X to the right (in FIG. 4).
Next, the derivation of the number X will be described. As shown in FIG. 4, triangles defined by LOW and LlB are similar. The following equation shows this relationship.
W:A.sub.0 =L.sub.0 :l
Consequently, as W/L 0 =A 0 /l,
W=(L.sub.0 *A.sub.0)/l (equation A)
Supposing that a number of picture elements per unit length at the CCD 204 is k, W and W 0 can be expressed as follows.
W=k*X
W.sub.0 =k*X.sub.0
The following equation is derived from the above two equations.
W/W.sub.0 =X/X.sub.0
Therefore,
X=W*X.sub.0 /W.sub.0
The following equation is further derived from the above equation and the equation A.
X=(L.sub.0 *A.sub.0 /l)*X.sub.0 /W.sub.0 =(L.sub.0 *X.sub.0 *A.sub.0 /W.sub.0)/l
Holding the values of L 0 , X 0 , A 0 and W 0 constant in the last equation, the number X of picture elements to be shifted is inversely proportional to the distance l between the imaging lens and the object B.
FIG. 5 shows a flow chart of the convergence control operation in accordance with one embodiment. First, the electronic zoom ratio is set at 1.5 in step S1. A horizontal position of the extracting area is set at a predetermined position corresponding to the center position of the extracting area in step S2. In step S3, predetermined values concerning the convergence angle control are set in memory. Namely, the separation of the two optical axis of the two cameras is set at 2A 0 , the horizontal length of the CCD is set at 3W 0 , the number of picture elements of the CCD along the horizontal direction is set at 3X 0 , and the focal length is set at L 0 .
In the following step S4, right and left AF data is obtained. The data of each of the right and the left AF may be proportional to the distance l between the imaging lens and the object. The AF data of the two channels may be averaged in step S5. Based upon the average value, the shift value x is calculated in step S6.
The derived value x is compared to a predetermined value X 0 /2 in step S7. Depending on the comparison, the next operation varies. If the value x is larger than the predetermined value X 0 /2, the value x is set at a predetermined value X 0 /2 in step S9. If the value x is smaller than the predetermined value X 0 /2, the derived value x is used. This comparison is made because of the maximum shift amount defined by the electronic zooming ratio. For an electronic zooming ratio of 1.5 and a horizontal length of the maximum imaging area of 2X 0 , a possible movable amount in one direction on the CCD is equal to X 0 /2.
The value x determined in steps S7 or S9 is used in steps S8 and S10. In step S8, the extracting area is shifted to the right by the value x in the electronic zooming operation of the left image. Further, the extracting area is shifted to the left by the value x in the electronic zooming operation of the right image in step S10. After these steps S8 and S10, step S4 through the step S10 are repeated. For AF data generated at every field period such as 1/60 second, the series of steps (from S4 to S10) is repeated every 1/60 second or at a 60 Hz rate.
In the electronic zooming operation, the final output signal is compensated and enlarged by 1.5. However, for convergence angle control, the enlarging operation is not required. Therefore, if the size of the extracting area is equal to the final output size, the extracting operation is sufficient for convergence angle control.
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A stereo-graphic apparatus has first and second imaging devices to provide a first image and a second image, respectively. The first and the second imaging device are spaced from each other to define a predetermined convergence angle. A distance detecting apparatus detects distance from the first and the second imaging device to an object for imaging. A first electric zooming apparatus receives a signal from the first imaging device and extracts image data of a predetermined area from the first image. A second electric zooming apparatus receives a signal from the second imaging device and extracts image data of a predetermined area of image. A control device controls the extraction of image data according to the distance information. According to the distance information, the extracting area is moved so that the focused object is located on the center of each of the provided images. As a result, the convergence angel is substantially changed according to the distance between the object and the imaging device.
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BACKGROUND OF THE INVENTION
This invention relates to a glass form, preferably a fiber, which resists high temperatures, at least 1900° F. and higher, while retaining at least some of its tensile strength and other physical properties.
In numerous applications, fabrics are utilized in systems which resist high temperatures. An example of the use of such fabrics is in reinforced coating systems. In these systems, the fabric is embedded in a char-forming, fire-resistive coating such as those described in Deogon, U.S. Pat. No. 5,591,791. Briefly, such coatings include ablative coatings, which swell to less than twice their original thickness when exposed to fire or other thermal extremes, intumescent coatings such as those disclosed in Nielsen et al., U.S. Pat. No. 2,680,077, Kaplan, U.S. Pat. No. 3,284,216, or Ward et al., U.S. Pat. No. 4,529,467, which swell to produce a char more than five times the original thickness of the coating, and subliming char-forming coatings of the type disclosed in Feldman, U.S. Pat. No. 3,849,178, which undergo an endothermic phase change and expand two to five times their original thickness to form a continuous porosity matrix. The intumescent and subliming coatings are denoted "active" thermal protective coatings.
The time required for a given temperature rise across a predetermined thickness of the composition, under specified heat flux, environmental, and temperature conditions, is a measure of the composition's effectiveness in providing thermal protection to an underlying substrate.
Eventually, the char is consumed by physical erosion and by chemical processes, such as oxidation by oxygen in the air and by free radicals produced by the coating or otherwise in a fire environment, and protection is substantially reduced. Before the char is totally consumed, degradation of the char layer leaves it crumbled and without the necessary strength to sustain itself, causing it to fail by being blown off or simply falling off (spalling).
Some of these chars degrade rapidly during exposure to high temperature, high heat flux environments. In the case of coatings which swell when exposed to thermal extremes, the degradations are usually in the form of fissures which are formed in the char as a result of differential thermal stresses produced by the high thermal gradients with them, and differential thermal expansion between the virgin material and the char.
To increase the strength of char layers during exposure to thermal extremes, and to limit spalling and fissures, fabrics have long been incorporated in the coating materials. As set out in Feldman et al., U.S. Pat. No. 5,622,774, fiberglass fabric provides an inexpensive, easy to install, reinforcement in many high temperature applications. In certain applications, however, such as coatings which may be exposed to high velocity petroleum fires or to high-temperature, high heat flux fires which will raise the fabric to temperatures above the softening point of the glass (around 1600° F.), the fiberglass fabric has disintegrated. Other fabrics have therefore been required. Graphite cloth, as taught in the foregoing Feldman et al. U.S. Pat. No. 5,622,774 and in Kobayashi et al., U.S. Pat. No. 5,401,793, is very expensive. Refractory materials, such as quartz (Refrasil) fabric is also expensive. Metal mesh is inexpensive but it is heavy and difficult to install, particularly because it generally requires welding metal studs to the substrate to be protected.
Other examples of fabric-reinforced systems are laminates in which the fabric is embedded directly in a structural resin material itself, for example in the structure of a furnace or a rocket nozzle. Generally, these materials also produce a char when exposed to sufficiently high temperatures, although in many applications they are routinely exposed to high temperatures below their char-forming temperature for extended periods. In other applications they are exposed for short periods to temperature, heat flux, and environmental conditions which do not cause a char to form, but which are sufficiently high to cause serious loss of structural properties. Examples of these latter systems are automobile gasoline tanks and trunks, which can be made of plastic material if they can pass a test involving preventing structural failure (such as drop through or explosion in the case of a gasoline tank) when the tank or trunk is placed over a fire of a specified temperature and intensity for a predetermined period such as two minutes. In all of these conditions, a fabric which resists complete degradation under the foregoing conditions can provide sufficient structural integrity to impede failure of the system.
Attempts have been made for many years to produce a glass fiber which retains a substantial portion of its mechanical properties even when subjected to very high temperatures, greater than 1600° F. (871° C.), and preferably on the order of 1900° to 2000° F. (1038° to 1093° C.). Examples are Nordberg, U.S. Pat. No. 2,461,841, Parker et al., U.S. Pat. No. 2,491,761, and Leeg et al., U.S. Pat. No. 2,992,960. These patents all involve leaching of the glass fiber with mineral acid, followed by treatment with a sizing material. Heretofore, such attempts have failed to provide a reliable, reproducible, and efficient process of converting commercial grade fiberglass (such as Type E and Type F glass fibers) into a material capable of withstanding elevated temperatures and aerodynamic shear which may be coupled with elevated temperatures.
BRIEF SUMMARY OF THE INVENTION
One of the objects of the present invention is to provide a reliable, reproducible, and efficient method of converting commercial grade fiberglass into a material capable of withstanding elevated temperatures.
Another object is to provide such a method which produces a fiberglass material capable of withstanding aerodynamic shear which may be coupled with elevated temperatures.
Another object is to provide such a method which produces a fiberglass material which retains at least a substantial part of its "hand" after prolonged exposure to elevated temperatures.
Another object is to provide such a method which is adaptable to a wide variety of applications.
Another object is to provide such a method which is easy to apply and extremely effective.
Another object is to provide an improved fiberglass cloth material.
Another object is to provide improved structural elements incorporating the improved fiberglass cloth material.
Another object is to provide improved structural elements incorporating a structural resin, a fabric, and an active thermal protective material.
Other objects will become apparent to those skilled in the art in light of the following disclosure.
In accordance with one aspect of the present invention, generally stated, a method of making a heat-resistant fiberglass fabric is provided comprising soaking a fiberglass fabric in a carefully selected acid bath for a selected time at a selected temperature. We have found that soaking the fiberglass in a mixture of acids containing at least 15% sulfuric acid at room temperature for a period of more than twenty-four hours, preferably at least about forty-eight hours, produces a material which maintains a substantial part of its physical characteristics even when heated to a temperature of at least 1600° F. for a period of at least one hour. The molality of the mixed acids is below 8, preferably around 5. It is anticipated that shorter soak times may be achieved with higher temperatures.
We have also found that the acid-treated fiberglass can be given superior qualities, such as improved "hand" (texture) both before and during exposure to high temperatures, by soaking the fiberglass in a low viscosity organo-metallic material, such as a low molecular weight silicone to fill the pores of the glass. The silicone is preferably in the form of a water-in-oil emulsion of low molecular weight silicone, such as dimethyl polysiloxane. The use of a water-in-oil emulsion, rather than an oil-in-water emulsion, inhibits the formation of silicone micelles and enhances absorption of the silicone into the pores of the glass fibers. We have found that soaking a fiberglass fabric for a period of more than forty-eight hours, preferably at least seventy-two hours, at room temperature in a low molecular weight, low viscosity, silicone bath produces superior results.
Certain combinations of acid treatment and treatment with low molecular weight silicone have been found to produce materials which consistently will withstand being heated to a temperature of 1900° F. for at least one hour in a muffle furnace.
The improved fabric has numerous uses, as will be apparent to those skilled in the art. It provides a superior reinforcement in thermal protective coating systems of the types previously described. For example, it may be embedded in fire-protective coatings of subliming, intumescing and ablative types, and has been found to provide excellent results as a reinforcement in sprayed-on subliming coating systems. It may also be used in active or passive cast or molded self-supporting thermal protective systems such as the system described in Feldman, U.S. Pat. No. 4,493,945.
In accordance with another aspect of the invention, structural members formed of thermoplastic resins are strengthened and protected from fire for extended periods by incorporating in them a high-temperature fiberglass fabric made in accordance with the present invention. The fabric is preferably pressed into a resin sheet as the sheet is formed into a container or other functional entity. In accordance with yet another aspect of the invention, such structural members are protected with a fabric or mesh which is pretreated with an active (intumescing or subliming) thermal protective coating material and then embedded in the thermoplastic material. The fabric is preferably a high-temperature fiberglass made by the method of the invention. Preferably, the fabric comprises an open weave mesh having from 0.5 to 20 openings per square centimeter. The active fire retardant material can be impregnated into the fiberglass or surface coated. It can be completely cured in a rigid or elastic form; it can also be supplied in a precured condition or in a semi-cured condition to be cured during processing. The cells of the treated or impregnated fiberglass can be open or filled. For some materials such as polypropylene, an open cell is preferred as it enables the softened polypropylene to pass through the opening and form a mechanical lock.
DETAILED DESCRIPTION OF THE INVENTION
To determine the effect of different acid compositions and exposure times at a constant temperature and acid molality, and to determine the effect of further treatment in a low molecular weight polysiloxane at a constant temperature for different time periods, a series of tests was made. The results of these tests are shown in Table 1.
TABLE 1__________________________________________________________________________ Acid Bath Time Wt Time in Wt ChangeSample Mole Ratio in Bath Change Silicone Wt Change In FromNo. Cl NO3 SO4 Hr. % Hr. From orig From acid muffle orig. Comments__________________________________________________________________________Blank -12.44% -12.44% shrunk, melted A-1 1 1 1 3 -0.08% 0 -0.08% 0.00% -11.76% -11.83% fragile, crisp A-2 1 1 1 3 -0.77% 6 5.82% 6.64% -16.89% -12.05% slightly fragile A-3 1 1 1 3 -0.34% 24 6.28% 6.63% -17.40% -12.22% slightly fragile A-4 1 1 1 3 0.00% 72 7.68% 7.68% -17.38% -11.04% slightly fragile A-5 1 1 1 8 -0.30% 0 -0.22% 0.08% -13.80% -13.98% less fragile A-6 1 1 1 8 -0.69% 6 5.66% 6.39% -17.24% -12.55% less fragile A-7 1 1 1 8 -0.35% 24 7.51% 7.89% -18.56% -12.44% less fragile A-8 1 1 1 8 -0.60% 72 7.01% 7.64% -17.37% -11.58% very nice A-9 1 1 1 24 -2.92% 0 -2.93% -0.10% -17.81% -20.21% less fragile A-10 1 1 1 24 -3.88% 6 2.84% 6.83% -21.10% -18.86% less fragile A-11 1 1 1 24 -1.92% 24 6.92% 8.97% -20.33% -14.81% less fragile A-12 1 1 1 24 -2.12% 72 0.18% 2.30% -20.07% -19.92% nice A-13 1 1 1 48 -6.59% 0 -6.15% 0.04% -23.14% -27.86% very nice - fuzzy A-14 1 1 1 48 -7.04% 6 3.91% 11.22% -26.89% -24.03% soft - fuzzy A-15 1 1 1 48 -6.38% 24 3.98% 10.62% -26.33% -23.39% very nice - fuzzy A-16 1 1 1 48 -4.54% 72 -3.38% 1.00% -26.16% -28.66% very nice - fuzzy B-1 2 3 1 3 -0.25% 0 -0.27% -0.02% -10.58% -10.82% fragile B-2 2 3 1 3 -0.39% 6 6.86% 7.28% -14.91% -9.07% fragile B-3 2 3 1 3 0.02% 24 6.01% 5.98% -18.29% -13.38% fragile B-4 2 3 1 3 -0.32% 72 7.62% 7.97% -16.37% -10.00% less fragile B-5 2 3 1 8 -0.85% 0 -0.79% 0.05% -13.56% -14.24% fragile B-6 2 3 1 8 -0.95% 6 4.26% 5.25% -17.62% -14.11% less fragile B-7 2 3 1 8 -1.10% 24 5.56% 6.71% -15.79% -11.11% nice B-8 2 3 1 8 -0.85% 72 5.48% 6.38% -18.26% -13.78% slightly fragile B-9 2 3 1 24 -5.47% 0 -5.27% -0.10% -16.44% -20.85% less fragile B-10 2 3 1 24 -3.24% 6 1.86% 5.16% -20.06% -18.56% nice B-11 2 3 1 24 -4.40% 24 4.70% 9.31% -20.89% -17.18% less fragile B-12 2 3 1 24 -4.31% 72 0.79% 5.14% -20.59% -19.96% nice B-13 2 3 1 48 -10.86% 0 -9.58% 0.23% -19.86% -27.54% very nice - fuzzy B-14 2 3 1 48 -10.29% 6 1.02% 11.42% -24.77% -24.00% nice - fuzzy B-15 2 3 1 48 -9.63% 24 3.29% 13.24% -24.99% -22.52% nice - fuzzy B-16 2 3 1 48 -10.89% 72 -0.31% 10.54% -24.76% -24.99% nice - fuzzy C-1 4 2 1 3 -0.09% 0 -0.10% -0.01% -13.10% -13.19% fragile C-2 4 2 1 3 0.00% 6 5.52% 5.52% -16.48% -11.87% slightly fragile C-3 4 2 1 3 -0.15% 24 7.62% 7.78% -16.79% -10.45% less fragile C-4 4 2 1 3 -0.08% 72 7.30% 7.39% -18.17% -12.20% slightly fragile C-5 4 2 1 8 -0.94% 0 -0.85% 0.07% -13.07% -13.81% slightly fragile C-6 4 2 1 8 -1.04% 6 4.57% 5.66% -18.14% -14.40% less fragile C-7 4 2 1 8 -0.67% 24 4.30% 4.99% -18.83% -15.34% slightly fragile C-8 4 2 1 8 -0.53% 72 4.78% 5.34% -19.15% -15.28% slightly fragile C-9 4 2 1 24 -4.83% 0 -4.63% -0.02% -16.68% -20.54% less fragile C-10 4 2 1 24 -5.38% 6 1.54% 7.00% -18.95% -17.70% slightly fragile C-11 4 2 1 24 -5.18% 24 3.98% 9.36% -19.70% -16.50% less fragile C-12 4 2 1 24 -4.62% 72 1.52% 6.21% -19.55% -18.32% less fragile C-13 4 2 1 48 -11.42% 0 -10.10% 0.17% -18.76% -26.96% nice C-14 4 2 1 48 -11.08% 6 1.59% 12.85% -23.59% -22.38% less fragile C-15 4 2 1 48 -10.30% 24 4.90% 15.71% -25.06% -21.38% less fragile C-16 4 2 1 48 -10.51% 72 0.06% 10.57% -22.90% -22.85% less fragile D-1 1 1 4 3 8.87% 0 1.78% -7.24% -15.64% -14.14% slightly fragile D-2 1 1 4 3 1.56% 6 10.81% 9.08% -17.73% -8.84% slightly fragile D-3 1 1 4 3 0.88% 24 12.22% 11.23% -16.50% -6.30% fragile D-4 1 1 4 3 1.29% 72 9.14% 7.73% -20.98% -13.76% fragile D-5 1 1 4 8 1.32% 0 1.36% 0.02% -15.18% -14.03% nice D-6 1 1 4 8 0.77% 6 9.52% 8.67% -21.82% -14.38% slightly fragile D-7 1 1 4 8 0.27% 24 7.21% 6.93% -19.01% -13.17% slightly fragile D-8 1 1 4 8 0.58% 72 4.50% 3.90% -19.29% -15.66% less fragile D-9 1 1 4 24 1.45% 0 1.71% 0.24% -18.33% -16.93% nice D-10 1 1 4 24 0.63% 6 12.25% 11.54% -22.71% -13.25% nice fuzzy D-11 1 1 4 24 2.10% 24 12.89% 10.52% -22.24% -12.21% nice fuzzy D-12 1 1 4 24 2.09% 72 0.08% -2.01% -21.21% -21.15% nice D-13 1 1 4 48 4.73% 0 8.04% 2.93% -23.89% -17.77% nice D-14 1 1 4 48 10.98% 6 18.84% 5.78% -24.70% -10.52% soft fuzzy D-15 1 1 4 48 10.92% 24 22.15% 8.80% -24.48% -7.75% nice fuzzy D-16 1 1 4 48 11.01% 72 -1.13% -12.01% -23.98% -24.84% nice fuzzy E-1 1 0 4 3 0.29% 0 0.31% 0.02% -11.51% -11.23% slightly fragile E-2 1 0 4 3 0.54% 6 10.84% 10.25% -18.64% -9.82% slightly fragile E-3 1 0 4 3 0.46% 24 12.85% 12.33% -18.33% -7.84% slightly fragile E-4 1 0 4 3 0.56% 72 9.88% 9.27% -21.75% -14.02% less fragile E-5 1 0 4 8 2.41% 0 2.55% 0.08% -17.69% -15.60% slightly fragile E-6 1 0 4 8 2.64% 6 11.64% 8.70% -18.82% -9.37% slightly fragile E-7 1 0 4 8 3.02% 24 8.06% 4.80% -18.54% -11.97% less fragile E-8 1 0 4 8 3.49% 72 3.58% -0.03% -18.44% -15.52% slightly fragile E-9 1 0 4 24 7.70% 0 8.08% -0.24% -22.04% -15.74% very nice E-10 1 0 4 24 5.88% 6 14.80% 8.05% -24.62% -13.47% soft fuzzy E-11 1 0 4 24 7.78% 24 17.76% 9.78% -24.16% -10.69% very nice E-12 1 0 4 24 7.04% 72 -0.18% -7.21% -21.80% -21.94% nice fuzzy E-13 1 0 4 48 10.58% 0 11.47% -0.32% -22.83% -13.98% soft fuzzy E-14 1 0 4 48 8.31% 6 18.63% 8.78% -25.45% -11.56% very nice fuzzy E-15 1 0 4 48 11.11% 24 15.43% 2.62% -25.56% -14.07% nice fuzzy E-16 1 0 4 48 3.15% 72 0.37% -2.79% -24.33% -24.05% nice fuzzy__________________________________________________________________________ Examined E13, A15, B15, C15, D15 & E15 E13 & E15 showed no visible differences under 30× microscope Weave threads of samples E13, E15 & D15 looked swollen These samples also had a softer "hand" and drooped more.
In making these tests, the following procedure was followed.
An acid bath was prepared by weighing the relative quantities of acid, mixing the acid thoroughly, and adding sufficient water to obtain a 5.0 molal solution. The selection of the 5.0 concentration was arbitrary, but it has been found that molalities of 8 or above do not function as well.
Samples of the unraveled fiberglass material (Type E, J. P. Stevens Type 1353) were weighed and then totally immersed in the acid bath for the indicated number of hours.
At the completion of each individual immersion period, the fiberglass sample was removed from the acid bath, carefully washed with clean water, dried, and weighed. This weight was compared to the weight of the sample in its virgin state.
Some of the acid-treated fiberglass samples were then totally immersed in a bath of low molecular weight dimethyl polysiloxane in the form of a dispersion of water in the polysiloxane oil. The dispersion was formed from a concentrate of low molecular weight dimethyl polysiloxane in a water-in-oil emulsion, as sold by Blackhawk Specialty Products, Inc., Rock Island, Illinois, as its BSP-89W. The time spent in the silicone bath is recorded in Table 1 for each sample.
The sample was then placed in a muffle furnace which was maintained at a constant temperature of about 1600° F. This temperature was selected to represent a typical average temperature within a char layer which results from the exposure of a subliming or intumescing material which is applied to a steel substrate in thicknesses that are capable of meeting relevant ASTM E-119 type fires for one, two, or more hours in duration.
The sample was kept in this environment for a period of about sixty minutes, then removed from the muffle furnace and cooled. Upon completion of cooling, it was examined for embrittlement, "hand" retention, and weight loss. If the sample retained its "hand" (indicated by the word "nice" in the comments section of Table 1) then it was subjected to further tests. It will be seen from Table 1 that samples A-8, A-12 through A-16, B-7, B-10, B-11 through B-16, C-13, D-5, D-9 through D-16, and E-9 through E-16 met the foregoing criterion and were tested further. All of these samples were soaked in the room temperature acid for a period in excess of three hours. All but C-13 had been soaked in a mixture including in excess of 15% sulfuric acid.
Fresh samples taken from corresponding lots as the foregoing samples were further exposed to 1600° F. in the muffle furnace for a period of sixty minutes. After cooldown, they were again checked for "hand retention," and results recorded. The samples which were embrittled were eliminated from further testing, leaving samples A-13 through A-16, D-13 through D-16, and E-13 through E-16 to be tested further.
Fresh samples taken from corresponding item lots as the foregoing samples were exposed to a muffle furnace fire at a temperature of about 1900° F. to about 2000° F. for a period of one hour. This temperature was selected because it represents a thermal environment most likely encountered within the char layer of a subliming or intumescing material which is exposed to a hydrocarbon fire environment as defined by Underwriters Laboratory procedure 1709 or a jet fire environment as defined by British Offshore Technology Report OTO 93 028 (Dec. 21, 1993). After cooldown, the samples were checked for "hand" retention, and results were recorded. The three item samples which were not embrittled were A-16, D-13, and E-16. All the most successful samples had been soaked at room temperature for over twenty-four hours in an acid solution containing in excess of 15% molal sulfuric acid, and two of the three samples had been soaked at room temperature for over twenty-four hours in the low-viscosity silicone emulsion.
Preliminary fire tests of the treated fiberglass fabric in a subliming fire-protective coating system indicate that the system provides superior results.
To further test the treated fabrics, and to demonstrate their usefulness in composite materials, the material was embedded in small (approximately 10 cm square) test polypropylene sheets as follows. In separate tests, two active fire protective materials were applied to the fabric: a subliming material (Thermal Science, Inc. THERMO-LAG 440-1) and a thin-film intumescent material (Thermal Science, Inc. THERMO-LAG 2000). In each case, the active thermal protective material was thinned in a solvent or low viscosity resin diluent. The treated fiberglass fabric was placed in a container of the thinned material and squeezed in a wringer to remove excess coating. This produces a coating of material on the fabric which covers the fibers of the fabric but does not close the individual cells in the fabric mesh. The coated fabric was heated to semicure the subliming material or to cure the intumescent material. The fiberglass remained somewhat elastic.
Polypropylene is a hard material with a surface that is difficult to adhere to. The test square was heated to 200° to 210° C. The female portion of a mold was heated to 60-70° C. The mold includes a ram with a platen which is heated to 60-70° C. The thermoplastic square was quickly placed into the mold with the fabric on top of it, and the ram was be moved quickly to mold the plastic before a skin is formed on the plastic. The sample was removed from the mold. This process caused the polypropylene to exude through the openings in the woven fabric and physically lock the fabric to the plastic sheet. Comparative flame tests without reinforcement, with untreated fiberglass, with treated fiberglass, and with treated fiberglass coated with each of the active thermal protective materials showed that the treated fiberglass systems provided substantial increases in time to failure, and the coated fiberglass provided dramatic increases in time to failure.
Based on the foregoing tests, it is believed that the treated fiberglass fiber of the present invention can be embedded into thermoplastic structures by the same process of incorporation during the molding process. Other fibers, coated with active thermal protective materials, can also be embedded into thermoplastic structures. Composite sheets including the treated and/or coated fabric may also be formed either by passing a single heated thermoplastic sheet and a structural automotive elements, firewalls and other high temperature barriers such as used on jet engines. These variations are merely illustrative.
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A glass fiber capable of withstanding temperatures in excess of 1900° F. is produced by treating a glass, preferably E-glass, fiber. The glass fiber is first leached with selected acids, and then the leached fiber is treated with organo-metallic materials of low viscosity, such as a dispersion of low molecular weight water-in-oil emulsion of dimethyl polysiloxane. The fiber is used in such applications as embedding it in a fire-resistant active coating material or embedding it into one surface of a polyolefin or composite plastic, such as a polypropylene sheet. The treated fiberglass can be used as a sole component or in concert with a fire-resistant or fire retardant material to further enhance its fire-resistant properties.
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SUMMARY
In order to automate the feed of a toe-sewing machine for pantyhoses and to permit simultaneously the automated feed of a pantyhose transfer device, use is made of a first carrousel (A1), with several arms and as many stations, and a second carrousel (A2), in a cascade arrangement with the first carrousel (A1), and also equipped with several arms and as many stations, where the loading station of the first carrousel (A1) coincides with the ejection station of a known machine (T) for forming pantyhoses and the ejection station of the second carrousel (A2) coincides with the loading station of pantyhose transfer device (G).
Each arm in the first carrousel (A1) is composed of two horizontal tubes (3), in order to receive inside the two legs, drawn in separately, and outside the reversed panty of the garment, which is transferred here from the machine (T) for forming the panty by means of a first transfer device (B1), operating at the loading station of the carrousel (A1) and equipped with two pincers (5) with horizontal prongs capable of opening out.
The second station of the first carrousel is equipped with devices to reverse the legs, positioning the toes to be sewn, and the third, or the third and the fourth stations are equipped with devices to sew separately, but either simultaneously or not, the toes of the two legs. After sewing the toes, the product is transferred onto an arm of the second carrousel (A2) by means of a second transfer device (B2)--similar to the first transfer device (B1)--operating at the ejection station of the first carrousel (A1).
Each arm in the second carrousel (A2) is composed of a pair of parallel horizontal tubes (31), capable of rotating around their longitudinal axis and equipped with a transverse bar (32) to stretch the product and enable it subsequently to be seized by a conveyor (G) through the opening in the garment to be fitted with the gusset.
The second station in the second carrousel (A2) is equipped with cutting devices (35), to make an opening eventually, if not present in the product.
DESCRIPTION
The invention concerns a process and a machine for sewing the toes of pantyhoses which comprises a direct and automated feed from a first machine, which machine sews the two stockings to form the panty of the pantyhose, which pantyhose is subsequently to be fitted with a gusset, and which further comprises an automated ejection mechanism suitable for a subsequent automated transfer of the garment, such as, for example, a transfer to a gusset-sewing machine.
From Spanish Pat. No. 504,417, an automatic device is already known which removes the garment from a machine which sews the two stockings to form the panty of the pantyhose, and then fit the panty with a gusset, and transfer it to a machine that sews the gussets. It is also known that before forming the pantyhose or after sewing the gusset it is necessary to sew the toes of the stockings by means of a further machine which until now has been fed manually.
The principal purpose of the present invention is to automate the feed operation of a machine for sewing the toes of the stockings and to make it possible for the subsequent sewing of the gusset, by means of a fully automated process.
This result has been achieved in conformity with the present invention by adopting the idea which consists in sewing the toes of a pantyhose by removing it from the machine which forms the pantyhose, that is, before sewing the gusset, and further in providing for the ejection of the pantyhose with the toes sewn in such manner as to make it possible to use a known device which transfers the garment to a gusset-sewing machine.
In conformity with the invention, the process comprises:
(A) transferring and positioning of the garment from the machine forming the panty (T) to a first carrousel of a toe-sewing machine (CP) by means of the following operations:
(a1) introducing and applying suction to the legs, separately, to suck the legs into two corresponding reversing tubes in the toe-sewing machine;
(a2) seizing and opening the waist of the panty and removal thereof from machine (T) and transfer thereof onto the tubes in the toe sewing machine (CP);
(B) reversing the legs and positioning the toes of the legs of the pantyhose relative to the tubes to enable them subsequently to be properly sewn; and after sewing the two toes; and
(C) transferring and positioning of the garment from the first to the second carrousel in the toe sewing machine (CP) by means of the following operations:
(c1) suctioning of the toes of the pantyhose into their respective tubes; and
(c2) seizing and opening the waist of the panty and removal and transfer and arrangement thereof toward a known device (G), which transfers the garment to a gusset-sewing machine (S).
And the machine to carry out the process according to the invention comprises:
means to draw the legs of the garment that is placed on machine (T) into two reversing tubes in machine (CP);
means to remove from panty forming machine (T) the panty of the garment by its waist by means of pincers with parallel outward-spreading prongs;
means to transfer the panty onto the reversing tubes in (CP);
means to reverse the legs and position the toes in the toe-sewing position;
means to sew the toes; and
means to remove the panty from the reversing tubes and position it relative to a known garment transfer or conveyor device (G), which transfers the garment to a gusset-sewing machine.
The advantages of the present invention essentially consist in that the sewing is applied to the toes of the two stockings which form a pantyhose to sew the toes; that the sewing of the toes is possible both for pantyhoses with seams, with or without a gusset, and for seamless ones, that is, those pantyhoses formed in a single piece, without or with gusset; that the feed of the pantyhoses with seams is automated and simultaneous with their production; that the sewing of two toes is simultaneous or not, depending on whether two or one cutting and sewing machines are used; that the ejection of the pantyhoses is automated.
These and further advantages and features of the invention will be more fully and better understood by any expert in the field from the following description and with the aid of the attached explanatory drawings, not to be regarded as limiting its scope, wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a plan view of a combination of a known machine (T), which produces pantyhoses with seams, with the two secions (A1-A2) of a toe-sewing machine according to the invention fed by the machine (T), with a known device (G) which transfers the pantyhoses from the toe-sewing machine to a known gusset-sewing machine, and with a gusset-sewing machine (S);
FIG. 2 shows a detail plan view of the carrousel in section (A1) of a toe-sewing machine according to the invention;
FIG. 3 shows a front view of the detail in FIG. 2;
FIG. 4 shows a detail front view of a machine (T) which produces the pantyhoses with seam with the finished garment;
FIG. 5 shows a side view of the detail in FIG. 4;
FIG. 6 shows a detail side view of the device that transfers the garment from a machine (T) which produces the pantyhoses with seams to a toe-sewing machine according to the invention in the starting position;
FIG. 7 shows an enlarged plan view of the detail in FIG. 6;
FIG. 8 shows an enlarged plan view of the detail in FIG. 6 in its final position;
FIGS. 9A through 9F and 10A through 10F show front and side views of the sequence of positions of the transfer device during the removal of the garment from a pantyhose-manufacturing machine;
FIGS. 11A through 11E and 12A through 12E show front and side views of the sequence of positions of said transfer device while placing the garment onto a toe-sewing machine according to the invention;
FIG. 13 shows a detail plan view of a garment-ejection device for a toe-sewing machine according to the invention;
FIG. 14 shows a front view of the detail in FIG. 13;
FIG. 15 shows an enlarged detail view of the garment-stretching device for the ejection device in FIG. 13; and
FIG. 16 shows a detail view of the product with the opening made by cutting devices.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In its basic form and with reference to the attached drawings, the process covered by the present invention comprises:
A first manual stage during which the two leg portions of the stocking (1) of the finished garment are placed spread out on two corresponding grooves (2) see FIG. 2 in the garment-forming machine, for the purpose of facilitating the start of the subsequent fully-automated stages, which involve:
Bringing the stockings (1) close to two corresponding reversing tubes (3) see FIG. 6 by means of two pneumatically-operated forks (23), for the purpose of facilitating their subsequent introduction;
Suctioning of the stockings (1) into the reversing tubes (3);
The stretching and opening into a rectangular shape of the waist (11) of the product still held by the machine (T) by means of two horizontally-moving pincers (5) and vertically-moving horizontal prongs (6), to obtain the detachment of the panty (12) from the machine (T);
The removal of the panty from machine (T) and simultaneous positioning with reversal on the tubes (3) of the toe-sewing machine by means of the same said pincers (5);
Reversing the legs of the garment on the tubes with an accurate positioning of the toes by means of friction rollers (7) for the purpose of permitting a proper sewing of the toes;
Bringing the toes to be sewn, separately, close to two corresponding cutting-sewing machines (8);
Separately sewing of the two toes;
Removing the panty (12) from the tubes (3) of an arm in the first carrousel (A1) and simultaneous positioning and straightening on the tubes (31) of an arm see FIGS. 13 and 14, in the second carrousel (A2) by means of two horizontally-moving pincers (51) and vertically-moving horizontal prongs (61); and
Stretching of the panty (12) by rotating the tubes (31) and positioning of the garment to enable it to be seized by a conveyor device (G) through the opening (13) left in the garment to receive the gusset; and
Eventually, cutting in the crotch area of the garment to form an opening (13), if missing, in the product.
Concerning the machine according to the invention to carry out the process and with reference to the attached drawings, essentially it comprises:
A first section or a first carrousel (A1) with a horizontally-rotating hexagonal-base turret, with stops at as many stations, from each face of which turret there project two parallel horizontal tubes (3), equipped with pneumatic suction and also fitted with two horizontal side wings (30), moving in a longitudinal direction toward the outside of the carrousel;
As best seen in FIGS. 1 and 6, first garment transfer device (B1) operating in front of the loading station of the toe sewing machine (CP) and composed of a fixed horizontal load-bearing structure (20), located above and extending radially and projecting toward the outside relative to the carrousel (A1); parallel to the structure (20) there is attached a running track (21) for a carriage (22) bearing two pincers (5), moving horizontally in different directions, transversely relative to the running track (21), each of which pincers is equipped with two horizontal and superimposed prongs (6), moving vertically, by means of corresponding pneumatic cylinders; the carriage (22) is equipped with known means for its translation and for that of the pincers (5);
Two forks (23) underneath the transfer device and are operated by corresponding pneumatic cylinders (24), with an active stroke toward the inlets of the tubes (3), for the purpose of collecting the legs (1) of the garment hanging from the machine (T) and bringing them close to the inlets;
Known means (see FIG. 2) to bring the wings (30) of the tubes (3) with the overhanging legs of the garment close to the corresponding cutting-sewing machines (8);
Known means (8) to sew the toes of the legs;
A second garment transfer device (B2), operating in front of the ejection station of the first carrousel (A1) and similar in all respects to the previous one (B1);
A second section or second carrousel (A2) with four arms, (see FIG. 13) rotating horizontally, with stops at as many stations, one of which is in front of the fifth station of the above-mentioned first carrousel (A1); each arm is composed of two horizontal and parallel tubes (31), rotating around their longitudinal axis and with their free ends equipped with a transverse bar (32) (see FIG. 15) pointing toward the opposite tube; to each one of the tubes (31) there is also attached a lever (33), whose end, by contacting the profile of a cam (34) attached concentrically to the carrousel (B2) causes--during the rotation of the carrousel and before the ejection station--the rotation of the tube (31) and simultaneously the opening out of the bar (32).
The second station in the second carrousel (A2) comprises cutting devices (35) to make, eventually, the opening (13), if not present, in the product.
The operation is as follows.
The cycle begins with the product in the position shown in FIGS. 4 and 5 and with the first transfer device (B1) in the position shown in FIG. 6 in the attached drawings.
Referring now more particularly to FIGS. 9 to 12, after the legs (1) of the garment have been brought close to the inlets of the tubes (3) in the first carrousel (A1), and there drawn in continuously, the panty forming transfer device (B1) goes into action to release and remove from the machine (T) the panty (12) of the garment, introducing into it the prongs (6) through the open area of the waist (11), and then lifting and stretching the upper edge and subsequently lowering and stretching the lower one, thereby obtaining a rectangular shape, as shown in FIGS. 9A through 9F and 10A through 10F in the attached drawings; subsequently, the carriage (22) moves toward and above the tubes (3) of an arm of the carrousel (A1)--which is aligned with that of the machine (T) which holds the garment--covering them with the above-mentioned panty as the latter is reversed as shown in FIGS. 11A through 11E and 12A through 12E in the attached drawings.
At this point, the carriage (22) moves back to its starting position and the carrousel (A1), rotating counterclockwise, moves the tubes (3) with the panty to the next station, where the legs of the garment, by means of the rollers (7), are reversed and the toes positioned on the tubes (3), to present their free ends in the proper position to undergo the subsequent sewing; the sewing, which takes place at the third station for the first leg and at the fourth station for the second leg, follows the outward translation of the wings (30) and the locking of the toe of the stocking by pincers (80). At the fifth station, the second transfer device (B2)--with operations that are the reverse of those performed at the first station--proceeds to transfer the panty of the garment onto the tubes (31) of an arm of the second carrousel (A2); subsequently, the panty of the garment is stretched and positioned so that, at a subsubsequent station, it becomes possible to remove it by means of a known transfer and conveyor device (G) through the opening (13) in the garment to be fitted with the gusset.
If the garment has no such opening (13), because it is in a single piece, seamless, the opening is then made by means of cutting devices (35) located at the second station in the second carrousel (A2).
In practice, the details of execution may vary equally anyway with respect to the shape, size, arrangement of the components, and nature of the materials used, without thereby departing from the spirit of the solution adopted, and therefore remaining within the scope of the protection granted under the present patent for industrial invention.
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Apparatus for sewing the toes of pantyhose, including a transfer device to seize and transfer a garment from a first carrousel to a second carrousel, and in which a loading station of the first carrousel coincides with an ejector station of a pantyhose-forming machine with transfer of the pantyhose being carried out by a similar transfer device, and each of the carrousels have a plurality of arms, one of each of which is aligned with each other when transfer therebetween takes place. Each arm of the second carrousel includes two horizontal tubes having their free ends fitted with a transverse bar, and the tubes are rotatable around the longitudinal axis through contact of a lever attached to the tubes with a profile of a fixed cam concentric with the second carrousel.
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TECHNICAL FIELD
[0001] The present disclosure is directed in general to weapon system design and more specifically to weapon mounts.
BACKGROUND OF THE DISCLOSURE
[0002] A weapon mount is used to pivot, balance, hold, move and target a supported weapon system. Such a weapon mount helps a user in the handling of the weapon system and makes it easier and quicker for the user to aim and fire at objects that may be stationary or moving. A weapon mount typically provides the ability to swing the weapon system easily in the horizontal plane, as well as move the weapon system up or down easily and quickly. A weapon mount may also provide a mechanism to lock the weapon system in place, restricting one or more of the degrees of freedom.
[0003] Weapon systems are usually back heavy. The weight of a weapon system depends on a variety of parameters, such as how many ammunitions are loaded, how many are left unused, and the type and number of accessories that are mounted on the weapon system. The basic weight of a weapon system varies from weapon system to weapon system. Most weapon mounts are designed to support a few selected weapon systems, usually in the same family of weapons. Because of the dynamic variations in weight and spatial distributions of weight during operation, weapon mounts have struggled to adopt dynamically to provide the best user interface. In addition, time is of the essence during tactical usage of the weapons systems, and ease of use plays a critical role in the use of the weapon systems.
SUMMARY OF THE DISCLOSURE
[0004] Various embodiments are disclosed that substantially enhance a user interface of a weapon system. For example, one or more embodiments make the retargeting of a weapon system quick and easy.
[0005] In a first embodiment, a mounting apparatus includes a housing configured to couple the mounting apparatus to a weapon mount and to secure one or more gas springs, where the one or more gas springs are configured to provide one or more forces. The mounting apparatus also includes one or more wire ropes associated with the one or more gas springs, where each wire rope is fixed at a first end to the weapon mount and has a hook at a second end. The mounting apparatus further includes one or more guides within the housing, where the one or more guides are configured to guide the one or more wire ropes. In addition, the mounting apparatus includes one or more bearings configured to facilitate movement of the one or more wire ropes. The one or more wire ropes are routed through the one or more guides using the one or more bearings, and the hook at the second end of each wire rope is attached to a front portion of the weapon mount or a weapon in the weapon mount. The one or more wire ropes are configured to couple movement of the one or more gas springs to a tensile force on the front portion of the weapon mount or the weapon so as to counter-balance a weight of the weapon in the weapon mount.
[0006] In particular embodiments, one or more adjustable knobs are configured to adjust the one or more forces from the one or more gas springs to offset for additional weight due to, for example, accessories or varying loads of loaded ammunition. Also, in particular embodiments, the mounting apparatus includes one or more locking mechanisms configured to restrict movement of the weapon or the weapon mount in one or more degrees of freedom.
[0007] In a second embodiment, a method includes mounting a housing on a weapon mount and mounting one or more gas springs on the housing. The method also includes attaching a first end of each of one or more wire ropes to a fixed portion of the weapon mount and routing the one or more wire ropes through one or more guides using one or more bearings in the housing. The method further includes attaching a second end of each of the one or more wire ropes to one or more front portions of the weapon mount or a weapon in the weapon mount. The one or more wire ropes are configured to translate one or more forces from the one or more springs into one or more tensile forces to counter-balance a weight of the weapon.
[0008] In a third embodiment, a weapon system counter-balance apparatus includes one or more gas springs configured to be mounted on a weapon mount or a weapon in the weapon mount, where the one or more gas springs are configured to provide one or more forces. The weapon system counter-balance apparatus also includes one or more translation mechanisms configured to direct the one or more forces from the one or more gas springs to counter-balance the weapon.
[0009] Other technical features may become readily apparent to one of ordinary skill in the art after review of the following figures and description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For a more complete understanding of the present disclosure and its advantages, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which like reference numerals represent like parts:
[0011] FIG. 1 shows a mounting apparatus according to an embodiment of the disclosure; and
[0012] FIGS. 2 and 3 show the mounting apparatus of FIG. 1 mounted on an MK93 weapon mount according to an embodiment of the disclosure.
DETAILED DESCRIPTION
[0013] The discussion below with reference to FIGS. 1 through 3 is by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present invention may be implemented in any type of suitably arranged device or system. It should be understood that, although example embodiments are described below, the present invention may be implemented using any number of techniques, whether currently known or not. The present invention should in no way be limited to the example implementations, drawings, and techniques described below. Additionally, the drawings are not necessarily drawn to scale.
[0014] The user interface problems identified above (due to dynamically varying weight and uneven distribution of weight around a primary pivot in a weapon mount) continue to affect the effectiveness of weapon systems today. Conventional attempts at solving this problem use mechanical adjustment mechanisms, such as screws and slides commonly referred to as traversing and elevation mechanisms. However, these mechanisms often require manual manipulation for targeting and are relatively slow and cumbersome to use. Additionally, such mechanisms can inhibit rotational freedom of a weapon system.
[0015] Some of the specific problems with available approaches include the following:
A user requires significant exertion to hold a weapon system in place. The user has to take his or her hand off of the weapon system and dedicate the hand to move the weapon system up or down. Once the user takes his or her hand off of the weapon system, the weapon system does not stay in place due to its weight and the weight of ammunition. Conventional screws and slides mechanisms are slow and cumbersome. This lack of ease of use, agility and slow speed adds time to retarget the weapon system.
[0020] Accordingly, certain embodiments are presented to overcome one, some, or all of these deficiencies. As shown in the figures and described below, embodiments of the present disclosure provide a counter-balancing design that is a bolt-on assembly to, for example, an MK93 mount or other weapon mount. Although embodiments will be described with reference to an MK93 mount, embodiments of the disclosure may be utilized with other configurations. More particularly, the embodiments in this disclosure are adaptable to many weapon mounts and many weapon systems.
[0021] According to certain embodiments, the design uses one or more gas springs to provide a tensile force through one or more wire ropes, which are attached to the pivoting portion of a weapon mount and to a gas spring housing. The housing has one or more integral wire guides and bearings to control the motion of the wire rope(s) during travel of the gas spring(s) as the weapon system is moved. Friction within the mount holds the position of the weapon system once it is released by a user.
[0022] According to particular embodiments, such a configuration provides an efficient method of freely targeting with either an MK19 or M2 weapon system as used in conjunction with an MK93 weapon mount. Additionally, according to particular embodiments, the solution can be tailored to account for variable weapon accessories or configurations and does not require modifications to standard hardware.
[0023] FIG. 1 shows a mounting apparatus 112 according to an embodiment of the disclosure. The mounting apparatus 112 includes one or more gas springs 102 (also referred to as gas spring cylinders) mounted within a housing 104 . The housing 104 contains integral bearings 106 and mounting points or pulleys 108 for a wire rope 114 . The wire rope 114 attaches to the housing 104 and to the rotating portion of an MK93 mount or other weapon mount 110 (shown in FIGS. 2 and 3 ). A mounting point 109 is the fixed end of the wire rope 114 . The wire rope 114 can be made of any suitable material, such as steel, stranded aluminum, a combination of alloys, polyurethane, Kevlar, or other like materials.
[0024] A particular configuration may contain a steel wire (stranded or solid) with a thickness in the range from 0.090 inches to 0.125 inches in diameter (inclusive) with a gas spring that asserts a force in the range of 50 lbs to 130 lbs (inclusive). Due to the pulley effect of the design shown in FIG. 1 , the tensile force exerted by the wire rope 114 will be approximately twice the force exerted by the gas spring 102 on the wire rope 114 . Additional pulley mechanisms can be added to change the net tensile force.
[0025] Note that any suitable tensile force can be provided by the mounting apparatus 112 . For example, the tensile force could counter-balance the weight of the weapon in the weapon mount to within a margin of ±10% of the weight.
[0026] FIGS. 2 and 3 show the mounting apparatus 112 of FIG. 1 mounted on an MK93 weapon mount 110 according to an embodiment of the disclosure. As shown here, the mounting apparatus 112 includes one or more knobs 105 that are used to adjust the tensile force on the wire rope 114 applied by the gas spring 102 .
[0027] The mounting apparatus 112 here uses two unused mounting holes to mount onto the MK93 weapon mount 110 , thus fitting into place using the available spacing of the existing MK93 weapon mount 110 without any modifications. The MK93 weapon mount 110 has a front pivot and a back primary pivot. The front pivot is located away from the center of gravity and towards the front barrel of a weapon system 116 . A hook in the top part of the wire rope 114 hooks close to the front pivot at a convenient location 111 , thereby allowing a counter-force and torque to balance the gravitational force and torque created by the weight of the weapon system 116 . In other weapon mounts, the top hook of the wire rope 114 can be mounted onto a bolt or any other portion of the front of the weapon system, such as a front pivot, to generate this counter-balancing effect in order to offset the force and torque generated by the weight of the weapon mount 110 .
[0028] Without the mounting apparatus 112 , the weapon mount 110 is usually in a default position of the front barrel pointing upwards and the heavy back pulled downwards. With the mounting apparatus 112 mounted on the weapon mount 110 , the default position could often be at the horizontal level as the gas spring 102 and the wire rope 114 assert the counter-balancing tensile force and torque to offset the weight of the weapon system 116 . When a user of the weapon system 116 takes his or her hands off the weapon system 116 or swings it laterally or moves it up or down, the weapon system 116 can typically stay substantially in place due to inherent friction in the weapon mount 110 and bearings and the mounting apparatus 112 providing the counter-balance to keep the weapon system 116 in place. As ammunitions get used by or accessories get added to the weapon system 116 , the tensile force asserted by the gas spring and wire assembly is usually adequate to still keep the weapon system 116 in place due to inherent frictions at the pivots and bearings, and the counter-balancing tensile force can be quickly adjusted if needed by the adjusting the knob(s) 105 of the gas spring as described earlier.
[0029] Different weapon mounts and different weapon systems may require one or more wire hooks, one or more gas springs, or different levels of tensile forces. The number and type of wire rope (such as material, type (solid or stranded), and thickness), the number and type of gas springs, and the number of wire hooks can all be chosen to fit the need of any target weapon mount and weapon system.
[0030] In the particular embodiment shown in FIG. 3 , two sets of gas springs 102 and wire ropes 114 are shown. However, only one set may be utilized in certain configurations. Additionally, more than two sets may be utilized in other configurations. Moreover, the gas springs 102 create a tensile load on the wire ropes 114 , which in turn provide a relatively consistent downward tensile force that counter-balances the weapon system 116 as well as any additional accessories 118 . Although gas springs 102 are shown in this configuration, other mechanisms capable of creating a tensile load may be used in other configurations. For instance, the gas springs 102 can be replaced with other types of springs or devices that can assert a similar tensile force on wire ropes 114 , such as variable-force springs, different springs with preset-forces, or other non-spring devices.
[0031] The force of a gas spring 102 can be altered based on the weapon system or accessories being used or based on user preferences. When properly balanced, the inherent friction within the mount 110 stabilizes the weapon system 116 to hold it in position when the user releases the hold, thereby allowing for optimal operational effectiveness. Additionally, according to certain embodiments, the design provides unrestricted rotation with little or no force, still keeping the balanced weapon system 116 in the same positions in other dimensions. Such a stable freedom of motion can become critical to operational effectiveness of the targeting solution.
[0032] The actual mounting locations of the gas springs 102 or the actual routings of the wire ropes 114 can be varied based on the weapon mount, weapon systems, and accessories mounted on the weapon systems. For example, there can be additional bearings 106 depending on the routing of the wire rope 114 , and there can be additional mounting points or pulleys 108 to add additional turns or additional load bearing capacities. There can also be additional fixed ends (with mounting points 109 ) or additional knobs 105 to provide for the necessary tensile and torques forces to fit the target systems for the intended purposes described here.
[0033] As seen in FIGS. 1 through 3 , the mounting apparatus 112 has a low profile to fit in place inside the spacing of the MK93 mount 110 without modification (as seen, for example, in FIG. 3 ). The profile height, width and length can be made as low as needed to fit in the available space of a weapon mount or a weapon system.
[0034] Certain embodiments of this disclosure can be configured to set the weapon system 116 to be pushed down (over-corrected) as opposed to being pulled up based on user preferences. The “pushed down” configuration allows the user to use the user's body weight to the user's advantage, as opposed to relying on the user's arm strength for targeting. This can reduce fatigue on the user and prolong operational effectiveness.
[0035] Nothing in this disclosure precludes the combined use of an embodiment having one or more inventive features with traditional techniques, such as traditional haversing and elevation mechanisms and locking mechanisms. The embodiment in FIG. 1 supports such use. For example, an embodiment disclosed here can be used with a traditional locking mechanism to restrict one or more degrees of freedom.
[0036] While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. For example, although particular mounts and weapons have been described, other mounts and weapons may avail from teachings of the disclosure. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure.
[0037] It may also be advantageous to set forth definitions of certain words and phrases used throughout this patent document. The terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation. The term “or” is inclusive, meaning and/or. The phrase “associated with,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, have a relationship to or with, or the like. In addition, “each” refers to each member of a set or each member of a subset of a set.
[0038] Modifications, additions, or omissions may be made to the systems, apparatuses, and methods described here without departing from the scope of the disclosure. The components of the systems and apparatuses may be integrated or separated. Moreover, the operations of the systems and apparatuses may be performed by more, fewer, or other components. The methods may include more, fewer, or other steps. Additionally, steps may be performed in any suitable order.
[0039] To aid the Patent Office, and any readers of any patent issued on this application in interpreting the claims appended hereto, applicants wish to note that they do not intend any of the appended claims or claim elements to invoke paragraph 6 of 35 U.S.C. Section 112 as it exists on the date of filing hereof unless the words “means for” or “step for” are explicitly used in the particular claim.
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An apparatus ( 112 ) includes a housing ( 104 ) configured to couple the apparatus to a weapon mount ( 110 ) and to secure one or more gas springs ( 102 ). The one or more gas springs are configured to provide one or more forces. The apparatus also includes one or more wire ropes ( 114 ), where each wire rope is fixed at a first end to the weapon mount and has a hook at a second end. The apparatus further includes one or more guides ( 108 ) configured to guide the one or more wire ropes. In addition, the apparatus includes one or more bearings ( 106 ) configured to facilitate movement of the one or more wire ropes. The one or more wire ropes are configured to couple movement of the one or more gas springs to a tensile force on a front portion of the weapon mount or a weapon ( 116 ) so as to counter-balance a weight of the weapon in the weapon mount.
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RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/302,396 filed Jul. 2, 2001 entitled “Printing Plate With Dyed And Anodized Surface.”
FIELD OF THE INVENTION
[0002] The present invention relates to printing plates suitable for imaging by digitally controlled laser radiation. More particularly, the invention relates to a printing plate having a dyed, anodized metal substrate.
BACKGROUND OF THE INVENTION
[0003] Printing plates suitable for imaging by digitally controlled laser radiation include a plurality of imaging layers and intermediate layers coated thereon. Laser radiation suitable for imaging printing plates preferably has a wavelength in the visible or near-infrared region, between about 400 and 1500 nm, typically at about 830 nm. Solid state laser sources (commonly termed “semiconductor lasers”) are economical and convenient sources that may be used with a variety of imaging devices. Other laser sources such as CO 2 lasers and lasers emitting light in the visible wavelengths are also useful.
[0004] Laser output can be provided directly to the plate surface via lenses or other beam-guiding components, or transmitted to the surface of a blank printing plate from a remotely sited laser through a fiber-optic cable. Some prior art patents disclosing printing plates suitable for imaging by laser ablation are Lewis et al. U.S. Pat. Nos. 5,339,737; 5,996,496 and 5,996,498. These prior art printing plates require multiple layers of differing materials and often are costly to produce. Accordingly, a need remains for a simple and inexpensive radiation treatable printing plate.
SUMMARY OF THE INVENTION
[0005] This need is met by the printing plate of the present invention having a metal substrate with an anodized surface portion. The surface portion defines a plurality of pores containing a radiation-absorbing composition. A coating composition covers the surface portion along with the radiation-absorbing composition. The metal may be an aluminum alloy that may be roll textured to have a roughness of about 5 to about 45 microinches.
[0006] The radiation-absorbing composition may be oleophilic while the coating composition is hydrophilic such as an acrylic polymer. A suitable acrylic polymer is a copolymer of vinyl phosphonic acid and acrylic acid cured under conditions such that said copolymer is hydrophilic or oleophilic. If the radiation-absorbing composition is hydrophilic, the coating composition may be oleophilic. Other suitable coating compositions include nickel acetate, silicate, and polyvinylphosphonic acid.
[0007] The coating composition may be ablated by radiation directed onto the coating composition overlying the radiation-absorbing composition. Alternatively, a first affinity for ink by the coating composition may change to a second affinity for ink when the coating composition overlying the radiation-absorbing composition is subjected to radiation without ablation of the coating composition.
[0008] The printing plate may further include a sealant composition disposed between the radiation-absorbing composition and the coating composition. In that case, both of the sealant composition and the coating composition overlying the radiation-absorbing composition are ablatable by radiation directed thereto. Alternatively, the sealant and coating compositions may not be ablated. Instead, a first affinity for ink by the coating composition may change to a second affinity for ink when the coating composition overlying the radiation-absorbing composition is subjected to radiation.
[0009] The present invention also includes a method of imaging having the steps of (i) providing a printing plate having a metal substrate with an anodized surface portion defining a plurality of pores, a radiation-absorbing composition received in the pores, and a coating composition covering the surface portion with the radiation-absorbing composition; and (ii) exposing the printing plate to a pattern of imaging radiation such that a first portion of the printing plate has an affinity for a printing fluid and a second portion of the printing plate has a different affinity for the printing fluid. The exposing step may include ablating the coating composition in the location of the pattern of imaging radiation to reveal the anodized surface portion as the first portion of the printing plate, the coating composition not exposed to the radiation being the second portion of the printing plate. Alternatively, the exposing step may include changing the affinity of the coating composition for a printing fluid in the location of the pattern of imaging radiation to the different affinity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a cross-sectional view of a printing plate made in accordance with the present invention having a coating composition;
[0011] [0011]FIG. 2 is a cross-sectional view of the printing plate shown in FIG. 1 following radiation ablation of the coating composition;
[0012] [0012]FIG. 3 is a cross-sectional view of an alternative view of the printing plate of FIG. 1 following radiation treatment of the coating composition to change the affinity of the coating composition for a printing liquid;
[0013] [0013]FIG. 4 is a cross-sectional view of a printing plate made in accordance with the present invention having a sealant layer;
[0014] [0014]FIG. 5 is a cross-sectional view of the printing plate shown in FIG. 4 following radiation ablation of the sealant layer;
[0015] [0015]FIG. 6 is a cross-sectional view of a printing plate made in accordance with the present invention having a sealant layer covered with a coating composition;
[0016] [0016]FIG. 7 is a cross-sectional view of the printing plate shown in FIG. 6 following radiation ablation of the sealant layer and coating composition; and
[0017] [0017]FIG. 8 is a cross-sectional view of the printing plate of FIG. 6 following radiation treatment of the coating composition to change the affinity of the coating composition for a printing liquid.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] For purposes of the description hereinafter, it is to be understood that the invention may assume various alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific products and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the invention. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered as limiting.
[0019] As shown in FIG. 1, the present invention includes a printing plate 2 having a metal substrate 4 with an anodized principal surface portion 6 defining a plurality of pores or wells 8 therein. A radiation-absorbing composition 10 , which absorbs radiation, is deposited in the pores 8 . A layer 12 of a polymeric coating composition covers the anodized surface portion 6 , including the radiation-absorbing composition.
[0020] The substrate 4 may be an anodizable metal such as an alloy of aluminum, titanium or magnesium. Suitable aluminum alloys include alloys of the AA 1000, 3000, and 5000 series. The substrate 4 preferably has a thickness of about 1-30 mils, preferably about 5-20 mils, and more preferably about 8-20 mils.
[0021] Preferably, the substrate 4 is roll textured using one or more rolls treated with a texturing means to provide an extended surface area to the substrate 4 . The texture of the treated roll has a substantially uniform topography which imparts a substantially uniform topography in the rolling and cross-rolling directions of the substrate 4 and having an Ra value of about 5 to about 45 microinches wherein the Ra ratio of rolling to cross-rolling is about 0.8 to 1.2, as described in U.S. Pat. No. 6,290,632 entitled “Ultrafine Matte Finish Roll for Treatment for Sheet Products and Method of Production”, incorporated herein by reference. The texturing means may be electron discharge texturing, laser texturing, electron beam, shot peening, mechanical texturing, and chemical etching and some combination thereof, preferably electron discharge texturing.
[0022] The principal surface portion 6 may be cleaned to remove surface contaminants such as lubricant residues. Suitable chemical surface cleaners include alkaline and acid aqueous solutions. Plasma radiation, corona discharge and laser radiation may also be used.
[0023] A conventional anodization process may be used to create the pores 8 . For an aluminum alloy substrate, the substrate 4 is placed in a conventional anodizing bath containing a conductive electrolyte such as sulfuric acid, phosphoric acid, oxalic acid, chromic acid or salicylic acid to produce a layer of porous alumina. The dimensions of the pores 8 may be controlled by the concentration of the electrolyte in the bath and the bath temperature. A suitable concentration of the electrolyte is about 10-30 wt. %. A preferred electrolyte bath contains about 20 wt. % sulfuric acid. When the substrate 4 is an aluminum alloy, anodization creates a layer of alumina on the surface portion, which is about 0.05 to about 0.7 mil thick.
[0024] The radiation-absorbing composition 10 is applied to the surface portion 6 by spraying, brushing, dipping or the like and is absorbed into the pores 8 and become trapped therein. The radiation-absorbing composition 10 maybe an oleophilic material, which absorbs infrared radiation such as a black dye. A suitable dye is an azine compound or an azide compound or any other dye that absorbs light having a wavelength in the range of about 500 to about 1100 nanometers. One such dye is Nigrosine Base BA available from Bayer Corporation of Pittsburgh, Pa. The anodized metal generally is hydrophilic. However, by including an oleophilic radiation-absorbing composition 10 in the pores 8 , the surface portion 6 may become oleophilic depending on the amount and composition of the radiation-absorbing composition 10 deposited in the pores 8 . Alternatively, the radiation-absorbing composition 10 may be hydrophilic and the surface portion 6 remains hydrophilic following deposition of the hydrophilic radiation-absorbing composition 10 in the pores 8 .
[0025] The polymer coating composition 12 preferably includes an acrylic polymer, more preferably a copolymer of an organophosphorus compound. As used herein, the term “organophosphorus compound” includes organophosphoric acids, organophosphonic acids, organophosphinic acids, as well as various salts, esters, partial salts, and partial esters thereof. The organophosphorus compound may be copolymerized with acrylic acid or methacrylic acid. Copolymers of vinyl phosphonic acid are particularly preferred, especially copolymers containing about 5-50 mole % vinyl phosphonic acid and about 50-95 mole % acrylic acid and having a molecular weight of about 20,000-100,000. Copolymers containing about 70 mole % acrylic acid groups and about 30 mole % vinyl phosphonic acid groups are particularly preferred. The acrylic polymer may be applied in batch processing of sheet or in coil processing by conventional coating processes including roll coating, powder coating, spray coating, vacuum coating, emulsion coating or immersion coating. Preferably, the acrylic polymer is applied by roll coating, typically to a thickness of about 0.001-1.0 mil, preferably about 0.01-0.03 mil. Acrylic polymers including copolymers of vinyl phosphonic acid and acrylic acid are hydrophilic when cured at about 420° F. for about two minutes. These same acrylic polymers may be made oleophilic when cured at about 500° F. for about two minutes.
[0026] In use, the printing plate 2 is imaged with a laser or the like. As shown in FIG. 2, a pattern of radiation R from a laser ablates the coating composition 12 in the regions 14 of the printing plate 2 in which ink is to be received. Ablation of the coating composition 12 exposes regions 14 of the substrate leaving unablated regions 16 . The ablated regions 14 are oleophilic while the unablated regions 16 remain hydrophilic. Ink of a printing liquid containing water or a fountain solution will adhere to the ablated regions 14 while the unablated regions 16 will be covered with water or a fountain solution.
[0027] The regions 14 and 16 may have a reverse affinity for ink and water. In that case, a hydrophilic material is used as the radiation-absorbing composition 10 (e.g. Nigrosine WLF from Bayer) and the polymer coating composition 12 is oleophilic. A suitable oleophilic polymer is a copolymer of vinyl phosphonic acid and acrylic acid cured at about 500° F. for about two minutes. Following ablative imaging with a laser, the ablated regions 14 are hydrophilic and the unablated regions 16 are oleophilic.
[0028] In another aspect of the invention shown in FIG. 3, the coating composition 12 includes a hydrophilic polymer, e.g. a copolymer of vinyl phosphonic acid and acrylic acid cured at about 420° F. for about two minutes. A pattern of imaging radiation R from a laser or the like causes regions 24 of the coating composition 12 to become oleophilic (without ablating the coating composition 12 ) while unexposed regions 26 remain hydrophilic. Ink of a printing liquid containing water or a fountain solution will adhere to the regions 24 while the regions 26 will be covered with water or a fountain solution. It is believed that when radiation is absorbed by the radiation-absorbing composition 10 , heat is generated which is conducted to the regions 24 of the coating composition 12 . Heating of the regions 24 is believed to change the surface chemistry of the polymer such that the affinity of the regions 24 for a printing liquid is altered.
[0029] A second embodiment of the invention is shown in FIGS. 4 and 5. Printing plate 40 includes a sealant layer 42 . The sealant layer 42 plugs the pores 10 and may be continuous or discontinuous over the principal surface portion 6 . Suitable materials for the sealant layer are oleophobic and include nickel acetate, silicate, polyvinyl phosphonic acid and copolymers of acrylic acid and vinyl phosphonic acid. Preferably, the sealant layer 42 is applied to the principal surface portion in an immersion process. A pattern of imaging radiation R shown in FIG. 5 causes the sealant layer to ablate in regions 44 leaving unablated regions 46 . The ablated regions 44 are oleophilic, while the unablated regions 46 are oleophobic. Ink of a printing liquid containing water or a fountain solution will adhere to the ablated regions 44 while the unablated regions 46 will be covered with water or a fountain solution.
[0030] A third embodiment of the invention is shown in FIGS. 6 - 8 . Printing plate 60 includes sealant layer 42 (as described above) and a coating composition 62 . Coating composition 62 is similar to coating composition 12 of FIG. 3 and includes a hydrophilic polymer, e.g. a copolymer of vinyl phosphonic acid and acrylic acid cured at about 420° F. for about two minutes. In one aspect of the invention shown in FIG. 7, a pattern of imaging radiation R from a laser or the like causes the sealant layer 42 and the polymer coating composition 62 to ablate in regions 64 leaving unablated regions 66 . Unablated regions 66 are hydrophilic while the ablated regions 64 are oleophilic.
[0031] Alternatively as shown in FIG. 8, radiation R causes regions 68 of the coating composition 62 to become oleophilic (without ablating the layer 62 ) while unexposed regions 70 remain hydrophilic. Ink of a printing liquid containing water or a fountain solution will adhere to the regions 68 while the regions 70 will be covered with water or a fountain solution. It is believed that when radiation is absorbed by the radiation-absorbing composition 10 , heat is generated which is conducted to the regions 68 of the layer 62 . Heating of the regions 68 is believed to change the surface chemistry of the polymer such that the affinity of the regions 68 to a printing liquid is altered.
[0032] 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. Accordingly, the particular embodiments described in detail herein are illustrative only and are not limiting to the scope of the invention.
[0033] Having described the presently preferred embodiments, it is to be understood that the invention may be otherwise embodied within the scope of the appended claims.
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A printing plate for computer-to plate lithography having a metal substrate with an anodized surface portion. The anodized surface portion has a porous texture in which a radiation-absorbing composition, preferably a black dye, is deposited. The surface portion with the radiation-absorbing composition is covered with a hydrophilic polymer or a sealant both. Upon exposure to laser radiation, the underlying oleophilic anodized surface portion containing the radiation-absorbing composition is revealed. Alternatively, laser radiation of the polymer composition may cause the affinity of the polymer for water and ink to change so that an irradiated portion of the polymer becomes oleophilic while the non-irradiated portion remains hydrophilic.
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BACKGROUND AND SUMMARY OF THE INVENTION
The invention is related to continuous digestion of fiber material and especially impregnation of the fiber material during transport to a digester. Such pre-impregnation of fiber material comprises a very important part of the delignification process and has as an object to replace the air or gas content of the fiber material with an impregnation liquid or with cooking liquor.
The driving off of air or gas in fiber material so that it may be impregnated is commonly done by means of steaming at a relatively small superatmospheric pressure with succeeding submerging into cooking liquor at higher pressure and temperature but also by means of other methods, e.g., first vacuum treatment or pressing and then submerging into a liquid before the cooking starts. Whether the impregnation is performed in one way or the other, certain equipment is needed which both, from an economical as well as from a space point of view, is to be limited as much as possible during simultaneous consideration that the impregnation should be as effective as possible. Fiber material, such as it arrives to a cooking installation, is made up of a heterogenous mixture of comminuted raw material, e.g., wood, grass, reeds, straw, etc. Even if coarse screening has been done, the variations from piece to piece are considerable both in size, shape and density. Especially with mixed raw material and with the popular use of "whole trees" as the raw material, the differences and the need for selective impregnation are accentuated.
According to the present invention, an effective impregnation is effected (possibly after steaming) by means of varying impregnation time in a simple and effective manner while the fiber material is surrounded by liquid. In this way, the heterogenous character of the fiber material is compensated for, and the pulp yield, evenness and strength characteristics are improved. Impregnation with time variations for separate fiber material particles is in itself previously known, e.g, through Swedish Pat. No. 174,656. The mentioned patent has as its main characterizing part, in an impregnation space separate from the digester itself, replacement of the air in the fiber material cells by cooking liquid by means of pressure variations and by provision of a selective impregnation of the fiber material in such a manner that the fast impregnatable fiber material is removed earlier from the impregnation space than the more difficult impregnatable fiber material. The impregnation process takes place in a standing impregnation vessel arranged at an angle to the horizontal plane, to which a mixture of fiber material and cooking liquor under pressure is fed by means of a first device and fed out by means of another device. The vessel is equipped on the inside with a screw conveyor for fiber material which has sunk in the cooking liquor and, at the same time, air is being expelled through a valve and the pressure variations are obtained by a vacuum pump and/or by tapping off liquid respectively by pumping in of cooking liquor and/or by use of pressure accumulators.
Improved impregnation can be effected according to the present invention in a simple and economically advantageous way be in connection with a Kamyr conventional continuous digester, the transition of fiber material from low to high pressure being accomplished by a conventional Kamyr high-pressure feeder. The fiber material is transported in liquid which is pumped to the digester top where the liquid is separated and returned back to the high-pressure feeder for renewed use as transport medium. Such a feed system is per se known, as illustrated by U.S. Pat. No. 3,802,956. In U.S. Pat. No. 3,802,956, from a high-pressure feeder, fiber material and liquid are pumped through a line up to the top of an impregnation vessel (separate from the digester) where liquid is separated off by a screen assembly and led back to the pump through a return line. The high-pressure feeder is conventional and primarily consists of a rotor equipped with through-going pockets in a housing equipped with inlet and outlet connections. When a rotor pocket is in vertical position, a mixture of liquid and fiber material is fed into the feeder, and in order to make the filling more effective, liquid is extracted at the lower end of the feeder housing through a screen to a pump which circulates liquid back to the feed-in line. Before the high-pressure feeder, the fiber material and liquid are normally at a small superatmospheric pressure of about 1 atm, while in transfer valve, high-pressure line fiber material and liquid can be exposed to a pressure corresponding to the cooking pressure, e.g., 10 atm. The pockets and the housing of the high-pressure feeder are designed so that one of the pockets is always being filled at the same time as another pocket is being emptied, whereby the flow of fiber material in the transfer line is continuous. Before the fiber material arrives at the high-pressure feeder, it has usually been treated with steam, whereby the greater part of the air has been driven out of the pores of the fiber material. The real impregnation with cooking liquor takes place during entrance into the cooking liquor which circulates through the high-pressure feeder and through the feeding line to the top part of the digester at full cooking pressure, whereby the greater part of the fiber material quantity, e.g., by means of a screen device, is separated from the transport liquid which, in the above-mentioned manner, is led back to the circulation pump. If the separation of transport liquid and fiber material in the digester top is done in a conventional manner with a so-called top screw surrounded by a concentric screen plate, mainly the smallest fiber particles which can pass the screen openings will follow the transport liquid back to the circulation pump, feeding apparatus -- feeder, and back to the digester top again until the particles fasten on any larger fiber particle and continue downwards in the digester. This extra circulation which means an extra impregnation time is generally undesirable since the small particles which can pass the screen in the digester top already are thoroughly impregnated and, therefore, do not need an extra impregnation time. Instead, it is desirable that larger fiber particles which are not sufficiently impregnated should receive an extra retention time before they are digested. This has been accomplished according to the invention in a surprisingly simple and effective manner.
According to the present invention, the fiber material that should have a longer retention time in impregnating liquid is retained longer, while the fiber material that does not need a longer retention time is not, by the substitution of a stilling well for the inlet-outlet arrangement at the top of the digester instead of the screw-feeder with screen as is conventional (see U.S. Pat. No. 3,802,956), and by directly connecting the high-pressure transfer valve to the stilling well. This allows the elimination of the impregnation vessel in U.S. Pat. No. 3,802,956 and in copending application Ser. No. 719,656, without subsequent loss of its function -- that is, proper impregnation of all of the fiber material is still achieved. While the utilization of a stilling well per se is known (see German Offenlegungsschrift No. 2,361,627) previously in the utilization of such a stilling well the practice has been to separate out all of the particles from the liquid while not utilizing screens and, therefore, such stilling wells have only been utilized in areas where the fiber material is always more dense than the liquid, or accessory means were employed to facilitate removal of the fiber material (see copending application Ser. No. 659,638). The method and apparatus according to the present invention are distinct from the prior art in that by design, a selected portion of the fiber material is recirculated with the liquid withdrawn from the stilling well and that selected fiber material is subjected to impregnation conditions for sufficient additional time so that eventually impregnation does take place before digestion.
In mill operation, the practice has been to install steaming/impregnation apparatus designed so that a large part of the raw material will be completely or in any case sufficiently impregnated, while a smaller part will remain "hungry" for chemicals, and this latter raw material part will, after treatment, remain partly uncooked, i.e., higher reject, especially at higher yields. It is typical that, depending upon the degree of impregnation, a portion of fiber material (e.g., chips) tends to either sink or to float. A chip can sink in water but still float in cooking liquor with higher specific weight. A chip piece which sinks in cooking liquor can generally be designated as sufficiently impregnated.
The present invention takes advantage of this physical phenomenon in order to reduce the total dimensions of the equipment through selective separation of "sinkers" and "floaters", especially in an established feed system for a continuous digester, in that the "sinkers" sink down in the digester cooking zone while the "floaters", which normally constitute a relatively small part of the total quantity, pass through the impregnation process a second time.
It is the primary object of the present invention to provide a simplified but effective method and apparatus for complete impregnation of all fiber material from a heterogenous source before digestion of that fiber material. This and other objects of the invention will become apparent from the detailed description of the invention and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawing provides a schematic illustration of exemplary apparatus according to the invention for accomplishing the method of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In the drawing, 11 is a conventional Kamyr continuous digester, 12 is a conventional Kamyr high-pressure feeder, 13 comprises means for directly connecting the transfer valve 12 to the digester 11 so that liquid containing fiber material is transferred to the digestive 11 from the transfer valve 12 under pressure, and 14 comprises means for withdrawing from the digester 11 liquid and fiber material insufficiently impregnated with liquid so that it has a density lesser than the density of the liquid while allowing fiber material sufficiently impregnated with said liquid so that it has a density greater than the density of the liquid to descend into and form a column in the digester 11, and means for directly recirculating the liquid and insufficiently impregnated fiber material back to the transfer valve 12 under pressure.
The function of the conventional high-pressure feeder 2 briefly is as follows: A feeder rotor pocket (A) in vertical position is filled with fiber material, as shown by arrow 30, through the line 31 together with liquid from line 32 which can consist of suitable impregnation liquid or liquid intended for the cooking process itself. In the feeder housing lower part, a liquid quantity is extracted through a screen 15 to a line 33 and further to a pump 34, which liquid is pumped further through a line 35 back to the line 32 through a screening device 36 in which a part of the liquid corresponding to the displacement of the fiber material in the feeder rotor pocket is extracted, such as shown by arrow 37. Through this circulation of liquid by means of pump 34, an effective filling of each feeder rotor pocket is secured. When later on a rotor pocket which now is completely or partly filled with fiber material and liquid after turning of the feeder rotor comes into horizontal position (B), the pocket with its content enters a circulation of liquid at relatively high pressure corresponding to the digester pressure. The liquid is extracted and recirculated by means 14 which includes line 40 and pump 41. Through the line 42, liquid is pumped into a horizontally positioned rotor pocket (B) and the liquid transports the pocket content of fiber material and liquid through the means to the digester 11. The means 13 leads concentrically into the digester top area 16. The digester inlet includes a funnel-shaped pipe 43 (downwards expanding conical pipe 43) which penetrates a distance into the space 16. Under the opening 44 of the pipe 43, a column of sinking fiber material will be formed while above the opening 44, from the liquid chamber 16, liquid can be extracted through line 40. With this system, a so-called "screenless separation" takes place. The digester outlet 45 is disposed vertically above the inlet opening 44.
The means 13 may comprise a conduit 46, and the conduit may be designed to increase the time of retention of fiber material entrained in liquid therein before being fed to the digester 11.
If longer retention time is desired for the impregnation, the conduit 46 can suitably have a relatively large diameter or possibly be conically designed with a gradually increasing cross-section in the direction of the flow on to the funnel 43. Other shapes of the conduit 46 also can be used, e.g., if the line in the vertical part of the pipe is shaped as a long vessel, from which top the fiber material and liquid by means of the liquid flow or by means of a mechanical feeding device (i.e., a rotating scraper 47) is fed out through a short pipe line to the funnel 43.
Means 48 may be provided at the top of chamber 16 for removing gas that is displaced by the liquid during impregnation. Also, the chamber 16 could be slightly conically shaped and have a lower termination consisting of a bottom with a concentrical outlet to the cooking zone (see dotted structure 49). Above this bottom, a scraper (50) can be placed in order to facilitate the feeding of fiber material to the underlying cooking zone in the digester, where higher temperature is maintained, as shown in U.S. Pat. No. 4,028,171.
The described apparatus functions as follows: Steamed fiber material which most often consists of finely comminuted wood or finely comminuted other raw material of, e.g., bamboo, bagasse, grass, reeds or straw, in a continuous flow 30 is fed in through line 31 to the high-pressure feeder 12, through which two circulations are maintained. The one circulation for filling of the high-pressure feeder pockets takes place by means of pump 34 and surplus liquid is fed out through line 37, which liquid normally is united with added fresh cooking liquor. The other circulation through the high-pressure feeder takes place by means of pump 41 and means 13. The digester 11 and the chamber 16 are kept essentially completely liquid-filled as is the means 13 and the funnel 43. The digester is kept at a superatmospheric pressure necessary for cooking, e.g., 10-20 atm, which is higher than the pressure corresponding to the temperature. Thereby steam development is prohibited and the sinking tendency of the chips is increased. In the digester, a heating of the fiber material takes place by a conventional (not shown) heating device and by use of a circulation system of cooking liquor to the desired temperature, e.g., 170° C. In the digester, counter-current washing can take place in another circulation, which is not shown since it has no influence on the explanation of the invention. Fiber material which has been treated is fed in a continuous flow out through the line 58 to succeeding treatment stages which are not shown but which, e.g., can consist of a continuous diffuser washing installation.
Fiber material 30 can, e.g., have been precedingly steamed in a steaming vessel 29 at a superatmospheric pressure of about 1 atm. When a rotor pocket in the high-pressure feeder 2 has turned to horizontal position (B), the fiber material is suddenly exposed to, in principal, the same pressure as in the digester top, if the difference in static pressure is excluded, thereby the fiber material undergoes a pressure impregnation at a temperature lower than the real cooking temperature during a time which corresponds to the transport time from the high-pressure feeder 12 to the place where the fiber material, as mentioned, is heated in the digester itself. This time can be increased if the conduit 46 is made larger or vessel-shaped, conical or cylindrical, as above described, but the pressure conditions are still the same as mentioned. The main part of the fiber material will build up a level at or slightly below the opening 44 below the funnel.
Fiber material which does not sink and form a column at the funnel opening 44, but which floats up, i.e., follows the liquid upwards through the liquid chamber 16, follows the liquid through the return pipe 40, passes the pump 41 and the feeder 12, and returns after a certain time to the digester through means 13 and funnel 43. If the fiber material, after this extra impregnation time, still is not really impregnated so that it sinks during the prevailing pressure conditions, it can in principle be returned still more times and circulated back to the digester. During "round travel", the fiber material is exposed to the variation of pressure corresponding to the difference in static height between the digester top and the high-pressure feeder. With the digester of up to 100 m height, the difference can be rather great and still more influence on the impregnation procedure in a favorable direction. In order to make the recirculation of fiber material possible, especially the line 40 and the pump 41 must be given a suitable design. The line 40 must have a cross-section and bends so that fiber material pieces can pass therethrough. Suitably, the line 40 can extend into the chamber 16 and there may be provided two or more evenly distributed outlet openings 51 so that an even extraction can be obtained over the cross-section of the chamber 16. The pump 41 must be equipped with rotor and housing which can permit the passing of fiber parts of the size which it is here question about. The feeder 12 and the conduit 46 are normally made for transport of fiber material and liquid and, therefore, no alterations have to be made to these conventional parts. The method and the device according to the invention can, as is readily understood from the above description, be employed in existing installations with a minimum of rebuilding.
Through the invention, it is possible in a normal liquid feeding of fiber material to a continuous digester to obtain an improvement of the fiber material impregnation with cooking liquor. The invention can be used in principally all continuous cooking processes since for all of them it is of importance to obtain as even and effective and impregnation, with special impregnating liquid, or cooking liquor of the fiber material as possible. The system with the high-pressure feeder 12, which without mechanical action on the fiber material feeds fiber material in a liquid circulation from a relatively low to a relatively high pressure and which in hundreds of installations in practical operation has proved to be a very reliable and technically good piece of machinery is thus even further varied in function.
While the invention has been herein shown and described in what is presently conceived to be the most practical and preferred embodiment, it will be apparent to those or ordinary skill in the art that many modifications may be made thereof within the scope of the invention which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and methods.
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Impregnation of fiber material before digestion is accomplished utilizing a minimum amount of equipment. Liquid with entrained fiber material -- both fiber material sufficiently impregnated with liquid to be denser than the liquid and material insufficiently impregnated to be denser than the liquid -- is fed from a high-pressure transfer valve to an inlet at the top of a continuous digester. The digester has an outlet disposed vertically above the inlet, and liquid along with fiber material of lesser density than the liquid is withdrawn from the outlet. The withdrawn liquid and fiber material is recirculated back to the transfer valve through a conduit adapted to allow the passage of fiber material entrained in liquid therethrough. Each individual portion of fiber material is continuously circulated until it becomes sufficiently impregnated with liquid to descend into the digester and form a fiber column therein.
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FIELD OF THE INVENTION
The present invention relates to novel self-adhesive sheet-like structures comprising at least one support layer and at least one adhesive layer based on polyurethane gel. The sheet-like structures can be obtained by coating a very wide variety of support materials with a reaction mixture which comprises diisocyanates and/or polyisocyanates and an excess amount of high molecular weight polyols, followed by curing, and they can be used, for example, for medical purposes as an adhesive plaster tolerated by the skin, or for industrial applications as an adhesive.
BACKGROUND OF THE INVENTION
Various embodiments of self-adhesive sheet-like structures are known, such as, for example, medical plasters. Skin plasters for medical purposes customarily have adhesive surfaces based on rubber resins or polyacrylates. The plasters having rubber adhesive surfaces have the disadvantage that residues, which are difficult to remove, remain on the skin when these plasters are removed again. In addition, these plasters frequently lead to skin irritation. The disadvantages of plasters having adhesive surfaces based on polyacrylates are the occasionally occurring skin reddening, which may progress to skin irritation, and the skin softening processes which are generally seen when there is inadequate access for air. These disadvantages appear particularly intense when polyacrylate adhesive surfaces remain on the skin for longer than one day, and when the surface covered by the adhesive is relatively large in extent.
Self-adhesive sheet-like structures which are used for industrial purposes and whose adhesive effect is based on polyvinyl chloride (PVC), (PVC being used either as an adhesive coating on a support material or as a self-adhesive film) have the disadvantage that an adequate adhesive effect is only achieved on smooth and even substrates. In addition, some of the low molecular weight plasticizers generally contained in PVC act, because of their chemical structure, as solvents and/or they are able to migrate into the substrates.
It has now been found that self-adhesive sheet-like structures which adhere well even to rough and uneven surfaces, can be removed again leaving virtually no residues and, in addition, are tolerated by the skin, are obtained by coating any desired support materials with a polyurethane reaction mixture which cures with the formation of a highly elastic gel of firm structure. Gels similar to those used in the present invention are disclosed in U.S. Pat. No. 4,456,642 including some gels which have a tacky gelatinous consistency. However, the disclosure does not teach that gels within its broad teaching could have utility as adhesive materials nor does it teach how to select gels within its broad teachings which have this property.
BRIEF DESCRIPTION OF THE INVENTION
Thus, the invention relates to self-adhesive sheet-like structures containing at least one support layer and at least one adhesive layer, one of the two surfaces of the sheet-like structure being at least partially covered with an adhesive layer, characterized in that this adhesive layer is a gel which contains
(A) about 15-62% by weight, preferably about 20-57% by weight, particularly preferably about 25-47% by weight, relative to the total of (A) and (B), of a covalently crosslinked polyurethane as the high molecular weight matrix and
(B) about 85-38% by weight, preferably about 80-43% by weight, particularly preferably about 75-53% by weight, relative to the total of (A) and (B), of one or more polyhydroxy compounds which are immobilized in the matrix by intermolecular forces and have an average molecular weight between about 1,000 and 12,000, preferably between about 1,500 and 8,000, particularly preferably between about 2,000 and 6,000, and an average OH value between about 20 and 112, preferably between about 25 and 84, particularly preferably between about 28 and 56, as a liquid dispersing agent, the dispersing agent `15 being essentially free of hydroxy compounds having a molecular weight below about 800, preferably below about 1,000, particularly preferably below about 1,500, and, where appropriate,
(C) 0-100% by weight, relative to the total of (A) and (B), of fillers and/or additives and which can be obtained by reaction of a mixture of
(a) one or more polyisocyanates,
(b) one or more polyhydroxy compounds having an average molecular weight between about 1,000 and 12,000 and an average OH value between about 20 and 112,
(c) where appropriate, catalysts for the reaction between isocyanate and hydroxyl groups, preferably between about 0.05 and 10 weight % of the total weight of the gel, and, where appropriate,
(d) fillers and additives which are known per se from polyurethane chemistry, this mixture being essentially free of hydroxy compounds having a molecular weight below about 800, the average isocyanate functionality of the polyisocyanates (F I ) being preferably between 2 and 4, the average hydroxyl functionality of the polyhydroxy compounds (F P ) being at least 3, and the isocyanate number (K) obeying the formula ##EQU2## in which X≦120, preferably X≦100, and particularly preferably X≦90, and in which the isocyanate number (K) is the ratio of isocyanate (NCO) to hydroxyl (OH) equivalents in the reaction mixture multiplied by 100.
The indicated average figures for molecular weight and OH value are to be understood to be number averages.
The invention also relates to a process for the preparation of self-adhesive sheet-like structures based on support materials coated with polyurethane gel: the process is characterized in that the reaction mixtures which are capable of gel formation and are defined above are applied to the surface of a support material by a direct or reverse process by pouring, knife coating or spraying, the surface being only partly covered by the gel-forming reaction mixture where appropriate.
Finally, the invention also relates to the use of the self-adhesive sheet-like structures in medicine, in particular as adhesive or wound plasters, dressings or gauze bandages.
DETAILED DESCRIPTION OF THE INVENTION
The sheet-like structures according to the invention can be prepared from the starting compounds which are known per se from polyurethane chemistry by techniques which are broadly described in, for example, DE-OS (German Published Specification) 3,103,499, DE-OS (German Published Specification) 3,103,500 and U.S. Pat. No. 4,404,296, incorporated herein by reference. However, it is essential that, in the selection of the gel-forming components, the conditions defined above are observed, since otherwise non-adhesive, elastic gels are obtained in place of self-adhesive gel layers.
Polyhydroxy compounds preferred according to the invention are polyether-polyols as are detailed in the above-mentioned German Offenlegungsschriften (German Published Specifications) and U.S. Pat. No. 4,404,296. Both (cyclo)aliphatic and aromatic isocyanates are suitable as the polyisocyanate component. Preferred (cyclo)aliphatic polyisocyanates are 1,6-hexamethylene diisocyanate and its biurets and trimers, and hydrogenated diphenylmethane diisocyanate ("MDI") types. Preferred aromatic polyisocyanates are those which are obtained by distillation, such as MDI mixtures of 4,4'- and 2,4'-isomers or 4,4'-MDI, and toluylene diisocyanate ("TDI") types. The TDI types can also contain more highly functionalized fractions based on modifications, such as biuretization or trimerization.
In a preferred manner according to the invention, the starting components are selected such that, in the gel-forming reaction mixture, the average NCO functionality is between 2 and 4, the average polyol functionality is between 3 and 6, and the isocyanate number (K) is between about 15 and 70, preferably between about 18 and 55, and particularly preferably between about 20 and 45.
The adhesive layers consisting of polyurethane gel on the sheet-like structures according to the invention can, where desired, contain additives known per se from polyurethane chemistry, such as, for example, fillers and short inorganic- or organic-based fibers, metal pigments, water-binding agents, surface-active substances or liquid extenders, such as substances having a boiling point above 150° C.
Examples of inorganic fillers which may be mentioned are barytes, chalk, gypsum, kieserite, soda, titanium dioxide, cerium oxide, quartz sand, kaolin, carbon black and hollow glass microspheres.
Examples of organic fillers which can be used are powders based on polystyrene, polyvinyl chloride, urea-formaldehyde and polyhydrazodicarbonamide (for example from hydrazine and toluylene diisocyanate).
Examples of suitable short fibers are glass fibers 0.1-1 mm in length, or fibers of organic origin such as, for example, polyester or nylon fibers. Metal powders such as, for example, iron or copper powder, can likewise be used in the gel formation. In order to confer the desired coloration to the gels according to the invention, it is possible to use organic- or inorganic-based dyestuffs or coloring pigments known per se for the coloring of polyurethanes, such as, for example, iron oxide or chromium oxide pigments, or phthalocyanine- or monoazo-based pigments. Zeolites are the preferred water-binding agents. Examples of surface-active substances which may be mentioned are powdered cellulose, active charcoal, silica products and chrysotile asbestos.
Examples of suitable liquid extenders are alkyl-, alkoxy- or halogen-substituted aromatic compounds, such as dodecylbenzene, m-dipropoxybenzene or o-dichlorobenzene, halogenated aliphatic compounds, such as chlorinated paraffins, organic carbonates, such as propylene carbonate, carboxylic esters, such as dioctyl phthalate, ethyl stearate, lauric acid hexyl ester, isopropyl myristate, isopropyl palmitate or dodecylsulphonic esters or organic phosphorus compounds, such as tricresyl phosphate. In addition, it is also possible to use as liquid extenders high molecular weight polyols whose hydroxyl groups have been etherified, esterified or urethanized, or also silicone oils or paraffin oils.
The content of fillers and extenders in the gel layer can amount to up to about 50% by weight relative to the total weight of the gel.
Where appropriate for modification of the adhesion properties of the gel layer, it is possible to add polymeric vinyl compounds, polyacrylates and other copolymers customary in adhesive technology, as well as adhesives based on natural materials, up to a content of about 10% by weight, relative to the weight of the gel composition.
The thickness of the gel layer can be between, for example, about 0.001 mm and 5 mm, preferably between about 0.01 mm and 2 mm, and particularly preferably between about 0.1 mm and 1 mm.
A very wide variety of origins is possible for the support materials contained in the self-adhesive sheet-like structures according to the invention, that is to say materials based on natural, cellulosic or synthetic raw materials and of organic or inorganic origin can be used. For example, it is possible to employ plastic films and metal foils, mats, bonded fiber webs, and knitted or woven fabrics of organic or inorganic fibers, paper, board, wood, leather and plastic foam sheeting, or combinations of these support materials. Sheet-like structures which are permeable to air and moisture are preferred for medical applications, for example microporous and macroporous plastic films, elastic textile support materials, in particular stretch fabric, and gauze bandages.
The gels contained in the sheet-like structures according to the invention can be prepared by various means.
For example, it is possible to use a one-shot process or a prepolymer process. In the one-shot process, all the components, that is to say polyols, diisocyanates and/or polyisocyanates, the catalysts accelerating the isocyanate polyaddition reaction and, where appropriate, fillers and additives, are together placed in one vessel and thoroughly mixed with one another.
In the prepolymer process, there are two possible procedures. Either first an isocyanate prepolymer is prepared by reacting an appropriate fraction of the amount of polyol with the total amount of isocyanate intended for gel formation, and then the remaining amount of polyol and, where appropriate, fillers and additives are added to the resulting prepolymer, with thorough mixing: or the entire amount of polyol intended for gel formation is reacted with a portion of the amount of isocyanate to give a hydroxy prepolymer, and then the remaining amount of isocyanate is mixed in.
A particularly advantageous procedure according to the invention is a variant of the one-shot process and of the hydroxy prepolymer process. In this, the polyol or mixture of polyols, where appropriate the fillers and additives, the catalyst and two different diisocyanates are put together in one shot and mixed thoroughly, one diisocyanate being aromatic and one diisocyanate being aliphatic. It can be assumed that, due to the great difference in reactivity of the two diisocyanates, first a hydroxy prepolymer is produced, which then, within minutes, reacts with the other diisocyanate to form a gel.
In these procedures, the transport, dosage and mixing of the individual components or mixtures of components can be carried out with devices known per se to the expert in polyurethane chemistry.
The sheet-like structures according to the invention can be produced continuously or discontinuously. The procedure depends on the sheet-like structures which it is intended to provide with an adhesive layer. When support material which has already been cut to shape is supplied, a discontinuous procedure is frequently advantageous. For coating support materials which are continuous, for example in the form of rolls, a continuous procedure is advisable. This can entail the gel-like adhesive layer being applied to the support material either directly or by a reverse process. In the processes mentioned, the reaction mixture which is capable of gelling can also be knife-coated or spray-coated before it congeals due to the reaction. The spray process makes it possible, for example, for wide-mesh fabrics to be straightforwardly coated in dot form.
Preferably, the sheet-like structures according to the invention are exposed to gamma radiation. By means of this after-treatment the adhesion capacity of the gel layer is improved, i.e there is stronger adhesion to substrates of any kind.
An essential advantage of the sheet-like structures according to the invention when used as medical plasters is that they are well tolerated by the skin. No softening, or other damage to the skin caused by impermeability to air or water vapor, is found. Moreover, as plasters, the sheet-like structures according to the invention can be detached again from the skin by a gentle tug, with no epilation occurring, and they leave virtually no residue.
Thus, a particular embodiment of the sheet-like structures according to the invention is represented by wound dressings which consist of a support material having a self-adhesive polyurethane gel layer, on the center of which is located a pad for the wound, in order to enclose the wound on all sides. In this context, the support material can consist of, for example, a plastic film based on, for example, polyurethane (PUR) or PVC, a plastic foam sheeting based on, for example, PVC, PUR or polyethylene or, preferably, bonded fiber textiles based on, for example, viscose fibers, and fabrics based on, for example, rayon, or stretch knitted fabrics based on, for example, PUR/nylon blended yarns. It is possible to use as the absorbent central pad for the wound those materials known to be tolerated by wounds, such as, for example, cotton gauze, PUR plastic foam sheeting or viscose textile webs having a fabric structure. However, combinations of a wound pad based on, for example, cotton gauze or viscose textile webs, which is, where appropriate, aluminized, and an absorbent layer based on, for example, cellulose, viscose or viscose/ cotton (25:75) blends are preferred. The pad for the wound can also consist of a chemically crosslinked gel which absorbs discharge from the wound, for example a PUR gel according to European Patent A 0,057,839, the gel being optionally expanded to increase its absorbence, thus being an expanded gel. Possible applications of wound dressings of this type are for caring for wounds which are dry or discharging slightly, and, in a special embodiment, that is to say with a soft central cushion pad, also as a dressing for the eyes or a dressing for corns.
It is possible to produce, as a variant of the wound dressing which is suitable for caring for minor wounds, first-aid dressings which can consist of, for example, the same material combinations as the wound dressings, but have, in place of the central pad for the wound, a continuous pad for the wound.
A further embodiment of the sheet-like structures according to the invention is represented by inelastic (inextensible) and elastic bandages based on cotton or cotton/PUR or cotton/nylon blended yarns, the bandages being provided with the self-adhesive non-slip PUR gel by wetting or coating. Bandages of these types can be used for compression and support dressings and as sports strapping, advantageously on joints or tapering parts of the body. The extensibility required for each elastic bandage is normally achieved not only by the type of yarn but, in particular, by the technique of weaving or knitting the bandages, which are then provided with the gel.
The fixing tapes which are used for a variety of purposes in medical applications consist, according to the invention, of a support material which is provided with an adhesive layer of polyurethane gel. Examples of support materials which can be used for this are plastic films based on, for example PVC or PUR, plastic foam sheeting based on, for example, polyethylene, PVC or PUR, bonded fiber textiles based on, for example, viscose, fabrics based on, for example, rayon, cotton or, preferably, stretch knitted fabrics based on, for example, PUR/nylon blended yarns. By punching suitable rows of holes or serrated edges, the fixing tapes can be designed in a form which can be torn by hand. The fixing tapes according to the invention can be used for attaching, for example, tubes, catheters, measuring probes, dressings, ointment compresses, wound compresses, eye compresses or navel compresses.
An embodiment of a skin plaster containing an active compound which is suitable for transdermal administration of the active compound consists, according to the invention, of a support material which is provided with an adhesive layer of polyurethane gel, on the center of which is located a pad containing active compound. Between this support material coated with gel and this pad containing active compound, there is a separating layer which seals off diffusion of the particular active compound and is composed of, for example, aluminum foil, which is optionally provided on the side facing the pad containing the active compound with a sealable film, for example based on EVA (ethylene vinyl acetate), in order to be able to lock the active compound in tightly by means of a sealable covering layer. It is possible to use as the support material for the pad containing active compound, depending on the purpose for which it is used and the type of active compound, gel-like compositions based on, for example, polyurethane, PVC or polyisobutylene, and bonded fiber webs based on, for example, viscose. The support material, which has the adhesive gel layer, for the plaster containing active compound can consist of the same materials as are described above for the case of wound dressings.
It is possible for the various plasters, bandages and dressings to be coated with the gel which produces the adhesive effect either throughout or only partially: they can be microporous or macroporous or even perforated. Thus, for example, it is possible for gauze bandages or other inelastic or elastic bandages to be provided with the self-adhesive gel composition in only small areas (for example on the longitudinal margins, in the form of strips at right angles to the direction of winding or as dots), for example to achieve a non-slip effect.
A further advantage of the sheet-like structures according to the invention is their ability to adhere even to rough, uneven and highly contoured substrates. For this reason, there are industrial applications of the sheet-like structures according to the invention in many embodiments, for example as adhesive surfaces for notice and information boards: as material for temporary repair of cracked materials or broken parts: as a fixing aid for promotional material: in the form of adhesive films or fabrics which can be cut to produce modeling material for children; as a surface for insects to adhere to; as adhesive labels; as an adhesive surface for envelopes: as a protective film on car windows to counter the deposition of layers of ice at night.
The examples which follow illustrate the present invention.
Quantitative data are to be understood to be percentages by weight or parts by weight unless otherwise indicated.
The following polyisocyanates and polyols were used in the examples:
Polyisocyanate 1: 1,6-Hexamethylene diisocyanate.
Polyisocyanate 2: Commercial 1,6-hexamethylene diisocyanate which has been biuretized and has an average NCO functionality of 3.6, an NCO content of 21% and an average molecular weight (number average) of about 700 (Desmodur®N of Bayer AG)
Polyisocyanate 3: Mixture of isomers comprising 80% 2,4- and 20% 2,6-toluylene diisocyanate
Polyisocyanate 4: 4,4'-Diisocyanatodiphenylmethane liquefied by prepolymerization with tripropylene glycol; average NCO functionality: 2.05: NCO content: 23%
Polyisocyanate 5: 1,6-Hexamethylene diisocyanate modified by trimerization, average NCO functionality: 3.4: NCO content: 21.5%: average molecular weight (number average)=about 675.
The polyether-polyols used in the examples are compiled in the table below.
They were prepared by addition, in a manner known per se, of propylene oxide, and, where appropriate, ethylene oxide, onto the starter molecules indicated.
______________________________________Polyol Propylene Ethylene Starter OH OHNo. oxide % oxide % molecule value functionality______________________________________1 80 20 PET 36 42 100 -- Sorbitol 46 63 73 27 Sorbitol 30 64 45 55 TMP 56 35 100 -- PET 72 46 100 -- TMP 56 37 90 10 Sorbitol 83 68 100 -- EDA 61 49 83 17 TMP 35 310 100 -- PET 45 4______________________________________ PET = pentaerythritol TMP = trimethylolpropane EDA = ethylenediamine
EXAMPLE 1
100 parts of polyether 1, 6.1 parts of polyisocyanate 4 and 0.6 parts of dibutyltin dilaurate are, within one minute, thoroughly mixed and poured out onto silicone-treated paper to give a layer 0.5 mm thick. After 10 minutes, the gel-forming reaction starts and the viscosity of the reaction mixture slowly increases. An elastic knitted fabric based on nylon/polyurethane fibers is applied, without creases, to the highly viscous film of the reaction mixture. After 20 minutes, the mixture has congealed to form a gel. The gel-coated stretch material is divided into pieces each 12×10 cm in size, and pieces of wound gauze each 4×6 cm in size are applied to the gel-coated side in such a manner that an adhesive layer of gel, which is 3 cm wide, is retained around the periphery of each. A wound dressing of this type is suitable for caring for wounds on parts of the body which are subject to extensive movement, such as, for example, joints.
EXAMPLE 2
100 parts of polyether 3, 3.9 parts of polyisocyanate 4 and 1 part of dibutyltin dilaurate are, within one minute, thoroughly mixed and poured out onto silicone-treated paper to give a layer 0.5 mm thick. After 10 minutes, the gel-forming reaction starts, and the viscosity of the reaction mixture slowly increases. A bonded fiber textile based on viscose is applied, without creases, to the highly viscous film of the reaction mixture.
After 20 minutes, the mixture has congealed to form a gel. The gel-coated bonded fiber textile is divided into pieces each 8×10 cm in size, and pieces of wound gauze, which are each 4×6 cm in size, are applied to the gel-coated side in such a manner that an adhesive layer of gel, which is 2 cm wide, is retained around the periphery of each.
The resulting wound dressing is suitable for caring for wounds which are dry or discharging slightly.
EXAMPLE 3
100 parts of polyether 4, 9.8 parts of polyisocyanate 4 and 2 parts of dibutyltin dilaurate are, within one minute, thoroughly mixed and spread on a Teflon plate to form a layer 0.1 mm thick. After 10 minutes, the gel-forming reaction starts and the viscosity of the reaction mixture slowly increases. An elastic knitted fabric based on nylon/polyurethane fibers is applied, without creases, to the highly viscous film of the reaction mixture. After 20 minutes, the mixture has congealed to form a gel. The gel-coated stretch material is divided into strips 8 cm wide. Strips of viscose textile web (with a fabric structure) which are each 2.6 cm wide are glued onto the center of the gel-coated side of the strips, in a longitudinal direction in such a manner that a zone of adhesive gel, which is 2.7 cm wide on each side, is retained in the longitudinal direction on the borders.
The resulting strips can be divided across in pieces which are 1 to 3 cm wide and which then can be used as first-aid dressings for caring for minor wounds.
EXAMPLE 4
100 parts of polyether 2, 5.3 parts of polyisocyanate 4 and 1 part of dibutyltin dilaurate are, within one minute, thoroughly mixed and, using a spray gun, sprayed onto an elastic bandage (cotton weft threads, crimped nylon warp threads), the amount of gel composition applied being 35 parts per square meter. Coagulation to form a gel is complete after 10 minutes.
The resulting bandage which has been sprayed with gel is suitable for applying dressings to tapering parts of the body, since the individual layers of the bandage adhere very well to one another, and thus do not slip during movement.
EXAMPLE 5
A mixture of 100 parts of polyether 1, 3.6 parts of polyisocyanate 5 and 3.parts of dibutyltin dilaurate is used to coat, by the procedure described in Example 1, an elastic knitted fabric based on nylon (84%) and polyurethane (16%).
The 3 cm-wide strips obtained by dividing the coated stretch knitted fabric are suitable for immobilizing catheters and tubes as well as emergency wound gauze dressings.
EXAMPLE 6
The process is carried out exactly as in Example 5 but, in place of the combination of polyether 1 and polyisocyanate 5, the combinations of polyethers and polyisocyanates listed below are used:
______________________________________100 parts of are mixed with the following partspolyether by weight of polyisocyanates______________________________________No. 2 4.3 parts of polyisocyanate 5No. 4 6.6 parts of polyisocyanate 5No. 5 8.5 parts of polyisocyanate 5No. 6 7.6 parts of polyisocyanate 5No. 1 3.6 parts of polyisocyanate 2No. 2 4.1 parts of polyisocyanate 2No. 3 2.46 parts of polyisocyanate 2No. 4 5.2 parts of polyisocyanate 2No. 7 5.0 parts of polyisocyanate 2No. 1 2.9 parts of polyisocyanate 1No. 3 1.8 parts of polyisocyanate 1No. 9 4.15 parts of polyisocyanate 2______________________________________
EXAMPLE 7
A mixture of 100 parts of polyether 7, 7.56 parts of polyisocyanate 4 and 2 parts of dibutyltin dilaurate is, within one minute, thoroughly mixed and spread on a Teflon plate to give a film 0.3 mm thick. A bonded fiber textile based on viscose is laid, without creases, onto the film which is becoming highly viscous due to the reaction. After gel formation is complete, the bonded fiber fabric which has been provided with a film of gel is divided into strips 2 cm wide.
Strips of this type are suitable for attaching information sheets or advertising posters to shop windows.
EXAMPLE 8
The process is carried out exactly as in Example 7, but in place of the combination of polyether 7 and polyisocyanate 4, the combinations of polyethers and polyisocyanates listed below are used:
______________________________________100 parts of are mixed with the following partspolyether of polyisocyanate______________________________________No. 8 9.9 parts of polyisocyanate 4No. 1 3.14 parts of polyisocyanate 3No. 4 5.15 parts of polyisocyanate 3 No. 10 8.8 parts of polyisocyanate 4______________________________________
EXAMPLE 9
100 parts of polyether 2, 15 parts of an oil based on polydimethylsiloxane (Baysilone oil M 5000, Bayer AG) with a viscosity of 5000 mm 2 /sec at 25° C., 5 parts of polyisocyanate 4 and 0.1 part of dibutyltin dilaurate are thoroughly mixed together, poured onto a Teflon plate and spread to form a layer 0.1 mm thick.
The viscosity has increased greatly after 10 minutes An extensible knitted fabric based on nylon/ polyurethane is laid onto the highly viscous reaction mixture. After 30 minutes, the gel-coated knitted fabric is detached from the plate and cut into strips 3 cm wide. Strips of this type can be used as fixing tapes for medical applications, such as, for example, for affixing dressings.
EXAMPLE 10
The process is carried out exactly as in Example 9 but, in place of the oil based on polydimethylsiloxane, an oil based on polymeric methylphenylsiloxane (Baysilone oil PH 300, Bayer AG) with a viscosity of 300 mm 2 /sec at 25° C. is used.
The resulting gel-coated strips can likewise be used as fixing tapes for mcdical applications.
The adhesion capacity of sheets according to the invention may be determined by the following method: a gel-coated strip (125 mm×25 mm) is pressed onto a clean smooth plate of VA-steel with a pressure of 7,5 Newton. Then the strip is detached from the steel surface at a rate of 100 mm/min. The force which has to be used to detach the specimen from the substrate is plotted by means of an x-y- recorder against the distance which has been detached. From the force/length diagram obtained the average force F is determined which has to be applied to detach the first 75 mm of the test specimen. F should be at least 0,5 N, preferably at least 1, 0 N, more preferably at least 2 N for sheet like structures according to the invention.
Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims.
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The present disclosure is concerned with self-adhesive sheet-like structures made by adhering an adhesive polyurethane gel material to a supporting substrate and the utilization of such structures in the medical field to adhere materials such as plasters, wound dressings and appliances to the human body, and in other fields to connect articles, such as the parts of a fractured or cracked object, to one another by means of an adhesive bond. The gel is formed by immobilizing a high molecular weight polymeric polyol in the matrix of a covalently crosslinked polyurethane which is prepared by reacting polyisocyanates having an isocyanate functionality of at least 2 with higher molecular weight polyhydroxyl compounds having a hydroxyl functionality of at least 3. These reactants are selected in accordance with the following formula which relates the isocyanate number, K, (isocyanate to hydroxyl equivalents ratio times 100) to the average functionalities of the polyisocyanates (F I ) and of the polyhydroxyl compounds (F P ) as follows: ##EQU1## wherein X is less than or equal to 120. These reactants are also selected to give a weight ratio of matrix to immobilized polymeric polyol of between about 15:85 and 62:38.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to engine controls, and more particularly to an engine torque control algorithm to reduce undesirable accelerations and oscillations from the powertrain during a closed throttle to open throttle transition.
2. Background and Summary of the Invention
Vehicles equipped with manual transmissions will develop a rapid undesirable acceleration (known as jerk) and oscillations (known as bobble) from the powertrain during the closed throttle to open throttle transition. Typically, what happens when the accelerator pedal is released during low speed operation such as city driving, and is then subsequently reapplied, the engine produces a sudden increase in torque which causes some of the powertrain components such as the drive shaft to twist (somewhat like a torsion spring), as the components of a powertrain become spring loaded, the release of the spring tension creates the undesirable accelerations and oscillations which are most prominently experienced during low speed operation of a vehicle having a manual transmission.
The present invention provides a torque algorithm to control the rate at which torque is produced from the engine. On manual transmission vehicles equipped with mechanical throttle bodies, spark advance/retard has the greatest effect on controlling the torque rate. The control system of the present invention controls spark advance/retard in order to control the torque rate.
The present invention provides a torque control algorithm for reducing jerk and bobble for an automotive vehicle powertrain including means for determining a proportional error term by monitoring an amount of torque the engine will produce and is presently producing during a closed to open throttle transition. Means are provided for determining a derivative error term by monitoring a rate of change of the engine speed during a closed to open throttle transition. Means are provided for determining a torque error term as the greater of the proportional error term and the derivative error term. Means are further provided for converting the torque error term to a spark compensation amount and for delivering the spark compensation amount to an engine control scheme. The proportional error term is determined based upon a sum of a potential torque term and a desired torque term minus an actual torque term. The derivative error term is determined based upon a derivative of engine acceleration over time since open throttle. The derivative error term is compared to be within a control window, and if not, is converted to a torque error value.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood however that the detailed description and specific examples, while indicating preferred embodiments of the invention, are intended for purposes 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 and the accompanying drawings, wherein:
FIG. 1 is a block diagram of the open throttle torque control scheme of the present invention;
FIG. 2 is a block diagram of the enabling conditions for the open throttle torque control scheme according to the principles of the present invention;
FIG. 3 is a block diagram for determining the derivative control term of the open throttle torque control scheme according to the principles of the present invention;
FIG. 4 is a block diagram of the torque reduction calculations for the open throttle torque control scheme of the present invention;
FIG. 5 provides a sample graphical illustration of each of the terms utilized in generating the proportional control term as well as the derivative control term according to the principles of the present invention; and
FIG. 6 is a graphical illustration of the reduced jerk and bobble that is obtained using the torque control scheme as compared to no torque control scheme according to the principles of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As described hereinbelow, the engine torque control algorithm of the present invention controls engine spark advance/retard in order to reduce and/or eliminate jerk and bobble. With reference to FIG. 1, a block diagram of the control scheme of the present invention is shown. The control scheme includes an input block 10 which receives data including coolant temperature, corrected throttle flow, delta throttle, engine run time, engine speed, manifold absolute pressure, engine/vehicle speed ratio, and vehicle speed. Each of these values is typically available from the engine controller which keeps track of, and updates each of, the above data. The control scheme as shown in FIG. 1 includes an enable conditions block 12 which is described in greater detail with reference to FIG. 2 . If the control scheme is enabled as determined in the block diagram shown in FIG. 2, the control scheme includes a torque reduction calculation block 14 which determines the proportional and derivative control term which will be described in greater detail herein. The torque reduction calculation block 14 provides a torque error term to block 16 which provides a torque to spark conversion which is then delivered to the engine controller as illustrated in block 18 .
With reference to FIG. 2, the enable conditions block 12 will be described in greater detail. Briefly, the enabling conditions require that the coolant temperature, engine run time, manifold absolute pressure, vehicle speed and engine speed all exceed predetermined values, that the throttle is open and that the engine speed/vehicle speed ratio is within a predetermined window and/or the clutch switch is active. Specifically, the enable conditions block first determines at block 22 if the coolant temperature is greater than a predetermined value. If not, the open throttle torque control scheme of the present invention is disabled at block 24 . If the coolant temperature is greater than a predetermined value, then the enable conditions block 12 determines if the engine run time is greater than a predetermined value at block 26 . If not, the control scheme of the present invention is disabled at block 24 . If the engine run time is determined to be greater than a predetermined value at block 26 , then control proceeds to block 28 wherein it is determined whether the manifold absolute pressure is greater than a predetermined value. If not, the control scheme of the present invention is disabled at block 24 . If at block 28 , the manifold absolute pressure is determined to be greater than a predetermined value, then the control scheme proceeds to block 30 where it is determined where the engine and vehicle speed ratio is within a predetermined window and/or the clutch switch is active. If not, the control scheme is disabled at block 24 . If the engine/vehicle speed ratio is within the predetermined window and/or the clutch switch is active, the control proceeds to block 32 where is determined whether the vehicle speed is greater than a predetermined value. If not, the control scheme is disabled at block 24 . If the vehicle speed is determined to be greater than a predetermined value at block 32 , then the control scheme proceeds to block 34 where it is determined if the engine speed is greater than a predetermined value. If not, the control scheme is disabled at block 24 . If the engine speed is determined to be greater than a predetermined value at block 34 , the control scheme proceeds to block 36 where it is determined if the throttle is open. If not, the control scheme is disabled at block 24 . If it is determined at block 36 that the throttle is open, then the control scheme of the present invention is enabled at block 38 .
The open throttle torque control system of the present invention is a proportional/derivative type control algorithm. The proportional torque error term is generated by monitoring how much torque the engine will produce and is presently producing during the closed to open throttle transition. The proportional error term for the proportional control is determined by the equation
P-term torque error= T POT +( T D− T A ) (1)
where T POT =T A− T P and T D =T C +T I. T pot is the torque potential. T A is the actual torque which is gathered from a surface look-up table of engine speed and manifold absolute pressure on the engine control module loop time, i.e., each time the software does a complete loop.
T P is the predicted torque which is gathered from a surface look up of corrected throttle flow and engine speed. Corrected throttle flow is a flow through the throttle body corrected to barometric pressure and ambient air temperature. T C is the captured actual torque which is the actual torque at the moment the throttle is sensed open. The captured actual torque value T C is maintained until the throttle is closed again. T I is the torque increment rate which is determined from a look-up table of the torque increment rate based on engine and vehicle speed. T D is the desired torque which is equal to the captured actual torque T C plus the torque increment rate T I .
The P-term torque error is determined according to the above equation and is provided at block 40 as shown in FIG. 4 .
The error term for the derivative control (D-term torque error) is generated by the rate of change of the engine speed during a period from the closed to open throttle transition as illustrated in FIG. 3 . At block 42 , the engine rpm acceleration is determined based upon the equation: RPM at current time minus RPM as determined at time 0 divided by accumulated time.
The accumulated time is the time since the open throttle was detected. The RPM acceleration term is delivered to block 44 where the true derivative of the RPM acceleration is taken by subtracting the previous RPM acceleration from the current RPM acceleration value and dividing by the engine control unit loop time since the last cycle. Block 44 provides an RPM jerk term which is provided to block 46 where the RPM jerk term is compared to be within a control window. If the RPM jerk term value exceeds a predetermined high threshold value or a predetermined low threshold value, the control proceeds to block 48 where the RPM jerk term is converted to a torque error value by a table look up of RPM jerk versus D-term torque error. The D-term torque error value is supplied at block 52 in FIG. 4 . An exemplary surface look-up table is provided below.
Table Look-up for RPM Acceleration to Torque Error
X-input: RPM Acceleration (RPM/sec)
Y-output: Torque Error (N-m)
RPM Acceleration
Torque Error
0
0
1000
−25
2000
−30
5000
−55
10000
−70
25000
−90
If in block 46 , the RPM jerk term is determined to be within the predetermined window, then the derivative term is set at 0 at block 50 .
As shown in FIG. 4, the torque error is determined at block 54 to be the greater of the P-term torque error and the D-term torque error. The torque error, as determined at block 54 , is converted at block 16 to an amount of spark compensation by multiplying the output of a surface look up of RPM versus manifold absolute pressure (MAP). The output of the surface look up is a number of degrees of spark per one unit of torque. An exemplary surface look-up table is provided below.
Surface Look-up for Torque to Spark conversion
X-input: RPM
Y-output: MAP (Kpa)
Surface output: No. of degrees of Spark/N-m
MAP
13
.00
.75
.73
.70
.85
.88
33
.00
.65
.64
.60
.76
.81
46
.00
.53
.52
.50
.65
.71
59
.00
.44
.43
.40
.55
.60
78
.00
.30
.33
.32
.40
.43
92
.00
.20
.22
.27
.30
.33
RPM
900
1000
2000
3000
4000
5000
The spark compensation value is delivered to the engine at block 18 as shown in FIG. 1 in order to retard or advance the engine spark in order to reduce and/or eliminate the jerk and bobble associated with the close throttle to open throttle transition.
With reference to FIG. 6, the engine rpm is mapped against time for the torque control system of the present invention as shown in solid lines while the dashed line represents the engine rpm with no torque control. From FIG. 6, it is clear that the magnitude of the sudden increase in torque is shown to be greatly reduced and the oscillating effect is also greatly reduced as compared to the no torque control curve.
According to the principles of the present invention, the torque reduction calculation block 14 of the present invention includes a proportional error term determination module 40 and a derivative error term determination module 52 . The greater of the P-term and D-term is utilized by the torque to spark conversion module 16 in order to retard or advance the engine spark in order to reduce jerk and bobble.
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 intended to be included within the scope of the following claims.
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A method is provided for controlling engine torque during a closed to open throttle transition in order to eliminate undesirable accelerations and oscillations from the powertrain.
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TECHNICAL FIELD
[0001] This disclosure relates to a polyphenylene sulfide (hereinafter abbreviated as PPS) monofilament and its package and, more specifically, a PPS monofilament suitable for the application of high precision filter.
BACKGROUND
[0002] PPS has excellent heat resistance, chemical resistance, and electric insulation and, also, excellent mechanical strength and molding workability. Accordingly, PPS is widely used as a metal substitute material and a material capable of enduring extreme environment. Various applications are also proposed for PPS fibers in view of these properties, and exemplary applications include filter, bristle of brush, canvas of dryer in paper making, electric insulation paper and other industrial materials. For example, Japanese Unexamined Patent Publication (Kokai) No. H10-60734 discloses a method of producing a PPS fiber with reduced fineness irregularity in a stable manner.
[0003] Recently, use of the PPS monofilament has been investigated as a substitute for SUS steel wire in the production sites of the fields including chemistry, electrics and electronics, automobiles, foods, precision machines, and pharmaceutical products and medicine. For example, Japanese Unexamined Patent Publication (Kokai) No. 2012-246599 proposes a method wherein a multifilament is first produced and then separated into monofilaments for the production of the monofilament with high productively at low cost. In that method, however, stretching and thermal setting are conducted with the monofilaments entangled by the entanglement treatment in step of producing the multifilament and the stretching and thermal setting are likely to be inconsistent between respective monofilaments, and the monofilaments after the separation are likely to suffer from fineness irregularity in axial direction of the fiber detracting from the production of consistent monofilaments. In addition, many guides and similar members are present in the separating steps, and the filaments are easily damaged by the friction and, because of the frictional tension and the like, the monofilament after the separation exhibited increased variation of the continuous heat shrinkage stress in axial direction of the fiber detracting from the production of consistent monofilament. Accordingly, the consistency in the physical properties in axial direction of the fiber was lost in the separated filament, and such separated filament was incapable of producing the high precision filters.
[0004] Furthermore, Japanese Unexamined Patent Publication (Kokai) No. 2011-106060 proposes a method wherein a small amount of a polyalkylene terephthalate is added to obtain the PPS monofilament having improved dimensional stability. However, due to addition of the polyalkylene terephthalate, that method suffered from the problems of loss of heat resistance and chemical resistance as well as loss of consistency in the physical properties in longitudinal direction by the blend irregularity, which resulted in the incapability of use for the high precision filter.
[0005] Furthermore, Japanese Unexamined Patent Publication (Kokai) No. 2009-68149 proposed a PPS monofilament having improved consistency of fineness in the intention of improving filter performance. While that PPS monofilament was certainly capable of producing filters having a certain precision, it was found that that PPS monofilament was incapable of responding to the recent demand for drastic increase in filter precision because an increase in filter precision requires control of the variety in the tension during the weaving of the filter, and Japanese Unexamined Patent Publication (Kokai) No. 2009-68149 does not at all indicate the method of solving such problems. As described above, there has been no PPS monofilament adapted for use in producing a high precision filter having an extremely low aperture variation rate and, accordingly, there is a strong demand for a PPS monofilament adapted for use in high precision filter.
[0006] It could therefore be helpful to provide a PPS monofilament with a very low aperture variation rate that is highly adapted for use in high precision filters.
SUMMARY
[0007] We thus provide:
[0000] (1) A polyphenylene sulfide monofilament wherein variation of continuous heat shrinkage stress in axial direction of the fiber is up to 5%, and consistency of fineness (U %, Normal value) is up to 1.2%.
(2) A drum-shaped package having the polyphenylene sulfide monofilament according to the above (1) wound thereon.
(3) A method of producing a polyphenylene sulfide monofilament comprising the steps of melting a polyphenylene sulfide resin, extruding filaments from a spinning nozzle and cooling the filaments by a cooler, applying an oil agent to the filaments, taking the filaments on a heated take up roller, stretching the filaments between the take up roller and a heated stretching roller, and winding the filaments in drum shape; wherein (a) temperature inconsistency between the center and periphery of the spinning nozzle surface is up to 3° C., and (b) each filament is cooled by a cooling gas stream at a temperature of at least 5° C. and up to 20° C. in the area within 100 mm from the spinning nozzle.
[0008] Use of the PPS monofilament enables provision of a high precision filter having high heat resistance and chemical resistance as well as extremely low aperture variation rate.
BRIEF DESCRIPTION OF THE DRAWING
[0009] FIG. 1 is a schematic view showing our spinning process.
EXPLANATION OF NUMERALS
[0000]
1 : nozzle
2 : heated vapor generator
3 : heater under the nozzle
4 : cooling gas stream
5 : cooling gas stream blower
6 : filament
7 : oiling roller
8 : first roller
9 : second roller
10 : winder
11 : package
DETAILED DESCRIPTION
[0021] The PPS has a basic repetitive structural unit comprising p-phenylene sulfide, and it may also contain other copolymerization structural units. Exemplary such copolymerization structural units include aromatic sulfides such as m-phenylene sulfide and biphenylene sulfide, and any of these substituted with an alkyl or a halogen. Also, other polymers may be added by mixed spinning, composite spinning or the like, and exemplary such other polymers include a polyester, polyamide, polyolefin, and polyimide. The amount of the copolymerization component and the polymer added is preferably up to 3% by weight since the heat resistance and the chemical resistance will be retained at high level when the amount is in such range. The amount is more preferably up to 1% by weight and, still more preferably, the copolymerization component and the polymer are preferably not added.
[0022] Also, additives such as antioxidant, heat resisting agent, agent to prevent thermal degradation, weathering agent may be added preferably at an amount of up to 1% by weight. Favorable spinnability can be realized when the amount is up to 1% by weight. The amount of additives added is more preferably up to 0.5% by weight.
[0023] In addition, the PPS is preferably polymerized by a quenching method with reduced content of the low molecular weight PPS. Use of such polymer with reduced content of the low molecular weight PPS prevents smudging of the nozzle during spinning, and stable production of the PPS monofilament is thereby enabled.
[0024] To produce a filter having a very high precision, variation of the continuous heat shrinkage stress in axial direction of the PPS monofilament should be suppressed simultaneously with the realization of the improved evenness of the fineness.
[0025] The continuous heat shrinkage stress in the axial direction of the fiber is the shrinkage stress continuously measured in axial direction of the fiber while generating the shrinkage stress by moving the fiber under heat treatment. More specifically, the continuous heat shrinkage stress in axial direction of the fiber is determined by moving the filament between a filament-feeding roller and a filament-take up roller, subjecting the filament to dry heating treatment between these rollers, and continuously measuring the shrinkage stress (cN) by using a tensiometer provided behind the rollers. Variation of the continuous heat shrinkage stress in axial direction of the fiber is a value obtained by dividing standard deviation of the thus measured continuous heat shrinkage stress by the average. More specifically, the measurement is conducted at a measurement frequency of 6 measurements/1 cm, and by regarding the average of these measurements as 1 data, 1000 data are collected. The average and the standard deviation are then calculated from these 1000 data, and the variation of the continuous heat shrinkage stress is calculated by the following equation. The average and the standard deviation are automatically calculated when using “continuous heat shrinkage measuring instrument FTA-500” manufactured by TORAY ENGINEERING Co., Ltd.
[0000] (Variation of the continuous heat shrinkage stress)=(standard deviation)/(average)×100
[0026] We found that this variation of continuous heat shrinkage stress in axial direction of the fiber affects the variation of tension in the weaving of the filter. In other words, if the continuous heat shrinkage stress is stable, variation in the tension during the weaving will also be reduced, and this enables production of a high precision filter. The variation of the continuous heat shrinkage stress required for realization of such situation is up to 5%, and more preferably up to 3%. The lower limit is at least 0%.
[0027] One preferable means of reducing this variation of the continuous heat shrinkage stress in axial direction of the fiber to the range of up to 5% is suppressing the variation of stretching tension in the step of stretching the filament.
[0028] To suppress the variation of stretching tension, variation in the temperature of the nozzle surface is preferably reduced to up to 3° C., and more preferably up to 1.5° C. The variation of nozzle surface temperature is the difference between the maximum temperature and the minimum temperature of 5 positions in total (the center of the nozzle and the arbitrary 4 points at a distance 5 mm from the outer periphery of the nozzle). We found that temperature of the ejected polymer will be consistent and stable when the variation in the temperature of the nozzle surface is up to 3° C. and the ejection and the cooling will also be stable, and that this leads to the stable stretching tension in the subsequent stretching step. An exemplary method of suppressing the variation of nozzle surface temperature is heating the nozzle from the underside of the nozzle surface by a heater, and more preferably, the underside of the nozzle is filled with heated vapor. The temperature of the heater under the nozzle surface is preferably in the range of spinning temperature±20° C., and more preferably the spinning temperature±10° C.
[0029] Another important property for the production of the filter having an extremely high precision is consistency of the PPS monofilament fineness. The consistency of fineness is represented by Uster irregularity (U %, Normal value), and a U % of up to 1.2%, preferably up to 1.0%, and more preferably up to 0.9% is required for the production of the filter having an extremely high precision. The lower limit is at least 0%. To realize such high consistency of fineness, the step of cooling the polymer ejected from the nozzle is very important.
[0030] In the cooling step, the medium used for the cooling is preferably a gas (air). The cooling by a gas (cooling gas stream) will receive lower resistance from the polymer compared to the cooling by a liquid and this is favorable in view of the consistency of fineness.
[0031] The cooling gas stream is preferably at a temperature of at least 5° C. and up to 20° C., and more preferably at a temperature of at least 5° C. and up to 10° C. When the temperature of the cooling gas stream is up to 20° C., the polymer will be sufficiently cooled, and this leads to the improvement in the consistency of fineness.
[0032] In addition, the distance at the start of the cooling is preferably up to 100 mm and more preferably up to 80 mm from the nozzle surface. When the distance at the start of the cooling is up to 100 mm, solidification point of the polymer ejected from the nozzle will be stable, and this leads to the improvement in the consistency of fineness.
[0033] In the production of a high precision filter, winding shape of the PPS monofilament is also extremely important, and the package is preferably in a drum shape. When the package is in a drum shape, the defect in the form of streak called “pirn mark” that occurs in the use of a pirn-shape package can be suppressed.
[0034] The PPS monofilament may preferably have a fineness of 6 to 33 dtex and more preferably 6 to 22 dtex. When the fineness is 6 to 33 dtex, pressure loss by filtration will be reduced even if the filter has a higher density.
[0035] In addition, the PPS monofilament preferably has a strength of at least 3.0 cN/dtex, and more preferably at least 3.5 cN/dtex. When the strength is at least 3.0 cN/dtex, the filter will exhibit an improved durability.
[0036] The PPS monofilament also preferably has a dimensional change rate by hot water immersion of up to 10%, and more preferably up to 6%. When the dimensional change rate by hot water immersion is up to 10%, the filter will enjoy an improved dimensional stability when used in high temperature environment.
[0037] The PPS monofilament is preferably produced by a one-step method wherein the monofilament is produced by direct spinning. Use of a one-step method results in the reduced variation of the stretching tension and this leads to decrease in the variation of the continuous heat shrinkage stress. The use of a one-step method also results in the drastically improved productivity.
[0038] Another exemplary method of producing the PPS monofilament is production of multifilament followed by division into the monofilament. However, the preferred is use of the one-step method wherein the monofilament is produced by direct spinning.
[0039] Next, a preferable example of the method of producing the monofilament is described.
[0040] The PPS resin is as described above.
[0041] The PPS resin used for the spinning is preferably adjusted by using a dryer so that content of the low molecular weight components is up to 0.15% by weight, and more preferably up to 0.1% by weight before its use for the spinning. By removing the polymer components having a lower boiling point to the minimum possible content, smudging of the nozzle face in the melt spinning will be suppressed and stable production of a PPS monofilament having excellent consistency of fineness as well as reduced variation of the continuous heat shrinkage stress will be possible.
[0042] In the melt spinning, the melt extrusion of the PPS resin may be conducted by a known method. The extruded polymer is guided through the piping, a known measuring instrument such as gear pump where it is measured, a filter for foreign body removal, and then to the nozzle. The polymer at this stage is preferably at a temperature of 300 to 330° C., and more preferably at 310 to 320° C.
[0043] To produce the PPS monofilament having excellent consistency of fineness, the nozzle hole may preferably have a hole diameter D of at least 0.10 mm and up to 0.50 mm, and the ratio of the land length L of the nozzle hole (length of the straight pipe section having the diameter the same as the nozzle hole) to the hole diameter D of the hole, namely, L/D is preferably at least 1.0 and up to 8.0. The number of holes per nozzle is preferably at least 4 in view of the productivity and up to 8 in view of cooling the filament.
[0044] The nozzle surface temperature and the cooling of the filament ejected from the nozzle are as described above.
[0045] The cooled and solidified filament is taken up by a heated first roller, and continuously stretched between the first roller and the second roller as described above. While a single hook type, separate roller type, and Nelson type may be used for the first roller and the second roller, use of a Nelson type is preferable in view of improving stability in the filament heating and fixing the filament heating speed.
[0046] The take up speed of the first roller is preferably 300 to 1000 m/min, and more preferably 400 to 800 m/min.
[0047] The first roller is preferably heated to a temperature not lower than the temperature 10° C. lower than the glass transition temperature of the polymer and not higher than the temperature 20° C. higher than the Tg of the polymer. When the temperature is in such range, the stretching will be conducted in the state wherein flowability of the PPS is sufficient and variation of the stretching tension will be suppressed.
[0048] The second roller is preferably heated to a temperature of at least 140° C. and up to 250° C. When the temperature is at least 140° C., improvement in the strength and dimensional stability will be possible.
[0049] With regard to the winding, the winding may be conducted by using a known winder. The package, however, is preferably a drum-shape package as described above.
[0050] The thus obtained PPS monofilament is used in the warping by a warping machine to realize the intended opening, and after interlacing the wefts by rapier loom, water-jet loom, or the like, the resulting woven product is cut for use as a filter. Exemplary applications of this filter include injection filter in automobile engines and filters used in medical field.
EXAMPLE
(1) Aperture Variation Rate
[0051] PPS monofilaments were aligned in a warping machine at 380 monofilaments/inch (2.54 cm) and weaving was conducted by using a rapier loom at 380 monofilaments/inch (2.54 cm) (so that the aperture was square). The test woven product was observed by a scanning electron microscope (ESEM-2700 manufactured by Nikon) at a magnification of 1000. More specifically, inter-filament distance of the aperture at any 20 positions (the part with the maximum distance in each aperture) was respectively measured in the order of 0.1 μm. The aperture variation rate was calculated by the following equation:
[0000] (Aperture variation rate)=(standard deviation)/(average)×100
[0052] With regard to the aperture variation rate, the aperture variation rate of up to 3% which is the index for a high precision filter was evaluated “pass”.
(2) Variation of the Continuous Heat Shrinkage Stress
[0053] The measurement of the continuous heat shrinkage stress was conducted by using “continuous heat shrinkage stress measurement instrument FTA-500” manufactured by TORAY ENGINEERING Co., Ltd. The measurement was conducted by moving the filament between a filament-feeding roller and a filament-take up roller at 5 m/min, subjecting the filament to dry heating treatment between these rollers (temperature: 100° C.; unit length: 10 cm), and continuously measuring the stress caused by heat (cN) by a tensiometer provided behind the rollers. The measurement is conducted at a measurement frequency of 6 measurements/1 cm, and by regarding the average of these measurements as 1 data, 1000 data are collected. The average and the standard deviation were calculated from the thus obtained 1000 data, and the variation of the continuous heat shrinkage stress was calculated by the following equation. The average and the standard deviation are automatically calculated by the measurement instrument.)
[0000] (Variation of the continuous heat shrinkage stress)=(standard deviation)/(average)×100
(3) Uster Irregularity (U %)
[0054] Measurement was conducted by using USTER TESTER 5 manufactured by Zellweger Uster (measurement type, Normal mode; throttle used, AUTO; No twister) at a filament feeding speed of 800 m/min for 1 minute. The thus obtained value was used for the Uster irregularity (U %).
(4) Variation of Nozzle Surface Temperature
[0055] Temperature of 5 positions in total, namely, temperature at the center of the nozzle and temperature at arbitrary 4 points at a distance 5 mm from the outer periphery of the nozzle were measured by using a thermocouple. The difference between the maximum temperature and the minimum temperature was used for the variation of nozzle surface temperature.
(5) Variation of Stretching Tension
[0056] By using TTM-101 tensiometer manufactured by TORAY ENGINEERING Co., Ltd., the stretching tension was measured for 1 minute between the first and the second rollers at a position about 20 cm from the second roller, and the value was recorded at an interval of 0.1 second. Standard deviation and the average were calculated, and then, the variation of stretching tension was calculated by the following equation:
[0000] (Variation of stretching tension)=(standard deviation)/(average)×100
(6) Fineness
[0057] Fineness was calculated according to JIS L 1013 (2010) 8.3.1 A.
(7) Strength and Elongation
[0058] Strength and elongation were measured according to JIS L 1013 (2010) 8.5.1.
(8) Dimensional Change Rate by Hot Water Immersion
[0059] Dimensional change rate by hot water immersion was measured according to JIS L 1013 (2010) 8.18.1 A.
[0060] Next, our PPS monofilaments, methods and packages are described in detail by referring to Examples.
Example 1
[0061] The PPS polymer pellet used was E2280 (glass transition temperature; 93° C., quenching method) manufactured by Toray, and the content of the low molecular weight component of the pellet adjusted with a drier to the range of up to 0.1%. The pellets were subjected to melt spinning at a spinning temperature of 320° C. at a single nozzle ejection rate of 4.25 g/min. The polymer temperature at this stage was 313° C. The spinning machine used was a spinning machine for one-step method shown in FIG. 1 adapted for direct stretching. In the spinning, nozzle (1) having circular holes at 8 holes/nozzle was used. The diameter of the nozzle hole (D) was 0.40 mm, and the L/D was 6.0. The temperature of the nozzle surface was retained by heated vapor at 330° C. The variation of the nozzle surface temperature was 0.8° C. The polymer ejected from the nozzle was cooled by cooling gas stream (4) at 10° C. ejected from cooling gas stream blower (5) at a position 50 mm from the nozzle surface. After the oiling by oiling roller (7), the filament was taken up by first roller (8) heated to 100° C. at 625 m/min and continuously stretched between first roller (8) and second roller (9) heated to 200° C. to 4.00 folds. The variation of the stretching tension at this stage was 11.5%. The filament after the stretching was then wound by using a micro-cam traverse type winder (10) to obtain a drum-shaped fiber package (11), and woven by using a rapier loom.
[0062] The resulting PPS monofilament had yarn properties and evaluation results of the woven product as shown in Table 1.
[0063] The resulting PPS monofilament had the U % of 0.78% and the variation of the continuous heat shrinkage stress of 2.3%. The woven product was excellent with the aperture variation rate of 1.4%.
Example 2
[0064] PPS monofilament was produced by repeating the procedure of Example 1 except that the method used to retain the temperature of the nozzle surface was heating with air instead of heated vapor. The resulting PPS monofilament had yarn properties and evaluation results of the woven product as shown in Table 1.
[0065] A change in the method used to retain nozzle surface temperature to the heating by air resulted in a slight increase (1.3° C.) of the variation of the nozzle surface temperature. However, the variation of the stretching tension was 13.8%, the variation of the continuous heat shrinkage stress was 2.9%, and U % was 0.85%. The woven product was excellent with the aperture variation rate of 1.8%.
Example 3
[0066] PPS monofilament was produced by repeating the procedure of Example 2 except that the temperature of the cooling gas stream was 5° C. The resulting PPS monofilament had yarn properties and evaluation results of the woven product as shown in Table 1.
[0067] The change of the cooling gas stream temperature to 5° C. resulted in an improved cooling efficiency compared to Example 2 and the U % was 0.75%. However, the variation of the nozzle surface temperature increased to 2.2° C., and the variation of the stretching tension became 15.6%. As a result, the variation of the continuous heat shrinkage stress was 4.4%. However, the woven product was excellent with the aperture variation rate of 2.6%.
Example 4
[0068] PPS monofilament was produced by repeating the procedure of Example 2 except that the distance at the start of the cooling was 100 mm. The resulting PPS monofilament had yarn properties and evaluation results of the woven product as shown in Table 1.
[0069] The change of the distance at the start of the cooling to 100 mm resulted in the U % of 1.11%. However the variation of the nozzle surface temperature was stabilized to 1.0° C., and the variation of the stretching tension was at 12.5%, and the variation of the continuous heat shrinkage stress was 2.7%. The woven product was excellent with the aperture variation rate of 2.8%.
[0000]
TABLE 1
Example 1
Example 2
Example 3
Example 4
Spinning
Process
One-step
One-step
One-step
One-step
conditions
method
method
method
method
Package shape
Drum
Drum
Drum
Drum
Single nozzle ejection rate (g/min)
4.25
4.25
4.25
4.25
Spinning temperature (° C.)
320
320
320
320
Method of retaining nozzle surface
Heater under
Heater under
Heater under
Heater under
temperature
the nozzle
the nozzle
the nozzle
the nozzle
surface +
surface
surface
surface
Heated vapor
Temperature of heater under
330
330
330
330
the nozzle surface (° C.)
Distance at the start of the cooling (mm)
50
50
50
100
Temperature of cooling gas stream (° C.)
10
10
5
10
Spinning speed (m/min)
625
625
625
625
Stretch ratio (—)
4.00
4.00
4.00
4.00
Variation of nozzle surface
0.8
1.3
2.2
1.0
temperature (° C.)
Variation of stretching tension (%)
11.5
13.8
15.6
12.5
yarn
Variation of the continuous heat
2.3
2.9
4.4
2.7
properties
shrinkage stress (%)
U % (%)
0.78
0.85
0.75
1.11
Fineness (dtex)
17.0
17.1
17.0
16.9
Strength (cN/dtex)
4.21
4.16
4.41
3.99
Elongation (%)
25.4
24.8
23.8
26.5
Dimensional change rate by hot water
5.5
5.8
6.2
5.7
immersion (%)
Aperture variation rate (%)
1.4
1.8
2.6
2.8
Comparative Example 1
[0070] PPS monofilament was produced by repeating the procedure of Example 1 except that the nozzle surface was retained at a temperature of 290° C. The resulting PPS monofilament had yarn properties and evaluation results of the woven product as shown in Table 2.
[0071] By retaining the nozzle surface at a temperature of 290° C., the U % became 0.91%. However, the variation of the nozzle surface temperature increased to 3.4° C., and the variation of the stretching tension also increased to 18.9%. As a result, the variation of the continuous heat shrinkage stress increased to 5.3%. The woven product was unsatisfactory with the aperture variation rate of 3.9%.
Comparative Example 2
[0072] PPS monofilament was produced by repeating the procedure of Example 1 except that the distance at the start of the cooling was 15 mm. The resulting PPS monofilament had yarn properties and evaluation results of the woven product as shown in Table 2.
[0073] The change of the distance at the start of the cooling to 15 mm resulted in the U % of 0.84%. However, the variation of the nozzle surface temperature increased to 4.1° C., and the variation of the stretching tension also increased to 20.8%. As a result, the variation of the continuous heat shrinkage stress increased to 5.5%. The woven product was unsatisfactory with the aperture variation rate of 4.5%.
Comparative Example 3
[0074] PPS monofilament was produced by repeating the procedure of Example 1 except that the distance at the start of the cooling was 200 mm. The resulting PPS monofilament had yarn properties and evaluation results of the woven product as shown in Table 2.
[0075] The change of the distance at the start of the cooling to 200 mm stabilized the variation of the nozzle surface temperature to 0.7° C., and the variation of the stretching tension was 11.7%. As a result, the variation of the continuous heat shrinkage stress was 2.5%. However, an increase in the distance at the start of the cooling resulted in the U % of 1.41%. The woven product was unsatisfactory with the aperture variation rate of 3.2%.
Comparative Example 4
[0076] The PPS polymer pellet used was E2280 manufactured by Toray, and the content of the low boiling point component of the pellet adjusted with a drier to the range of up to 1.0%. The pellets were subjected to melt spinning at a spinning temperature of 320° C. at a single nozzle ejection rate of 4.25 g/min. In the spinning, a nozzle having circular holes at 8 holes/nozzle was used. The diameter of the nozzle hole (D) was 0.4 mm, and the L/D was 6. The temperature of the nozzle surface was retained by heated vapor at 330° C. The variation of the nozzle surface temperature was 0.9° C. The polymer ejected from the nozzle was cooled by cooling gas stream at 10° C. at a position 50 mm from the nozzle surface. After oiling, the filament was taken up by an unheated first roller rotating at a constant speed of 625 m/min to obtain the non-stretched filament.
[0077] This non-stretched filament was stretched in a stretcher between the first roller heated to 100° C. and the second roller heated to 200° C. to 4.00 folds. The variation of the stretching tension at this stage was 24.5%. The filament after the stretching was then wound in pirn-shape package and woven by using a rapier loom.
[0078] The resulting PPS monofilament had yarn properties and evaluation results of the woven product as shown in Table 2.
[0079] Use of the two-step method resulted in the U % of 0.86%. However, the variation of the stretching tension increased to 24.5%, and the variation of the continuous heat shrinkage stress also increased to 6.0%. The aperture variation rate also increased to 5.5%, and use of the pirn shape resulted in generation of irregularities in the form of streaks. Due to such quality loss, the woven product was unsatisfactory.
Comparative Example 5
[0080] PPS multifilament was produced by repeating the procedure of Example 1 except that 8 filaments were integrated into one filament after the cooling of the polymer, and conducting the oiling, the stretching and the winding after the integration. In this process, the variation of the nozzle surface temperature was 1.0° C. and the variation of the stretching tension was 12.0%, which were slightly higher than those of Example 1. The thus obtained PPS multifilament was divided in a separating machine. The filament after the separation was then wound in pirn-shape package, and woven by using a rapier loom.
[0081] The resulting PPS monofilament (separated filament) had yarn properties and evaluation results of the woven product as shown in Table 2.
[0082] A separating machine has many guides and similar members in the steps before the winding of the PPS monofilaments (separated filaments), and the filaments are easily damaged by the friction, and the variation of the continuous heat shrinkage stress of the separated filament was 6.1%. Also, the thermal setting was likely to be inconsistent between respective filaments since the thermal setting was conducted with the filaments entangled by the entanglement treatment in the step of producing the multifilament, and the U % of the separated filament was 1.53%. The aperture variation rate also increased to 6.5%, and use of the pirn shape resulted in generation of irregularities in the form of streaks. Due to such quality loss, the woven product was unsatisfactory.
[0000]
TABLE 2
Comparative
Comparative
Comparative
Comparative
Comparative
Example 1
Example 2
Example 3
Example 4
Example 5
Spinning conditions
Process
One-step
One-step
One-step
Two-step
One-step
method
method
method
method
method +
Separation
Package shape
Drum
Drum
Drum
Pirn
Pirn
Single nozzle ejection rate (g/min)
4.25
4.25
4.25
4.25
4.25
Spinning temperature (° C.)
320
320
320
320
320
Method of retaining nozzle surface temperature
Heater under
Heater under
Heater under
Heater under
Heater under
the nozzle
the nozzle
the nozzle
the nozzle
the nozzle
surface +
surface +
surface +
surface +
surface +
Heated vapor
Heated vapor
Heated vapor
Heated vapor
Heated vapor
Temperature of heater under the nozzle surface (° C.)
290
330
330
330
330
Distance at the start of the cooling (mm)
50
15
200
50
50
Temperature of cooling gas stream (° C.)
10
10
10
10
10
Spinning speed (m/min)
625
625
625
625
625
Stretch ratio (—)
4.00
4.00
4.00
4.00
4.00
Variation of nozzle surface temperature (° C.)
3.4
4.1
0.7
0.9
1.0
Variation of stretching tension (%)
18.9
20.8
11.7
24.5
12.0
Yarn properties
Variation of the continuous heat shrinkage stress (%)
5.3
5.5
2.5
6.0
6.1
U % (%)
0.91
0.84
1.41
0.86
1.53
Fineness (dtex)
16.8
17.0
17.1
17.3
17.0
Strength (cN/dtex)
4.10
4.30
4.09
4.62
3.98
Elongation (%)
23.8
22.7
26.8
24.4
14.6
Dimensional change rate by hot water immersion
5.4
6.3
5.0
6.7
7.2
(%)
Aperture variation rate (%)
3.9
4.5
3.2
5.5
6.5
[0083] As shown in Table 1 and Table 2, the PPS monofilaments obtained in the Examples exhibited low consistency of fineness (U %) and low variation of the continuous heat shrinkage stress, and these PPS monofilaments were capable of producing a woven product having a very low aperture variation rate, and hence a high precision filter. On the other hand, both the consistency of fineness (U %) and the variation of the continuous heat shrinkage stress could not be reduced in the PPS monofilaments obtained in the Comparative Examples, and these PPS monofilaments were incapable of producing a high precision filter.
INDUSTRIAL APPLICABILITY
[0084] The filters of extremely high precision produced by using the PPS monofilaments are suitable for use in the production sites in the fields including chemistry, electrics and electronics, automobiles, foods, precision machines, and pharmaceutical products and medicine.
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A polyphenylene sulfide monofilament is characterized by having a continuous heat-shrinking stress variation of at most 5% and a size uniformity (U %, Normal value) of at most 1.2%; and a drum-shaped fiber package includes the wound polyphenylene sulfide monofilament described. The polyphenylene sulfide monofilament has a very small aperture variation rate and is optimal for high-precision filters.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a floor-mounted (or pushdown) forging press of the kind having a static piston on the top beam of the press and a cylinder which slides on the piston for the forging stroke and acts as a toolholder, as well as a coaxial bore for supplying pressure medium to the moving cylinder, which bore extends through the top beam and the piston.
2. Description of the Prior Art
Multi-cylinder and single-cylinder forging presses are known wherein eccentric forces occur which may cause lateral movements or skewing of the toolholder, for example of the travelling, beam or cross-head of the press. In an arrangement comprising a stationary cylinder and a movable piston, for enabling these forces to be better absorbed, the piston forces are transmitted to the tool-holder through ball cups and a bearing shoe between them. The faces of the bearing shoe, machined to a barrelled shape, permit lateral movements as well as skewing of the travelling cross-head of the press. In this arrangement, at least two pistons are present in the forging press. In the classical example, a guide ram effects the central guiding of the travelling cross-head. This guide ram is known as a "Davy pin". The pistons move in stationary cylinders. The pressure medium is supplied at the cylinder side, so that the operative face of the piston can be closed off. (See Ernst Muller, "Hydralische Pressen und Druckflussigkeitsanlagen", Vol. 1: "Schmiedepressen", 3rd. edition, Springer-Verlag, Berlin/Gottingen/Heidelberg, 1962, pp 32-34 and 48-64, in particular page 59 and FIGS. 50 and 51 on page 63).
A disadvantage of the known arrangements is that with the use of ball cups and a bearing shoe for force-transmission, the press cylinder must always be designed to be stationary, so as to ensure supply of pressure medium.
Also known are single-cylinder presses wherein the cylinder executes the stroke movement, whereas the piston is stationary. The cylinder is also guided externally. The piston, firmly inserted in the top beam on the press, must of necessity participate in the guiding action if the machine is set in the ideal manner. From the design point of view, this means that the guides are excessively complicated, and in practice perfect operation can be achieved only if the outer guide of the cylinder is optimally adjusted. In practice, particularly in forging operations, it is very doubtful whether such optimal setting can be achieved with the existing means.
Brief Summary of the Invention
The object of the present invention is, therefore, to supply pressure medium to the cylinder chamber of a moving press cylinder while using ball cups and a bearing member therebetween, and secondly, to avoid the general disadvantages of over-complicated guides and to create conditions wherein, in all operational situations, including the occurrence of wear in the guides, the guide elements i.e. the main stuffing boxes and the glands between the cylinder and the piston are, to a considerable extent, relieved of load, and the wear in these zones is kept extremely light. In this connection, it should be mentioned that guide elements that are in direct contact with the operating medium are critical in that unavoidable abrasion persists in the medium and, despite the use of filters, this can cause damage to precision components such as pumps and control units.
This object is achieved in accordance with the invention, in that the piston is hollow and is articulatedly mounted by means of ball cups, fitted between the bottom of the static piston and the top beam of the press, and a bearing member between the ball cups, the piston being held in the vertical position on the top beam with the aid of a retaining means.
The moving cylinder can be used directly as a tool-holder, and it is guided externally in the press frame. Thus it is possible to dispense with a separate travelling cross-head.
In accordance with one embodiment of the invention, the retaining means for the piston is constituted by a pipe for supplying the pressure medium, which pipe is disposed centrally along the axis of the cylinder and is arranged in a bore in the top beam of the press and is sealed off. The pipe extends through the ball cups and the bearing member and through the bottom of the hollow piston which adjoins the lower ball cup, a further seal being provided between the pipe and the bottom of the piston and the pipe being secured, by a screwed connection for example, either in the top beam or in the bottom of the piston.
Thus it is possible to introduce pressure medium into the chamber of the moving cylinder in the presence of ball cups and a bearing member, through the pipe. In this arrangement, it is not necessary to forego the known advantages accruing from the use of ball cups and a bearing member. These advantages result in the avoidance of unilateral wear of the main stuffing box and gland and of the associated loss of fluid-tightness in the packing, and scoring of the face of the piston.
The centrally arranged pipe may be of such dimensions that skewing and lateral displacement of the piston, resulting from the mode of operation of the press, can be taken up by a deformable seal in the region of the bottom of the piston or near the beam of the press, the pipe being sufficiently rigid to enable lateral displacements of the piston to be taken up by the seal between the bottom of the piston and the pipe.
Alternatively the centrally arranged pipe is of such dimensions that skewing and lateral displacements of the piston, that result from the mode of operation of the press, can be taken up within the elastic range of the pipe. In other words, the wall thickness of the pipe is such that skewing or lateral displacements of the cylinder by way of the piston are taken up directly by the pipe. In this arrangement, the forces that can occur when adjusting the outer cylinder guides in the press frame cause no deformation, so that incorrect settings, relative to the middle of the press, cannot occur. Thus, it is ensured that the cylinder is always guided centrally.
In accordance with a further feature of the invention, the ball cup, located in the upper zone of the pipe centered in the beam, is centered by bearing against the inside of the beam, and the ball cup that bears against the bottom of the piston in the lower zone of the pipe is arranged to fit against the inner wall of the piston.
In this way the upper ball cup is held at the center of the press, whereas the lower ball cup can participate in the transverse movements to which the bottom of the piston is subjected.
In accordance with a still further feature of the invention, the centrally arranged pipe is provided with a shoulder which lies in a complementary recess in the piston, in the case in which the pipe is screwed into the beam, or in a recess in the beam, if the pipe is screwed into the bottom of the piston.
Normally, the piston is pressed firmly against the beam, by way of the ball cups and the bearing member, by the hydraulic pressure between the bottom of the piston and the cylinder. The provision of a shoulder at that end of the pipe remote from the screw-threaded portion results in the piston, together with the ball cups and the bearing member, being additionally secured.
Certain limits are set on the suspension of the hollow piston from the top beam by means of a pipe, which may be rigid or resilient and can therefore absorb the loads, due to eccentric forging forces, by way of a special seal or because of its own resilience. These limits are imposed, on the one hand, by the wall-thickness of the pipe, when elastic deformation occurs, and by the thus prescribed maximum diameter for the bore for supplying pressure medium to the moving cylinder, and on the other hand, by a certain limitation of the operating pressure of the pressure medium. For certain cases, particularly in larger presses, involving the supply of larger quantities of pressure medium to the cylinder per unit of time, and also when high and very high pressures are used, this type of piston suspension and the bore determined by the design, are inadequate.
Therefore, according to a further embodiment of the invention, pins, mounted on spherical surfaces, are provided as the retaining means for the piston, which pins, by way of a flange on the piston, resiliently hold the piston to the top beam and hold it in a freely movable but play-free manner against the ball cups arranged centrally in the piston, on the one hand, and in the top beam, on the other, the bearing member enclosed in the ball cups by way of partly spherical surfaces, also being so held. In this arrangement, the ball cups and the associated bearing member are provided with a bore which supplies the pressure medium, and the bore is sealed off from the exterior by two packing units arranged on the bearing member.
As a result of the freely movably mounted resilient suspension of the main piston by way of known elements, such as ball cups and interposed bearing member, the piston can readily follow changes in the setting of the moving cyclinder in the guides, e.g. skewing or lateral displacement, which changes are determined by the forging operation. The pressure medium can be easily supplied to the cylinder through the bore in the top beam, the ball cups, the bearing member and the bottom of the piston, since the diameter of the bore can be varied to suit requirements and is sealed off from the exterior by the packing units.
Preferably each of the packing units is arranged at the level of the radial center of the spherical face of the bearing member, and in each case a packing support ring is detachably connected to the bearing member. As a result of the packing unit at the level of the center of curvature, very little movement occurs at this point when the bearing member is deflected, i.e. the packing unit is deformed only slightly in this zone. The packing support ring participates in the movement of the bearing member and thus cannot apply any deformation effort to the packing unit.
The resilient biasing means between the pins and the top beam for resiliently suspending the piston preferably consist of spring-washer packs of "Belleville" spring type. These have a suitably steep spring-characteristic curve so as to provide advantageous resilient suspension of the piston on the top beam.
The part-spherical surfaces of the ball cups and of the bearing member preferably lie in the operating medium. As a result of the arrangement of the packing units on the exterior of the bearing member and against the inner surface of the piston, the contact surfaces between the ball cups and the bearing member lie in the operating medium, i.e. in the oil of the hydraulic system, and these surfaces are thus lubricated in an extremely efficient manner.
In the normal layout of the press, for example for an operating pressure of 315 bars and for a corresponding outside diameter of the piston to provide a given pressing force, the use of the piston arrangement in accordance with the invention results in ideal values as regards the division of the diameters, i.e. the bearing member can also be of sufficiently stable construction despite the presence of the bore in it. This also applies when the cylinder is to be filled beforehand under no pressure i.e. if, in this case, a relatively large bore of the duct through the ball cups the bearing member and the bottom of the piston has to be provided.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be explained in greater detail by way of example only with reference to the accompanying drawings, in which:
FIG. 1 is an elevational and partly cross-sectional view showing a free-form forging press with a closed frame and in cross-section a moving cylinder with an attached upper tool, and a pipe screwed to the press top beam for supplying pressure medium to the cylinder,
FIG. 2 is a view similar to FIG. 1, but the pipe for the supply of pressure medium screwed into the bottom of the press piston,
FIG. 3 is a view similar to FIG. 1, but showing the cylinder skewed and the pipe for the supply of pressure medium bent, owing to eccentric loading of the upper tool,
FIG. 4 is a view similar to FIG. 1, but showing a rigid pipe for the supply of pressure medium,
FIG. 5 is a vertical cross-sectional view showing a frame-type floor-mounted forging press with a moving cylinder and a freely movably braced main piston,
FIG. 6 is a view similar to FIG. 5, but on a larger scale and omitting the lower beam, showing the moving cylinder laterally offset relatively to the outer guides,
FIG. 7 is a view similar to FIG. 5, but on a larger scale and omitting the lower beam, showing the moving cylinder in a skewed position in the outer guides, and
FIG. 8 is a view similar to, but on a larger scale than FIGS. 6 and 7, showing a portion of the upper beam of the press, i.e. the upper parts of a bearing member and of a top ball cup.
DETAILED DESCRIPTION
FIG. 1 shows a floor-mounted push-down free-form forging press, with a press frame 1 consisting of an upper beam 2 and a lower beam 3 as well as of two connecting lateral and guide parts 4. A moving cylinder 6 slides in adjustable guides 5 in the press frame. At the bottom, the cylinder carries an upper press tool 7. A complementary lower tool 8 is secured to the lower beam 3.
In the FIG. 1 arrangement, a hollow piston 9 is guided in the cylinder 6 by way of a main bushing 10, a packing unit 11 and a stuffing box 12, arranged in said cylinder, the stuffing box 12 being secured to the endface of the cylinder 6 by means of a stuffing-box flange 13. Extending through the bottom 14 of the piston is a pipe 15 which passes through bores formed in a lower ball cup 16, a thrust bearing member 17 with spherically convex ends, and an upper ball cup 18, and into the upper beam 2. The pipe 15 is secured in the upper beam 2 by means of an external screw-thread 19. Through a further bore 20 in the upper beam 2, pressure medium can be passed, by way of the interior of the pipe 15, into the space between the bottom 14 of the piston and the cylinder 6. In operation the member 17 acts as a prop or strut transmitting forces from the piston to the top beam.
To prevent loss of pressure medium, a seal 21 is provided between the upper beam 2 and the pipe 15 and a further seal 22 is provided between the bottom 14 of the piston and the pipe 15.
To provide a better hold between the piston 9 and the ball cups 16 and 18 and the member 17 enclosed thereby the centrally arranged pipe 15 is provided with a shoulder 23, which engages in a recess 24 in the bottom 14 of the piston.
The upper ball cup 18 is centered on the lower face of the upper beam 2, whereas the lower ball cup 16, bearing against the bottom 14 of the piston, is fitted on the inner wall of the piston 9.
The pipe shown in FIG. 1 is designed as a "resilient" pipe 15, its wall-thickness being smaller, at least along the length of the member 17, than at the zones where it is fitted to the upper beam 2 and the bottom 14 of the piston. The convex ends of the member 17 have the same radius as the ball cups 16 and 18.
FIG. 2 shows a press basically the same as in FIG. 1, but in FIG. 2 the shoulder 23a of the pipe 15 lies in a recess 24a in the upper beam 2 and the pipe is secured in the bottom 14 of the piston by means of its external screw-thread 19a. Provided below the screw-thread 19a in the bottom 14 of the piston is a suitable seal 21a, and a further seal 22a is provided below the shoulder 23a in the upper beam 2. In this arrangement, pressure medium is again supplied from the upper beam 2 to the cylinder 6 by way of the interior of the pipe, the seals 21a and 22 preventing leakage losses.
As in FIG. 1, FIG. 2 shows, in broken lines, the position of the cylinder 6 and the upper tool 7 on the lower tool 8.
FIG. 3 shows a press as in FIG. 1, but in which an eccentric force F, resulting from the shaping operation, is shown as acting on the upper tool 7, and the effect of this force is that the moving cylinder 6, connected to the upper tool 7, bears heavily against the lower guide 5 at the right and against the upper guide 5 at the left. This moment, which results in skewing of the cylinder 6, is transmitted through the main bushing 10 to the stationary piston 9 and therefore to the pipe 15 which lies in the bottom 14 of the piston by way of the shoulder 23 engaging in the recess 24. The dimensions and particularly the wall-thickness of the pipe are such that it is able to take up this deformation in a resilient manner, and the pressing force can be transmitted to the upper beam 2 through the bottom 14 of the piston, the ball cups 16 and 18 and the member 17 enclosed between the cups. The supply of pressure medium by the pipe 15 which resiliently takes up the skewing and lateral movement of the cylinder 6 is not impeded. The moment applied by the pressing force has no disadvantageous effect upon the main bushing 10, the stuffing box 12 and the surface 9a of the piston.
FIG. 4 shows a similar arrangement to FIG. 1 with a pipe 15, screwed into the upper beam 2, and the seal 21. In the FIG. 4 arrangement however, the pipe 15 is rigid and has a correspondingly greater wall thickness. The seal 22 between the pipe 15 and the bottom 14 of the piston is formed as a resilient element which takes up the eccentric loads and skewing resulting from the working process, as well as lateral displacement of the cylinder, force being transmitted through the guide bushing 10 to the piston 9. The outer surface of the lower ball cup 16 fits against the inner wall of the piston 9, so that here again the pressing forces can be transmitted to the upper beam through the ball cup 16, the member 17 and the ball cup 18 when these elements are suitably set relatively to each other.
The further FIGS. 5 to 8 illustrate another arrangement of the movable piston on the upper beam of the forging press, which arrangement will now be described:
FIG. 5 shows a floor-mounted forging press 101 of the frame type and comprising an upper beam 102 and a lower beam 103 as well as side parts 104 which interconnect the beams and are designed as guides. A moving cylinder 105 is centrally guided on the side parts 104 in adjustable or fixed guides 106. An upper tool 107 is arranged directly at the bottom of the cylinder 105. A corresponding lower tool 108 is secured to the lower beam 103.
Retraction rods 109, which are connected through cross-bars 110 to retraction cylinder units 111 arranged on the upper beam 102, engage the cylinder 105. A main piston 112 slides in the moving cylinder 105; this piston is guided by way of a main bush 113, provided in the cylinder 105, and is sealed in the cylinder 105 by a packing unit 115 held between a stuffing box 114 and the main bush 113.
Located on the main piston 112 is an upper piston flange 116 which is provided with bores 117. Pins 118, to both ends of which a ball 119 is secured, pass through these bores 117. The main piston 112 is swivelly suspended by way of the lower balls 119. The piston is suspended by means of spring-washer packs 121, which are located in bores 120 in the upper beam 102 and which are retained by means of plates 122 secured on the upper beam 102. The main piston 112 is suspended by way of spherical surfaces from the spring-washer packs 121 with the aid of the pins 118 having the balls 119 at their ends. The main piston 112 is resiliently biased against the upper beam 102 by way of upper and lower ball cups 125, provided between a recess 123 in the upper beam and a further recess 124 in the main piston 112, a spherically-ended bearing member 126 being enclosed between the ball cups. The spring-washer packs 121 are so designed that they are able to carry and take up a multiple of the load resulting from the weight of the main piston 112, the ball cups 125 and the member 126 and the friction occurring in the guides. This results in the condition that the spring biased parts--the main piston 112, the upper and lower ball cups 125, with the member 126 enclosed between them, and the upper beam 102--lie one upon the other with no play between them. Thus, the known phenomenon whereby parts that lie loosely one upon the other are subjected to a rhythmic hammering effect under pressure is taken into account.
The member 126, which at both ends is mounted in the ball cups 125 by way of spherical surfaces, is provided at each of its two ends with a peripheral packing unit 127, which is retained by a packing support ring 128, which is arranged at the ends facing the spherical extremities of the member 126 (FIG. 6 to FIG. 8).
A bore 129 extends from the upper beam 102 to the moving cylinder 105 by way of the upper ball cup 125, the member 126, the lower ball cup 125 and the lower part of the main piston 112. This bore 129 serves to supply operating pressure medium. By arranging the packing unit 127 on the member 126 so that the cavities are sealed off from the exterior, the operating pressure medium can be supplied through the bore 129. The mating faces of the member 126 and the ball cups 125 are exposed to the pressure medium.
FIG. 6 illustrates, on a larger scale, the upper part of the floor-mounted forging press 101, the lower beam 103 and the lower tool 108 being omitted from the drawing. This figure shows in particular a leftward lateral displacement of the lower end of the cylinder 105 from the central position. Because of its resilient swivelling suspension, the main piston 112 matches this position of the cylinder 105 without any particularly great tilting occurring in the main bushing 113. Because of the presence of the bore 129 passes through the ball cup 125 and the member 126, and follows the lateral displacement of the main piston 112, supply of operating pressure medium is ensured in each case.
FIG. 7 shows on the same scale as FIG. 6 the same part of the floor-mounted forging press 101. In FIG. 7, however, the moving cylinder 105 is shown as being skewed as the result of eccentric forces. In the lower guide 106, the cylinder 105 has been pressed to the left away from the guide and in the upper guide 106 it has been pressed to the right (the deflection being exaggerated in the drawing). Here again, because of its resilient suspension and bracing relatively to the upper beam 102, the main piston 112 is able to occupy this skewed position without excessive stress on the main bushing 113 and the packing unit 115 and the stuffing box 114. Since the member 126 is also able to occupy the skewed position, the supply of operating pressure medium through the bore 129 to the cylinder 105 is always ensured.
FIG. 8 shows, on a still larger scale than that of FIGS. 6 and 7, parts of the upper beam 102, of the upper ball cup 125 and of the member 126. The packing unit 127 is disposed precisely level with the center point 130 of the radius of the part-spherical end of the member 126. The packing support ring 128, detachably secured on the member 126, secures the packing unit 127. As a result of this arrangement of the packing unit 127 at the level of the center of curvature 130 of the part-spherical end of the member 126, extremely small movement occurs in this zone upon deflection of the member 126, i.e. the packing unit 127 is only slightly deformed at this point.
To summarize, it should be noted that in all the cases illustrated in FIGS. 6 to 8, the main piston 112 follows the outer setting of the cylinder 105 while the member 126 occupies an angular position. Depending upon the setting, it dwells in this position or corrects its position during the stroke of the cylinder 105. In the event of a pitching movement of the cylinder 105, caused by play in the guides and eccentric forces, the member 126 likewise corrects its position. Because of the effective lever arms in conjunction with the unavoidable frictional locking in the ball cups 125, the forces occurring in guiding the main piston 112 remain within tolerable limits.
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A floor-mounted forging press has a static piston arranged on the top beam and a cylinder which slides on the piston and forms a toolholder, and a bore extending through the piston for supplying pressure medium to the cylinder. The piston is hollow and is swivelly mounted by means of ball cups at the lower end of the piston and on the top beam and a thrust bearing member between the ball cups, the piston being held in the vertical position on the top beam with the aid of retaining means. One form of retaining means is a partially resilient pressure medium pipe which holds the piston. Alternatively pins, mounted by means of spherical surfaces, suspend the piston by way of a flange on the piston and are resiliently biased to hold the piston against the top beam in a free-play, resilient and freely movable manner, a bore being provided through the ball cups and thrust bearing member.
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TECHNICAL FIELD
[0001] The disclosure relates to the field of exhaust fluid treatment and, in particular, to controlling operation of an exhaust fluid treatment apparatus having a diesel oxidation catalyst.
BACKGROUND
[0002] An exhaust fluid treatment apparatus may comprise a plurality of modules, wherein each module is intended to treat one or more constituents of an exhaust fluid. The modules may be arranged in series such that exhaust fluid flows through each module in sequence. In order to operate as intended, some modules may require the exhaust fluid to exceed a particular temperature.
[0003] An exhaust fluid treatment apparatus may comprise a diesel oxidation catalyst module and a selective catalytic reduction module, downstream of the diesel oxidation catalyst module. The selective catalytic reduction module may not operate as intended when the exhaust fluid is below a certain temperature. In order to increase the temperature of the exhaust fluid in the selective catalytic reduction module, it may be appropriate to use the diesel oxidation catalyst module to increase the temperature of the exhaust fluid passing through it in order to increase the temperature of exhaust fluid arriving at the selective catalytic reduction module. This may be achieved by introducing unburnt fuel upstream of the diesel oxidation catalyst for oxidation in the diesel oxidation catalyst thereby to increase the temperature of the exhaust fluid leaving the diesel oxidation catalyst module. However, it may be necessary to avoid injecting unburnt fuel into the diesel oxidation catalyst module if the temperature of the diesel oxidation catalyst module is too low to result in combustion of the fuel since otherwise the unburnt fuel may simply pass out of the diesel oxidation catalyst module and may thereby cause damage to subsequent features of the exhaust fluid treatment apparatus and/or pass directly to atmosphere.
[0004] Against this background there is provided a method of controlling operation of an exhaust fluid treatment apparatus.
SUMMARY OF THE DISCLOSURE
[0005] A method of controlling operation of an exhaust fluid treatment apparatus, wherein the apparatus comprises a diesel oxidation catalyst comprising an inlet and an outlet, the method may comprise:
[0006] receiving an input temperature data value being indicative of a temperature at the inlet;
[0007] receiving a flow rate data value being indicative of a rate of flow of fluid in the diesel oxidation catalyst;
[0008] receiving a threshold temperature data value indicative of a predicted temperature required for fuel in the diesel oxidation catalyst to oxidise;
[0009] receiving mode data indicative of whether the diesel oxidation catalyst is operating in a first mode or a second mode; and
[0010] sending, when the input temperature data value is greater than the threshold temperature data value, a fuel data value indicative of a quantity of fuel to be injected into the exhaust fluid upstream of the inlet for combustion in the diesel oxidation catalyst,
[0011] wherein the fuel data value is obtained from a data library which comprises a first set of fuel data values relating to the first mode and a second set of fuel data values relating to the second mode, each fuel data value of the first and second sets of fuel data values being associated with a particular combination of input temperature data value and flow rate data value.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows a schematic drawing of an embodiment of an exhaust fluid treatment apparatus to which the method may be applied;
[0013] FIG. 2 shows a more detailed schematic drawing of an embodiment of an exhaust fluid treatment apparatus to which the method may be applied;
[0014] FIG. 3 shows a schematic drawing of an external appearance of the embodiment of FIG. 2 ; and
[0015] FIG. 4 shows a flow chart which illustrates an embodiment of the method of the disclosure.
DETAILED DESCRIPTION
[0016] Before describing the specifics of an embodiment of the method of the disclosure, the following is an explanation of the features and broad operation of an exhaust fluid treatment apparatus to which the method of the disclosure might be applied.
[0017] Referring first to FIGS. 1 to 3 , there is illustrated an embodiment of an exhaust fluid treatment apparatus 1 . The apparatus 1 may comprise a fluid flow path through which fluid may flow sequentially through various conduits, such as a first conduit 10 , a first end coupling 15 , a second conduit 20 , a second end coupling 25 , and a third conduit 30 . The first, second and third conduits 10 , 20 , 30 may be substantially mutually parallel.
[0018] The fluid flow path comprises, in series, a diesel oxidation catalyst (DOC) module 110 , a diesel particulate filter (DPF) module 120 , a mixer module 130 , a selective catalytic reduction (SCR) module 140 and/or an ammonia oxidation catalyst (AMOX) module 150 .
[0019] In use, fluid may be supplied to the exhaust fluid treatment apparatus 1 via the inlet 4 . Fluid may pass into the DOC module 110 in the first portion of the first conduit 10 . Prior to receipt at the inlet 4 , the pressure of the exhaust fluid may be controlled by a back pressure valve (not shown).
[0020] The DOC module 110 may comprise one or more catalysts, such as palladium or platinum. These materials serve as catalysts to cause oxidation of hydrocarbons ([HC]) and carbon monoxide (CO) present in the fluid flow in order to produce carbon dioxide (CO 2 ) and water (H 2 O). The DOC may also serve to convert NO to NO 2 so as to achieve a NO:NO 2 ratio of 1:1. The catalysts may be distributed in a manner so as to maximise the surface area of catalyst material in order to increase effectiveness of the catalyst in catalysing reactions.
[0021] Fluid may flow from the DOC module 110 to the DPF module 120 which comprises features which are intended to restrictonward passage of carbon (C) in the form of soot. Carbon particles in the fluid may thus be trapped in the filter. The DPF module 120 may be regenerated through known regeneration techniques. These techniques may involve controlling one or more of the temperature of the fluid, the pressure of the fluid and the proportion of unburnt fuel in the fluid at this point in the apparatus.
[0022] Exhaust fluid may pass from the DPF module 120 into the first end coupling 15 where it flows past the injector module 16 . The injector module 16 may be associated with or attachable to a pump electronic tank unit (PETU). The pump electronic tank unit may comprise a tank for providing a reservoir for emissions fluid to be injected by the injector. Such emissions fluids may include urea or ammonia.
[0023] The PETU may further comprise a controller configured to control a volume of emissions fluid to be injected from the tank by the injector. The controller may have as inputs, for example, temperature information and quantity of NO x information which may be derived from sensors in the SCR module 140 .
[0024] Emissions fluid may pass from the injector module 16 into the mixer module (not shown) located in the second conduit 20 . The mixer module may comprise features for ensuring that the exhaust fluid originating from the first conduit 10 is well mixed with the emissions fluid originating from the injector 16 , to create a mixed fluid.
[0025] The mixed fluid from the second conduit 20 may pass into the SCR module located in the first portion of the third conduit via the second end coupling 25 . The SCR module 140 may comprise one or more catalysts through which the mixed fluid may flow. As the mixed fluid passes over the surfaces of the catalyst a reaction may occur which converts the ammonia and NO x to diatomic nitrogen (N 2 ) and water (H 2 O).
[0026] Fluid may pass from the SCR module 140 to the AMOX module 150 located in the second portion of the third conduit 30 . The AMOX module 150 may comprise an oxidation catalyst which may cause residual ammonia present in the fluid exiting the SCR module to react to produce nitrogen (N 2 ) and water (H 2 O).
[0027] Fluid may pass from the AMOX module 150 to the exhaust fluid treatment apparatus outlet located at the second end 32 of the third conduit 30 .
[0028] As shown in FIG. 2 , the exhaust fluid treatment apparatus 1 may comprise sensors for detecting characteristics of the fluids at particular stages in their flow through the exhaust fluid treatment apparatus 1 . There may be a first temperature sensor (not shown) upstream of the DOC 110 , a second temperature sensor 190 between the DOC 110 and the DPF 120 and/or a third temperature sensor 191 between the mixer module 130 and the SCR 140 . There may be a first NO x sensor 192 between the DPF module 120 and the injector 16 and there may be a second NO x sensor 193 downstream of the AMOX module 150 . There may also be a first soot sensor 194 immediately upstream of the DPF 120 and possibly a second soot sensor 195 immediately downstream of the DPF 120 .
[0029] Having described the features and broad operation of the exhaust fluid treatment apparatus, the method of the present disclosure will now be described.
[0030] Referring to FIG. 4 , there is illustrated a flow chart 200 showing an embodiment of the method of the disclosure.
[0031] The method may involve receiving data relating to three parameters. A first data value 210 may be indicative of a temperature of gas flowing into the DOC module 110 . A second data value 220 may be indicative of a threshold temperature at which fuel is likely to combust in the DOC module 110 . A third data value 230 may be indicative of a rate of flow of fluid in the DOC module 110 .
[0032] In use, exhaust fluid from an engine may be received into an inlet of the exhaust fluid treatment apparatus for onward travel to the DOC 110 . The exhaust fluid has a temperature at the point where it is received into the DOC 110 . The temperature of the gas at the point where it is received into the DOC 110 may not be directly measurable due to location of temperature sensors. That is, there may not be a temperature sensor immediately prior to the inlet of the DOC 110 . The method may therefore involve receiving temperature information at a point upstream of the DOC 110 and accounting, perhaps by predictive models or similar, for likely changes in temperature between the upstream point and the inlet to the DOC 110 . Whether directly measured or not, the first data value 210 is indicative of a temperature of gas flowing into the DOC module 110 .
[0033] The second data value 220 may be indicative of a threshold temperature at which fuel is likely to combust in the DOC 110 . This may or may not be dependent on operating conditions.
[0034] The third data value 230 may be indicative of the rate of flow of fluid in the DOC module 110 . More specifically, this may be indicative of the mass flow (kg/h) of fluid through the DOC or may be indicative of space velocity (s −1 ) of fluid in the DOC. The third data value 230 might be predicted based on measurements of fluid flow taken upstream or downstream of the DOC module, depending on location of appropriate sensors.
[0035] For example, the flow rate data value indicative of the rate of flow of fluid in the DOC might be obtained by a mass fluid flow sensor located in the fluid flow path adjacent (i.e. upstream or downstream of) the DOC. However, continuous likely variation in fluid temperature and a range of constituent products in the exhaust fluid may result in such sensors becoming damaged and/or unreliable.
[0036] Alternatively, the flow rate data value indicative of the rate of flow of fluid in the DOC might be obtained using a model in combination with a mass fluid flow sensor located at a gas (air) intake of the engine to which the DOC is attached. The model may take into account the flow of gas (air) into the engine, the volume of fuel injected into the engine, any potential exhaust gas recirculation and any other relevant parameters in order to estimate the rate of flow of fluid in the DOC.
[0037] Instead of or in addition to one or more mass fluid flow sensors, there may be provided a combination of temperature and pressure sensors from which rate of flow of fluid can be calculated, either in real time or by reference to a model, look-up table or similar. For example, by measuring temperature and pressure of gas (air) intake and of exhaust gas adjacent or within the DOC, mass fluid flow through the DOC may be estimated. Such an estimate may involve a model, look-up table or similar.
[0038] A mass flow value (kg/h) may be used, in combination with parameters relating to geometry of the DOC and other features of the apparatus, to estimate space velocity (s −1 ) of fluid in the DOC.
[0039] An engine control unit may collect some or all of these data for the present purpose and/or for other purposes. Models and/or look up table for the present purpose and/or for other purposes may be present in the engine control unit.
[0040] The method may comprise assessing 240 whether the first data value 210 is greater than the second data value 220 . In the event that the first data value 210 (indicative of the temperature of fluid flowing into the DOC 110 ) is lower than the second data value 220 (indicative of the minimum temperature for ignition of fuel in the DOC 110 ), the method may involve no injection of unburnt fuel to be received into the DOC since this may result in the unburnt fuel passing through the DOC 110 without oxidising. Rather, the method may loop back to the start 205 , perhaps with a delay before receiving new sets of data 210 , 220 , 230 . In the event that the first data value 210 is higher than the second data value 220 this may result in obtaining mode data 250 in order to determine an appropriate quantity of unburnt fuel to be released upstream of the DOC 110 for burning in the DOC.
[0041] In the event that the first data value 210 is higher than the second data value 220 , the method may involve making a check 260 , 265 of whether the conditions are indicative of a first mode or a second mode. As shown in the specific embodiment of FIG. 4 , the first mode may be a warm-up mode and the second mode may be a running mode. While FIG. 4 may imply that the checks are carried out sequentially (beginning with checking for warm-up mode and, if negative, checking for running mode), the sequence may be reversed or the checks may be carried out concurrently.
[0042] If neither the first nor the second mode is applicable, higher level control functions 280 may be used to determine next steps for control of the exhaust fluid treatment apparatus 1 .
[0043] If the first mode is applicable, the method may comprise consulting a data library for first mode fuel data associated with the input value obtained at step 210 and the input value obtained at step 230 .
[0044] If the second mode is applicable, the method may comprise consulting a data library for second mode fuel data associated with the input value obtained at step 210 and the input value obtained at step 230 .
[0045] The fuel data value 270 , 275 may be indicative of a quantity of fuel, or a rate of flow of fuel, to be injected into the fluid upstream of the inlet to the DOC 110 . The fuel may be injected immediately prior to the inlet to the DOC 110 . Alternatively, the fuel may be injected into one or more cylinders of the engine (in addition to fuel injected into one or more cylinders for combustion in those one or more cylinders, but at a different point in a stroke of the engine) such that the additionally injected fuel is intended not to combust in the engine cylinders but to pass through to the exhaust fluid treatment apparatus 1 for oxidation in the DOC 110 . For example, the injection of the fuel to be injected into the cylinder may occur when an exhaust valve of the cylinder is open.
[0046] The first mode fuel data value 270 may be different from the second mode fuel data value 275 since the appropriate amount of fuel to be injected may be different depending on the operating conditions of the engine. The values may be considerably different when the DOC is warming-up compared with when the DOC is running having already warmed-up.
[0047] In the FIG. 4 example, the first mode fuel data values may be used when the DOC is warming-up and the second mode fuel data values may be used when the DOC has already warmed-up and is in a normal running mode. An exhaust gas temperature may be lower during DOC warm-up than during normal running mode. Consequently, during warm-up there may be an increased risk that fuel intended for combustion in the DOC may not combust in the DOC due to the temperature being too low. Consequently, unburnt fuel may pass out of the exhaust fluid treatment apparatus altogether, which may be inefficient and undesirable for regulatory reasons. Therefore, the amount of unburnt fuel to be passed into the DOC for combustion therein may need to be limited to a lower quantity when the DOC is warming-up than when the DOC is already warmed-up. Limitation of the amount of fuel may be achieved in the warm-up mode by consulting an entirely independent data library than that used in the normal running mode. Alternatively, the limitation required in the warm-up mode may be achieved by obtaining corresponding data relating to the normal running mode but placing a limit on that data. The limit may be an absolute limit on the quantity of unburnt fuel to be injected for combustion in the DOC. Alternatively, the limit may act to restrict the rate of increase of injection of unburnt fuel for combustion in the DOC.
[0048] While the term data library is used in this disclosure, the data may be stored in any suitable facility for the storage of data such as a look up table. Alternatively, or in addition, there may be some element of calculation of the fuel data values, such as, for example, where the second mode fuel data values are obtained from the first mode fuel data values by a calculation according to some functional relationship. Such a relationship may be intended to limit the rate of increase of flow of fuel during DOC warm-up. In other words, in this example, the calculation may simply serve to limit the rate of injection of fuel until such time as the temperature of the fluid in the DOC is sufficient to ensure that the fuel will burn in the DOC rather than pass through the DOC without combusting. In a further example, calculation of first or second mode fuel data values may be appropriate where an actual measured input value is part way between two input values for which fuel data values are provided in the data library. In this case, the method might involve interpolation or some other form of calculation to determine the appropriate fuel data value.
[0049] There may be a variety of reasons why and circumstances in which it may be desirable to inject into engine cylinders fuel which is intended to pass through the cylinders unburnt. One example may be a desire to achieve desulphation of an SCR module located downstream of the DOC as part of a SCR desulphation procedure. Such a desulphation procedure may require an increased temperature in the SCR in order that sulphur combusts. The increased temperature in the SCR may be achieved by injecting unburnt fuel into the DOC (upstream of the SCR) for burning in the DOC and thereby increasing a temperature of the fluid arriving at the SCR. Such a procedure may take place intermittently and might occur only when a need for such a procedure has been identified as part of overall engine control. The method of the present invention may be used as part of this procedure.
[0050] While this disclosure does not recite one or more specific fuel data values for use with specific combinations of input value (i.e. data library values), nevertheless, the specific fuel data values may be intended (a) to minimise any delay before which fluid in the SCR 140 rises to a temperature above which the SCR 140 operates as intended by burning fuel in the DOC 110 upstream of the SCR 140 and (b) to minimise the possibility of unburnt fuel travelling through the DOC 110 without oxidising since this may result in reduction in efficiency of the DPF 120 or the SCR 140 and/or may result in unburnt fuel being released to atmosphere. Put another way, the quantity of additional fuel introduced upstream of the DOC 110 (the quantity being determined by the fuel data value) may be sufficient to result in the desired temperature increase in the DOC 110 but not so high as to result in unburnt fuel slipping through the DOC 110 . The quantity of fuel may be different depending on whether the DOC is operating in the warm-up mode or the running mode.
[0051] The method of the disclosure may not eliminate altogether the possibility of unburnt fuel passing through the DOC. There may be circumstances in which fuel volumes are selected such as to maintain below an acceptable threshold the volume of fuel likely to pass through the DOC unburnt.
[0052] The method may be applied periodically, perhaps as part of an in-use procedure or as part of a dedicated service procedure, in order to increase the temperature of exhaust fluid in the exhaust fluid treatment apparatus. The fuel may be burnt either with the intention of increasing the temperature of exhaust fluid leaving one module of the exhaust fluid treatment apparatus such that the temperature of exhaust fluid entering a subsequent module of the exhaust fluid treatment apparatus. Alternatively, it may be burnt with the intention of combusting particles which may have become trapped on filtering elements of the module in which the fuel is burnt.
[0053] There may be a variety of reasons why and circumstances in which it may be desirable to inject into engine cylinders fuel which is intended to pass through the cylinders unburnt. One example may be a desire to achieve desulphation of an SCR module located downstream of the DOC as part of a SCR desulphation procedure. Such a desulphation procedure may require an increased temperature in the SCR in order that sulphur combusts. The increased temperature in the SCR may be achieved by injecting unburnt fuel into the DOC (upstream of the SCR) for burning in the DOC and thereby increasing a temperature of the fluid arriving at the SCR. Such a procedure may take place intermittently and might occur only when a need for such a procedure has been identified as part of overall engine control. The method of the present invention may be used as part of this procedure.
[0054] The terms exhaust gas and exhaust fluid may be used interchangeably. The exhaust gas/fluid may include solid particles such as particles of soot which, while in the solid phase, may be understood to be a constituent of exhaust gas/fluid.
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An exhaust flow treatment apparatus to treat exhaust flow emitted by a combustion engine is configured to receive unburnt fuel for combustion therein after confirming that conditions are such that the unburnt fuel is likely to combust in the apparatus. A method of controlling operation of an exhaust flow treatment apparatus includes confirming that the temperature of fluid in the apparatus exceeds a threshold temperature before allowing unburnt fuel into the apparatus. The method may confirm a particular mode of operation of the exhaust flow treatment apparatus to determine the appropriate quantity of fuel for burning in the apparatus.
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STATEMENT OF GOVERNMENT RIGHTS
The United States government has rights in this invention pursuant to contract No. DE-AC05-840R21400 between the United States Department of Energy and Lockheed Martin Energy Research Corporation, Inc.
FIELD OF THE INVENTION
The invention relates generally to two-phase titanium aluminide alloy compositions useful for resistive heating and other applications such as structural applications.
BACKGROUND OF THE INVENTION
Titanium aluminide alloys are the subject of numerous patents and publications including U.S. Pat. Nos. 4,842,819; 4,917,858; 5,232,661; 5,348,702; 5,350,466; 5,370,839; 5,429,796; 5,503,794; 5,634,992; and 5,746,846, Japanese Patent Publication Nos. 63-171862; 1-259139; and 142539; European Patent Publication No. 365174 and articles by V. R. Ryabov et al entitled “Properties of the Intermetallic Compounds of the System Iron-Alminum” published in Metal Metalloved, 27, No.4, 668673, 1969; S. M. Barinov et al entitled “Deformation and Failure in Titanium Aluminide” published in Izvestiya Akademii Nauk SSSR Metally, No. 3, 164-168, 1984; W. Wunderlich et al entitled “Enhanced Plasticity by Deformation Twinning of Ti-Al-Base Alloys with Cr and S” published in Z. Metallkunde, 802-808, 11/1990; T. Tsujimoto entitled “Research, Development, and Prospects of TiAl Intermetallic Compound Alloys” published in Titanium and Zirconium, Vol. 33, No. 3, 19 pages, 7/1985; N. Maeda entitled “High Temperature Plasticity of Intermetallic Compound TiAl” presented at Material of 53 rd Meeting of Superplasticity, 13 pages, 1/30/1990; N. Maeda et al entitled “Improvement in Ductility of Intermetallic Compound through Grain Super-refinement” presented at Autumn Symposium of the Japan Institute of Metals, 14 pages, 1989; S. Noda et al entiitled “Mechanical Properties of TiAl Intermetallic Compound” presented at Autumn Symposium of the Japan Institute of Metals, 3 pages, 1988; H. A. Lipsitt entitled “Titanium Aluminides—An Overview” published in Mat. Res. Soc. Symp. Proc. Vol. 39, 351-364, 1985; P. L. Martin et al entitled “The Effects of Alloying on the Microstructure and Properties of Ti 3 Al and TiAl” published by ASM in Titanium 80, Vol. 2, 1245-1254, 1980; S. H. Whang et al entitled “Effect of Rapid Solidification in L 1 0 TiAl Compound Alloys” ASM Symposium Proceedings on Enhanced Properties in Structural Metals Via Rapid Solidification, Materials Week, 7 pages, 1986; and D. Vujic et al entitled “Effect of Rapid Solidification and Alloying Addition on Lattice Distortion and Atomic Ordering in L 1 0 TiAl Alloys and Their Ternary Alloys” published in Metallurgical Transactions A, Vol. 19A, 2445-2455, 10/1988.
Methods by which TiAl aluminides can be processed to achieve desirable properties are disclosed in numerous patents and publications such as those mentioned above. In addition, U.S. Pat. No. 5,489,411 discloses a powder metallurgical technique for preparing titanium aluminide foil by plasma spraying a coilable strip, heat treating the strip to relieve residual stresses, placing the rough sides of two such strips together and squeezing the strips together between pressure bonding rolls, followed by solution annealing, cold rolling and intermediate anneals. U.S. Pat. No. 4,917,858 discloses a powder metallurgical technique for making titanium aluminide foil using elemental titanium, aluminum and other alloying elements. U.S. Pat. No. 5,634,992 discloses a method of processing a gamma titanium aluminide by consolidating a casting and heat treating the consolidated casting above the eutectoid to form gamma grains plus lamellar colonies of alpha and gamma phase, heat treating below the eutectoid to grow gamma grains within the colony structure and heat treating below the alpha tansus to reform any remaining colony structure a structure having % laths within gamma grains.
Still, in view of the extensive efforts to improve properties of titanium aluminides, there is a need for improved alloy compositions and economical processing routes.
According to a first embodiment, the invention provides a two-phase titanium aluminum alloy having a lamellar microstructure controlled by colony size. The alloy can be provided in various forms such as in the as-cast, hot extruded, cold and hot worked, or heat treated condition. As an end product, the alloy can be fabricated into an electrical resistance heating element having a resistivity of 60 to 200 μΩ-cm. The alloy can include additional elements which provide fine particles such as second-phase or boride particles at colony boundaries. The alloy can include grain-boundary equiaxed structures. The additional alloying elements can include, for example, up to 10 at % W, Nb and/or Mo. The alloy can be processed into a thin sheet having a yield strength of more than 80 ksi (560 MPa), an ultimate tensile strength of more than 90 ksi (630 MPa), and/or tensile elongation of at least 1.5%. The aluminum can be present in an amount of 40 to 50 at %, preferably about 46 at %. The titanium can be present in the amount of at least 45 at %, preferably at least 50 at %. As an example, the alloy can include 45 to 55 at % Ti, 40 to 50 at % Al, 1 to 5 at % Nb, 0.5 to 2 at % W, and 0.1 to 0.3 at % B. The alloy is preferably free of Cr, V, Mn and/or Ni.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 a-d are optical micrographs at 200× of PMTA TiAl alloys hot extruded at 1400° C. and annealed for 2 hours at 1000° C. FIG. 1 a shows the microstructure of PMTA-1, FIG. 1 b shows the microstructure of PMTA-2, FIG. 1 c shows the microstructure of PMTA-3 and FIG. 1 d shows the microstructure of PMTA4;
FIGS. 2 a-d show optical micrographs at 500× of PMTA alloys hot extruded at 1400° C. and annealed for 2 hours at 1000° C. FIG. 2 a shows the microstructure of PMTA-1, FIG. 2 b shows the microstructure of PMAT-2, FIG. 2 c shows the microstructure of PMAT-3 and FIG. 2 d shows the microstructure of PMTA4;
FIG. 3 shows ghost-pattern bands observed in a back-scattered image of PMTA-2 hot extruded at 1400° C. and annealed for 2 hours at 1000° C. wherein the non-uniform distribution of W is shown;
FIG. 4 shows a back-scattered image of PMTA-2 hot extruded at 1400° C. and annealed for 2 hours at 1000° C.;
FIG. 5 a is a micrograph at 200× of PMTA-3 hot extruded at 1400° C and annealed for one day at 1000° C. and FIG. 5 b shows the same microstructure at 500 ×;
FIG. 6 a shows the microstructure at 200× of PMTA-2 hot extruded at 1400° C. and annealed for 3 days at 1000° C. and FIG. 6 b shows the same microstructure at 500 ×;
FIG. 7 a is an optical micrograph of TiAl sheet (Ti45Al-5Cr, at %) in the as-received condition and FIG. 7 b shows the same microstructure after annealing for 3 days at 1000° C., both micrographs at 500 ×;
FIG. 8 a shows a micrograph of PMTA-6 and FIG. 8 b shows a micrograph of PMTA-7, both of which were hot extruded at 1380° C. (magnification 200 ×);
FIG. 9 a is a micrograph of PMTAL and FIG. 9 b is a micrograph of PMTA-7, both of which were hot extruded at 1365° C. (magnification 200 ×);
FIG. 10 is micrograph showing abnormal grain growth in PMTA hot extruded at 1380° C.;
FIGS. 11 a-d are micrographs of PMTA-8 heat treated at different conditions after hot extrusion at 1335° C., the heat treatments being two hours at 1000° C. for FIG. 11 a, 30 minutes at 1340° C. for FIG. 11 b, 30 minutes at 1320° C. for FIG. 11 c, and 30 minutes at 1315° C. for FIG. 11 d (magnification 200 ×);
FIG. 12 is a graph of resistivity in microhms versus temperature for samples 1 and 2 cut from an ingot having a PMTA4 nominal composition;
FIG. 13 is a graph of hemispherical total emissivity versus temperature for samples 1 and 2;
FIG. 14 is a graph of diffusivity versus temperature for samples 80259-1, 80259-2 and 80259-3 cut from the same ingot as samples 1 and 2;
FIG. 15 is a graph of specific heat versus temperature for titanium aluminide in accordance with the invention; and
FIG. 16 is a graph of thermal expansion versus temperature for samples 80259-1H, 80259-1C, 80259-2H, 80259-3H, and 80259-3C cut from the same ingot as samples 1 and 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention provides two-phase TiAl alloys with thermo-physical and mechanical properties useful for various applications such as resistance heater elements. The alloys exhibit useful mechanical properties and corrosion resistance at elevated temperatures up to 1000° C. and above. The TiAl alloys have extremely low material density (about 4.0 g/cm 3 ), a desirable combination of tensile ductility and strength at room and elevated temperatures, high electrical resistance, and/or can be fabricated into sheet material with thickness <10 mil. One use of such sheet material is for resistive heating elements of devices such as cigarette lighters. For instance, the sheet can be formed into a tubular heating element having a series of heating strips which are individually powered for lighting portions of a cigarette in an electrical smoking device of the type disclosed in U.S. Pat. Nos. 5,591,368 and 5,530,225, the disclosures of which are hereby incorporated by reference. In addition, the alloys can be free of elements such as Cr, V, Mn and/or Ni.
Compared to TiAl alloys containing 1 to 4 at % Cr, V, and/or Mn for improving tensile ductility at ambient temperatures, according to the present invention, tensile ductility of dual-phase TiAI alloys with lamellar structures can be mainly controlled by colony size, rather than such alloying elements. The invention thus provides high strength TiAl alloys which can be free of Cr, V, Mn and/or Ni.
Table 1 lists nominal compositions of alloys investigated wherein the base alloy contains 46.5 at % Al, balance Ti. Small amounts of alloying additions were added for investigating effects on mechanical and metallurgical properties of the twophase TiAl alloys. Nb in amounts up to 4% was examined for possible effects on oxidation resistance, W in amounts of up to 1.0% was examined for effects on microstructural stability and creep resistance, and Mo in amounts of up to 0.5% was examined for effects on hot fabrication. Boron in amounts up to 0.18% was added for refinement of lamellar structures in the dual-phase TiAl alloys.
Eight alloys identified as PMTA-1 to 9, having the compositions listed in Table 1, were prepared by arc melting and drop casting into a 1″ diameter×5″ long copper mold, using commercially-pure metals. All the alloys were successfully cast without casting defects. Seven alloy ingots (PMTA -1 to 4 and 6 to 9) were then canned in Mo cans and hot extruded at 1335 to 1400° C. with an extrusion ratio of 5:1 to 6:1. The extrusion conditions are listed in Table 2. The cooling rate after extrusion was controlled by air cooling and quenching the extruded rods in water for a short time. The alloy rods extruded at 1365 to 1400° C. showed an irregular shape whereas PMTA-8 hotextruded at 1335° C. exhibited much smoother surfaces without surface irregularities. However, no cracks were observed in any of the hot-extruded alloy rods.
The microstructures of the alloys were examined in the as-cast and heat treated conditions (listed in Table 2) by optical metallography and electron superprobe analyses. In the as-cast condition, all the alloys showed lamellar structure with some degree of segregation and coring. FIGS. 1 and 2 show the optical micrographs, with a magnification of 200 × and 500 ×, respectively, for hot extruded alloys PMTA-1 to 4 stress-relieved for 2 hours at 1000° C. All the alloys showed fully lamellar structures, with a small amount of equiaxed grain structures at colony boundaries. Some fine particles were observed at colony boundaries, which are identified as borides by electron microprobe analyses. Also, there is no apparent difference in microstructural features among these four PMTA alloys.
Electron microprobe analyses reveal that tungsten is not uniformly distributed even in the hot extruded alloys. As shown in FIG. 3, the ghost-pattern bands in a darker contrast are found to be depleted with about 0.33 at % W. FIG. 4 is a back-scattered image of PMTA-2, showing the formation of second-phase particles (borides) in a bright contrast at colony boundaries. The composition of the borides was determined and listed in Table 3 together with that of the lamellar matrix. The second-phase particles are essentially (Ti,W,Nb) borides, which are decorated and pinned lamellar colony boundaries.
FIGS. 5 and 6 show the optical microstructures of hot extruded PMTA-3 and 2 annealed for 1 day and 3 days at 1000° C., respectively. Grain-boundary equiaxed structures are clearly observed in these long-term annealed specimens, and the amount increases with the annealing time at 1000° C. A significant amount of equiaxed grain structures exists in the specimen annealed for 3 days at 1000° C.
For comparison purposes, a 9-mil thick TiAl sheet (Ti45Al-5Cr, at %) was evaluated. FIG. 7 shows the optical microstructures of the TiAlCr sheet in both as-received and annealed (3 days at 1000° C.) conditions. In contrast to the dual-phase lamellar structure of the alloys according to the invention, the TiAlCr sheet has a duplex structure, and its grain structure shows no significant coarsening at 1000° C.
Tensile sheet specimens with a thickness of 9-20 mils and a gage length of 0.5 in were sectioned from the hot extruded alloys rods after annealing for 2 hours at 1000° C., using a EDM machine. Some of the specimens were re-annealed up to 3 days at 1000° C. prior to tensile testing. Tensile tests were performed on an Instron testing machine at a strain rate of 0.1 inch/second at room temperature. Table 4 summarizes the tensile test results.
All the alloys stress-relieved for 2 hours at 1000° C. exhibited 1% or more tensile elongation at room temperature in air. The tensile elongation was not affected when the specimen thickness varied from 9 to 20 mils. As indicated in Table 4, among the 4 alloys, alloy PMTAA appears to have the best tensile ductility. It should be noted that a tensile elongation of 1.6% obtained from a 20-mil thick sheet specimen is equivalent to 4% elongation obtained from rod specimens with a gage diameter of 0.12 in. The tensile elongation appears to increase somewhat with annealing time at 1000° C., and the maximum ductility is obtained in the specimen annealed for 1 day at 1000° C.
All the alloys are exceptionally strong, with a yield strength of more than 100 ksi (700 MPa) and ultimate tensile strength more than 115 ksi (800 MPa) at room temperature. The high strength is due to the refined fully lamellar structures produced in these TiAl alloys. In comparison, the TiAlCr sheet material has a yield strength of only 61 ksi (420 MPa) at room temperature. Thus, the PMTA alloys are stronger that the TiAlCr sheet by as much as 67%. The PMTA alloys including 0.5% Mo exhibited significantly increased strengths, but slightly lower tensile elongation at room temperature.
FIGS. 8 a-b and 9 a-b show the optical micrographs of PMTA6 and 7 hot extruded at 1380° C. and 1365° C., respectively. Both alloys showed lamellar grain structures with little intercolony structures. Large colony grains (see FIG. 10) were observed in both alloys hot extruded at 1380° C. and 1365° C., which probably resulted from abnormal grain growth in the alloys containing low levels of boron after hot extrusion. There is no significant difference in microstructural features in these two PMTA alloys.
FIGS. 11 a-d show the effect of heat treatment on microstructures of PMTA-8 hot extruded at 1335° C. The alloy extruded at 1335° C. showed much fewer colony size and much more intercolony structures, as compared with those hot extruded at 1380° C. and 1365° C. Heat treatment for 2 h at 1000° C. did not produce any significant change in the as-extruded structure (FIG. 11 a ). However, heat treatment for 30 mins at 1340° C. resulted in a substantially larger colony structure (FIG. 11 b ). Lowering the heat-treatment temperature from 1340° C. to 1320-1315° C. (a difference by 20-25° C.) produced a sharp decrease in colony size, as indicated by FIGS. 11 c and 11 d. The annealing at 1320-1315° C. also appears to produce more intercolony structures in PMTA-8. The abnormal grain growth is almost completely eliminated by hot extrusion at 1335° C.
Tensile sheet specimens of PMTA-6 to 8 with a thickness varying from 8 to 22 mils and with a gage length of 0.5 inch were sectioned from the hot extruded alloy rods after giving a final heat treatment of 2 h at 1000° C. or 20 min at 1320-1315° C., using an EDM machine. Tensile tests were performed on an Instron testing machine at a strain rate of 0.1 in/s at temperatures up to 800° C. in air. All tensile results are listed in Tables 5 to 8. The alloys PMTA4, -6 and -7 heat treated for 2 h at 1000° C. showed excellent strengths at all temperatures, independent of hot extrusion temperature. The hot extrusion at 1400-1365° C. gives low tensile ductilities (<4%) at room and elevated temperatures. A significant increase in tensile ductility is obtained at all temperatures when hot extruded at 1335° C. PMTA-8 which was hot extruded at 1335° C. exhibited the highest strength and tensile ductility at all test temperatures. There did not appear to be any systematical variation of tensile ductility with specimen thickness varying from 8 to 22 mils.
Tables 7 and 8 also show the tensile properties of PMTA- 6 and 7 heat treated for 20 min. at 1320° C. and 1315° C., respectively. As compared with the results obtained from heat treatment at 1000° C., the heat treatment at 1320-1315° C. resulted in higher tensile elongation, but lower strength at the test temperatures. Among all the alloys and heat treatments, PMTA-8 hot extruded at 1335° C. and annealed for 20 min at 1315° C. exhibited the best tensile ductility at room and elevated temperatures. This alloy showed a tensile ductility of 3.3% and 11.7% at room temperature and 800° C., respectively. PMTA-8 heat treated at 1315° C. appears to be substantially stronger than known TiAl alloys.
In an attempt to demonstrate the bend ductility of TiAl sheet material, several pieces of 11 to 20 mil PMTA-7 and PMTA-8 alloy sheets, produced by hot extrusion and heat treated at 1320° C., were bent at room temperature. Each alloy piece did not fracture after a bend of 42°. These results clearly indicate that PMTA alloys with a controlled microstructure is bendable at room temperature.
The oxidation behavior of PMTA-2, -5 and-7 was studied by exposing sheet samples (9-20 mils thick) at 800° C. in air. The samples were periodically removed from furnaces for weight measurement and surface examination. The samples showed a very low weight gain without any indication of spalling. It appears that the alloying additions of W and Nb affect the oxidation rate of the alloys at 800° C., and W is more effective in improving the oxidation resistance of TiAl alloys. Among the alloys, PMTA-7 exhibits the lowest weight gain and the best oxidation resistance at 800° C. Oxidation of PMTA-7 indicated that oxide scales are fully adherent with no indication of microcracking and spaling. This observation clearly suggests that the oxide scales formed at 800° C. are well adherent to the base material and are very protective.
FIG. 12 is a graph of resistivity in microhms versus temperature for samples 1 and 2 which were cut from an ingot having a nominal composition of PMTA4, i.e. 30.8 wt % Al, 7.1 wt % Nb, 2.4 wt % W, and 0.045 wt % B.; FIG. 13 is a graph of hemispherical total emissivity versus temperature for samples 1 and 2; FIG. 14 is a graph of diffusivity versus temperature for samples 80259-1, 80259-2 and 80259-3 cut from the same ingot as samples 1 and 2; FIG. 15 is a graph of specific heat versus temperature for titanium aluminide in accordance with the invention; and FIG. 16 is a graph of thermal expansion versus temperature for samples 80259-1H, 80259-1C, 80259-2H, 80259-3H, and 80259-3C cut from the same ingot as samples 1 and 2.
In summary, the hot PMTA alloys extruded at 1365 to 1400° C. exhibited mainly lamellar structures with little intercolony structures while PMTA-8 extruded at 1335° C. showed much finer colony structures and more intercolony structures. The heat treatment of PMTA-8 at 1315-1320° C. for 20 min. resulted in fine lamellar structures. The alloys may include (Ti,W,Nb) borides formed at colony boundaries. Moreover, tungsten in the hot-extruded alloys is not uniformly distributed, suggesting the possibility of high electrical resistance of TiAI alloys containing W additions. The inclusion of 0.5 at. % Mo significantly increases the yield and ultimate tensile strengths of the TiAl alloys, but lowers the tensile elongation to a certain extent at room temperature. Among the four hot extruded alloys PMTA 14, PMTA4 with the alloy composition Ti-46.5 Al-3 Nb-0.5 W-0.2 B (at %) has the best combination of tensile ductility and strength at room temperature. In comparison with the TiAICr sheet material (Ti45 Al-5Cr), PMTA4 is stronger than the TiAICr sheet by 67%. In addition, the TiAlCr sheet showed no bend ductility at room temperature while PMTAA has an elongation of 1.4%. The tensile elongation of TiAl alloys is independent of sheet thickness in the range of 9 to 20 mils. The alloys PMTA 4, 6 and 7 heat treated at 1000° C. for 2 h showed excellent strength at all temperatures up to 800° C., independent of hot extrusion temperature. Hot extrusion temperatures of 1400-1365° C., however, provides lower tensile ductilities (<4%) at room and elevated temperatures. A significant increase in tensile ductility is obtained at all temperatures when the extrusion temperature is 1335° C. PMTA-8 (Ti46.5 Al-3 Nb-1W-0.5B) hot extruded at 1335° C. and annealed at 1315° C. for 20 min. exhibited the best tensile ductility at room and elevated temperatures (3.3% at room temperature and 11.7% at 800° C.).
TABLE 1
Nominal Alloy Compositions
Alloy
number
Ti
A1
Cr
Nb
Mo
W
B
Compositions (at %)
PMTA-1
50.35
46.5
0
2
0.5
0.5
0.15
PMTA-2
50.35
46.5
0
2
—
1.0
0.15
PMTA-3
49.85
46.5
0
2
0.5
1.0
0.15
PMTA-4
49.85
46.5
0
3
—
0.5
0.15
PMTA-5
47.85
46.5
0
4
—
0.5
0.15
PMTA-6
49.92
46.5
0
3
—
0.5
0.08
PMTA-7
49.92
46.5
0
3
—
1.0
0.08
PMTA-8
49.40
46.5
0
3
—
1.0
0.10
PMTA-9
49.32
46.5
0
3
—
1.0
0.18
Compositions (wt %)
PMTA-1
60.46
31.36
0
4.64
1.20
2.30
0.04
PMTA-2
59.80
31.02
0
4.60
—
4.54
0.04
PMTA-3
58.86
30.83
0
4.57
1.18
4.52
0.04
PMTA-4
59.55
31.19
0
6.93
—
2.29
0.04
PMTA-5
57.71
30.85
0
9.14
—
2.26
0.04
PMTA-6
59.56
31.20
0
6.93
—
2.29
0.02
PMTA-7
57.98
30.68
0
6.82
—
4.50
0.02
PMTA-8
57.98
30.68
0
6.82
—
4.50
0.02
PMTA-9
57.97
30.67
0
6.82
—
4.49
0.05
TABLE 2
Fabrication and Heat Treatment Condition Used for PMTA Alloys
Hot extrusion
Alloy number
temperature (° C.)
Heat treatment (° C./time)
PMTA-1
1400
1000° C. for up to 3 days
PMTA-2
1400
1000° C. for up to 3 days
PMTA-3
1400
1000° C. for up to 3 days
PMTA-4
1400
1000° C. for up to 3 days
PMTA-5
PMTA-6
1380, 1365
1000° C./2 hours
PMTA-7
1380, 1365
1000° C./2 hr, 1320° C./20 min
PMTA-8
1335
1000° C./2 hr, 1315° C./20 min
TABLE 3
Phase Compositions in PMTA-2 Alloy Determined
by Electron Microphobe Analyses
Alloy elements (at %)
Phase
Ti
Al
W
Nb
Matrix phase
Balance
44.96
0.82
1.32
(dark contrast)
Matrix phase
Balance
44.70
1.15
1.32
(bright contrast)
Borides*
77.69
8.66
9.98
3.67
*metals elements only
TABLE 4
Tensile Properties of PMTA Alloys
Hot Extruded at 1400° C. and Tested at Room Temperature
Composition
Tensile
Nb—Mo—W
elongation
σ y
ρ ue
Alloy number
(at %)
(%)
(ksi)
(ksi)
2 hours/1000° C.
PMTA-1
2/0.5/0.5
1.0
114
118
PMTA-2
2/0/1.0
1.2
104
117
PMTA-3
2/0.5/1.0
1.1
123
132
PMTA-4
3/0/0.5
1.4
102
115
1 day/1000° C.
PMTA-3
2/0.5/1.0
1.4
115
131
3 days/1000° C.
PMTA-2
2/0/1.0
0.8
105
109
TABLE 5
Tensile Properties of PMTA-4 Hot Extruded at
1400° C. and Annealed for 2 h at 1000° C.
Test temperature
Yield strength
Ultimate tensile
Elongation
(° C.)
(ksi)
strength (ksi)
(%)
22
102.0
115
1.4
600
101.0
127
2.4
700
96.5
130
2.7
800
97.8
118
2.4
TABLE 6
Tensile Properties of PMTA-6 Hot Extruded at
1365° C. and Annealed at 1000° C. for 2 h
Test temperature
Yield strength
Ultimate tensile
Elongation
(° C.)
(ksi)
strength (ksi)
(%)
22
121.0
136
1.3
300
101.0
113
1.2
700
93.6
125
2.7
800
86.5
125
3.9
TABLE 7
Tensile Properties of PMTA-7 Hot Extruded at 1365° C.
Test temperature
Yield strength
Ultimate tensile
Elongation
(° C.)
(ksi)
strength (ksi)
(%)
Annealed for 2 h at 1000° C.
22
116.0
122
1.0
300
101.0
116
1.5
700
105.0
131
2.7
800
87.2
121
3.1
Annealed for 20 min at 1320° C.
20
84.5
106.0
3.0
300
71.4
89.8
2.5
700
68.5
97.2
4.5
800
63.5
90.2
4.5
TABLE 8
Tensile Properties of PMTA-8 Hot Extruder at 1335° C.
Test temperature
Yield strength
Ultimate tensile
Elongation
(° C.)
(ksi)
strength (ksi)
(%)
Annealed for 2 h at 1000° C.
22
122.0
140
2.0
300
102.0
137
4.3
700
95.0
131
4.7
800
90.2
124
5.6
Annealed for 20 min at 1315° C.
20
96.2
116
3.3
300
79.4
115
6.1
700
72.2
112
7.5
800
72.0
100
11.7
The foregoing titanium aluminide can be manufactured into various shapes or products such as electrical resistance heating elements. However, the compositions disclosed herein can be used for other purposes such as in thermal spray applications wherein the compositions could be used as coatings having oxidation and corrosion resistance. Also, the compositions could be used as oxidation and corrosion resistant electrodes, furnace components, chemical reactors, sulfidization resistant materials, corrosion resistant materials for use in the chemical industry, pipe for conveying coal slurry or coal tar, substrate materials for catalytic converters, exhaust walls and turbocharger rotors for automotive and diesel engines, porous filters, etc.
With respect to resistance heating elements, the geometry of the heating element blades can be varied to optimize heater resistance according to the formula: R=ρ(L/W×T) wherein R=resistance of the heater, ρ=resistivity of the heater material, L=length of heater, W=width of heater and T=thickness of heater. The resistivity of the heater material can be varied by changes in composition such as adjusting the aluminum content of the heater material, processing or by incorporation of alloying additions. For instance, the resistivity can be significantly increased by incorporating particles of alumina in the heater material. The heater material can optionally include ceramic particles to enhance creep resistance and/or thermal conductivity. For instance, the heater material can include particles or fibers of electrically conductive material such as nitrides of transition metals (Zr, Ti, Hf), carbides of transition metals, borides of transition metals and MoSs for purposes of providing good high temperature creep resistance up to 1200° C. and also excellent oxidation resistance. The heater material may also incorporate particles of electrically insulating material such as Al 2 O 3 , Y 2 O 3 , Si 3 N 4 , ZrO 2 for purposes of making the heater material creep resistant at high temperature and also improving thermal conductivity and/or reducing the thermal coefficient of expansion of the heater material. The electrically insulating/conductive particles/fibers can be added to a powder mixture of Fe, Al, Ti or iron aluminide or such particles/fibers can be formed by reaction synthesis of elemental powders which react exothermically during manufacture of the heater element.
The foregoing has described the principles, preferred embodiments and modes of operation of the present invention. However, the invention should not be construed as being limited to the particular embodiments discussed. Thus, the above-described embodiments should be regarded as illustrative rather than restrictive, and it should be appreciated that variations may be made in those embodiments by workers skilled in the art without departing from the scope of the present invention as defined by the following claims.
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A two-phase titanic aluminide alloy having a lamellar microstructure with little intercolony structures. The alloy can include fine particles such as boride particles at colony boundaries and/or grain boundary equiaxed structures. The alloy can include alloying additions such as ≦10 at % W, Nb and/or Mo. The alloy can be free of Cr, V, Mn, Cu and/or Ni and can include, in atomic %, 45 to 55% Ti, 40 to 50% Al, 1 to 5% Nb, 0.3 to 2% W, up to 1% Mo and 0.1 to 0.3% B. In weight %, the alloy can include 57 to 60% Ti, 30 to 32% Al, 4 to 9% Nb, up to 2% Mo, 2 to 8% W and 0.02 to 0.08% B.
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This is a division of application Ser. No. 07/766,981 filed Sep. 27, 1991, now U.S. Pat. No. 5,298,655.
BACKGROUND OF THE INVENTION
The Ras gene is found activated in many human cancers, including colorectal carcinoma, exocrine pancreatic carcinoma, and myeloid leukemias. Biological and biochemical studies of Ras action indicate that Ras functions like a G-regulatory protein, since Ras must be localized in the plasma membrane and must bind with GTP in order to transform cells (Gibbs, J. et al., Microbiol. Rev. 53:171-286 (1989). Forms of Ras in cancer cells have mutations that distinguish the protein from Ras in normal cells.
At least three post-translational modifications are involved with Ras membrane localization, and all three modifications occur at the C-terminus of Ras. The Ras C-terminus contains a tetrapeptide sequence motif, the Xaa is any amino acid (Willumsen et al., Nature 310:583-586 (1984)). Other proteins having this motif include the Ras-related GTP-binding proteins such as Rho, fungal mating factors, the nuclear lamins, and the gamma subunit of transducin.
Farnesylation of Ras by the isoprenoid farnesyl pyrophosphate (FPP) occurs in vivo on Cys to form a thioether linkage (Hancock et al., Cell 57:1167 (1989); Casey et al., Proc. Natl. Acad. Sci. USA 86:8323 (1989)). In addition, Ha-Ras and N-Ras are palmitoylated via formation of a thioester on a Cys residue near the C-terminal Cys farnesyl acceptor (Gutierrez et al., EMBO J. 8:1093-1098 (1989); Hancock et al., Cell 57:1167-1177 (1989)). Ki-Ras lacks the palmitate acceptor Cys. The last three amino acids at the Ras C-terminal end are removed proteolytically, and methyl esterification occurs at the new C-terminus (Hancock et al., ibid). Fungal mating factor and mammalian nuclear lamins undergo identical modification steps (Anderegg et al., J. Biol. Chem. 263:18236 (1988); Farnsworth et al., J. Biol. Chem. 264:20422 (1989)).
Inhibition of Ras farnesylation in vivo has been demonstrated with lovastatin (Merck & Co., Rahway, N.J.) and compactin (Hancock et al., ibid; Casey et al., ibid; Schafer et al., Science 245:379 (1989)). These drugs inhibit HMG-CoA reductase, the rate limiting enzyme for the production of polyisoprenoids and the farnesyl pyrophosphate precursor. It has been shown that a farnesyl-protein transferase using farnesyl-pyrophosphate as a requisite cosubstrate is responsible for Ras farnesylation. (Reiss et al., Cell, 62:81-88 (1990); Schaber et al., J. Biol. Chem., 265:14701-14704 (1990); Schafer et al., Science, 249:1133-1139 (1990); Manne et al., Proc. Natl. Acad. Sci. USA, 87:7541-7545 (1990)).
Inhibition of farnesyl-protein transferase and, thereby, farnesylation of the Ras protein, blocks the ability of Ras to transform normal cells to cancer cells. The compounds of the invention inhibit Ras farnesylation and, thereby, generate soluble Ras which, as indicated infra, can act as a dominant negative inhibitor of Ras function. While soluble Ras in cancer cells can become a dominant negative inhibitor, soluble Ras in normal cells would not be an inhibitor.
A cytosol-localized no wild type Ras tetrapeptide sequence motif membrane domain present and activated (impaired GTPase activity, staying bound to GTP) form of Ras acts as a dominant negative Ras inhibitor of membrane-bound Ras function (Gibbs et al., Proc. Natl. Acad. Sci. USA 86:6630-6634(1989)). Cytosol-localized forms of Ras with normal GTPase activity do not act as inhibitors. Gibbs et al., ibid, showed this effect in Xenopus oocytes and in mammalian cells.
Administration of compounds of the invention to block Ras farnesylation not only decreases the amount of Ras in the membrane but also generates a cytosolic pool of Ras. In tumor cells having activated Ras, the cytosolic pool acts as another antagonist of membrane-bound Ras function. In normal cells having normal Ras, the cytosolic pool of Ras does not act as an antagonist. In the absence of complete inhibition of farnesylation, other farnesylated proteins are able to continue with their functions.
Farnesyl-protein transferase activity may be reduced or completely inhibited by adjusting the compound dose. Reduction of farnesyl-protein transferase enzyme activity by adjusting the compound dose would be useful for avoiding possible undesirable side effects such as interference with other metabolic processes which utilize the enzyme.
These compounds and their analogs are inhibitors of farnesyl-protein transferase. Farnesyl-protein transferase utilizes farnesyl pyrophosphate to covalently modify the Cys thiol group of the Ras CAAX box with a farnesyl group. Inhibition of farnesyl pyrophosphate biosynthesis by inhibiting HMG-CoA reductase blocks Ras membrane localization in vivo and inhibits Ras function. Inhibition of farnesyl-protein transferase is more specific and is attended by fewer side effects than is the case for a general inhibitor of isoprene biosynthesis.
It is, therefore, an object of this invention to develop farnesyl pyrophosphate analogs which will inhibit farnesyl-protein transferase and the farnesylation of the oncogene protein Ras. It is a further object of this invention to develop chemotherapeutic compositions containing the compounds of this invention, and methods for producing the compounds of this invention.
SUMMARY OF THE INVENTION
The present invention includes farnesyl pyrophosphate analogs which inhibit farnesyl-protein transferase and the farnesylation of the oncogene protein Ras, chemotherapeutic compositions containing the compounds of this invention, and methods for producing the compounds of this invention.
The compounds of this invention are illustrated by the formula: ##STR1##
DETAILED DESCRIPTION OF THE INVENTION
The farnesyl pyrophosphate analog compounds of this invention are useful in the inhibition of farnesyl-protein transferase and the farnesylation of the oncogene protein Ras. The compounds of this invention are illustrated by the formula: ##STR2## wherein: X is CH 2 , CH(OH), C═O, CHCOR, CH(NH 2 ), CH(NHCOR), O, S(O)p, NH, NHCO, ##STR3## p is 0, 1 or 2; Y is PO 3 RR 1 or CO 2 R;
R is H, lower alkyl, or CH 2 CH 2 N + Me 3 A - ;
R 1 is H, lower alkyl, or CH 2 CH 2 N + Me 3 A - ;
A - is a pharmaceutically acceptable anion;
m is 0, 1, 2 or 3; and
n is 0, 1, 2 or 3;
or the pharmaceutically acceptable salts thereof.
The preferred compounds of this invention include:
______________________________________ FTaseNo. of IC.sub.50Scheme Structure (μM)______________________________________ 1 ##STR4## 310 2 ##STR5## 62 3 ##STR6## 100 4 ##STR7## 21 5 ##STR8## 0.044 6 ##STR9## 100 7 ##STR10## 0.042 8 ##STR11## 100 9 ##STR12## 1.710 ##STR13## 0.4211 ##STR14## 10012 ##STR15## 4213 ##STR16## 0.2214 ##STR17## 0.18______________________________________
The farnesyl pyrophosphate analog compounds of this invention were tested as follows for their ability to inhibit Ras farnesylation in vitro. Farnesyl-protein transferase from bovine brain was chromatographed on DEAE-Sephacel (Pharmacia, 0-0.8M NaCl gradient elution), N-octyl agarose (Sigma, 0-0.6M NaCl gradient elution), and a mono Q HPLC column (Pharmacia, 0-0.3M NaCl gradient). Ras-CVLS at 3.5 μM, 0.25 μM [ 3 H]FPP, and the indicated compounds were incubated with this partially purified enzyme preparation.
The FTase data presented above are the averages of 2-5 determinations and reflect the ability of the test compounds to inhibit Ras farnesylation in vitro.
In the present invention, lower alkyl, unless otherwise indicated, is 1-7 carbon straight or branched chain saturated alkyl having one or two hydrogens abstracted, and includes methyl, ethyl, propyl, isopropyl, butyl, isobutyl, t-butyl, pentyl, hexyl and heptyl.
The pharmaceutically acceptable salts of the compounds of this invention include the conventional non-toxic salts or the quartenary ammonium salts of the compounds of this invention as formed, e.g., from non-toxic inorganic or organic bases.
The pharmaceutically acceptable salts of the acids of the present invention are readily prepared by conventional procedures such as treating an acidic compound of this invention with an appropriate amount of a base, such as an alkali or alkaline earth metal hydroxide, e.g., sodium, potassium, lithium, calcium or magnesium, or an organic base such as an amine, e.g., dibenzylethylenediamine, trimethylamine, piperidine, pyrrolidine, benzylamine and the like, or a quaternary ammonium hydroxide such as tetramethylammonium hydroxide and the like.
The compounds of this invention inhibit farnesyl-protein transferase and the farnesylation of the oncogene protein Ras. The compounds of this invention are further useful in the inhibition of squalene synthetase. These compounds are useful as pharmaceutical agents for mammals, especially for humans. These compounds may be administered to patients for use in the treatment of cancer. Examples of the type of cancer which may be treated with the compounds of this invention include, but are not limited to, colorectal carcinoma, exocrine pancreatic carcinoma, and myeloid leukemias.
The compounds of this invention may be administered to mammals, preferably humans, either alone or, preferably, in combination with pharmaceutically-acceptable carriers or diluents, optionally with known adjuvants, such as alum, in a pharmaceutical composition, according to standard pharmaceutical practice. The compounds can be administered orally or parenterally, including intravenous, intramuscular, intraperitoneal, subsutaneous and topical administration.
For oral use of a chemotherapeutic compound according to this invention, the selected compounds may be administered, for example, in the form of tablets or capsules, or as an aqueous solution or suspension. In the case of tablets for oral use, carriers which are commonly used include lactose and corn starch, and lubricating agents, such as magnesium stearate, are commonly added. For oral administration in capsule form, useful diluents include lactose and dried corn starch. When aqueous suspensions are required for oral use, the active ingredient is combined with emulsifying and suspending agents. If desired, certain sweetening and/or flavoring agents may be added. For intramuscular, intraperitoneal, subcutaneous and intravenous use, sterile solutions of the active ingredient are usually prepared, and the pH of the solutions should be suitably adjusted and buffered. For intravenous use, the total concentration of solutes should be controlled in order to render the preparation isotonic.
The present invention also encompasses a pharmaceutical composition useful in the treatment of cancer, comprising the administration of a therapeutically effective amount of the compounds of this invention, with or without pharmaceutically acceptable carriers or diluents. Suitable compositions of this invention include aqueous solutions comprising compounds of this invention and pharmacologically acceptable carriers, e.g., saline, at a pH level, e.g., 7.4. The solutions may be introduced into a patient's intramuscular blood-stream by local bolus injection.
When a compound according to this invention is administered into a human subject, the daily dosage will normally be determined by the prescribing physician with the dosage generally varying according to the age, weight, and response of the individual patient, as well as the severity of the patient's symptoms.
In one exemplary application, a suitable amount of compound is administered to a human patient undergoing treatment for cancer. Administration occurs in an amount between about 0.1 mg/kg of body weight to about 20 mg/kg of body weight of a mammal per day, preferably of between 0.5 mg/kg of body weight to about 10 mg/kg of body weight of a mammal per day.
The compounds of this invention may be prepared according to the reaction schemes as set forth below. ##STR18##
EXAMPLES
Examples provided are intended to assist in a further understanding of the invention. Particular materials employed, species and conditions are intended to be further illustrative of the invention and not limitative of the reasonable scope thereof.
EXAMPLE 1
Preparation of 3-Hydroxy-7,11,15-trimethylhexadeca-6,10,14-trienoic acid
Step 1: Methyl 3-oxo-7,11,15-trimethylhexadeca-6,10,14-trienoate
Methyl acetoacetate (225 μL, 2.1 mmol) was added dropwise to a stirred suspension of sodium hydride (50% oil suspension, prewashed with hexane) (100 mg, 2.1 mmol) in anhydrous THF (5 mL) at 0° C. under an Argon atmosphere. The resulting solution was stirred 15 minutes at 0° C. and then treated with a 1.6M solution (1.3 mL, 2.1 mmol) of n-butylithium in hexane over 2 minutes. The yellow solution was stirred 15 min at 0° C. and then treated dropwise with farnesyl bromide (545 μL, 2.0 mmol). The cloudy orange solution was stirred at 20° C. for 11/2 hours and then quenched by dropwise addition of saturated aqueous NH 4 Cl solution. The resulting mixture was diluted with ethyl acetate and washed with water, dried, filtered and evaporated to give the crude product which was used in the next step without purification.
Diagonsitic peaks in the NMR (300 MHz, CDCl 3 ): δ 1.600 (6H, s), 1.614 (3H,s), 1.68 (3H, s), 1.9-2.1 (8H, m), 2.2-2.33 (2H, m), 2.58 (2H, t, J=6Hz), 3.448 (2H, s), 3.740 (3H,s), 5.05-5.15 (3H, m).
Step 2: Methyl 3-hydroxy-7,11,15-trimethylhexadeca-6,10,14-trienoate
Powdered sodium borohydride (38 mg, 1.0 mmol) was added at 0° C. to a stirred solution of methyl 3-oxo-7,11,15-trimethylhexadeca-6,10,14-trienoate (580 mg, 1.8 mmol) in methanol (5 mL) in one portion. The resulting mixture was stirred at 0° C. for 15 minutes, then treated with a saturated aqueous solution of NH 4 Cl (2 mL). The resulting mixture was extracted with diethyl ether. This extract was washed with water, dried, filtered and evaporated to give the crude product which was purified by flash chromatography. Elution of the column with hexane:ethyl acetate (10:1/v:v) afforded the title compound as a colorless gum.
H 1 NMR (300 MHz, CDCl 3 ): δ 1.600 (6H, s), 1.622 (3H,s), 1.681 (3H, s), 1.9-2.2 (12H, m), 2.38-2.55 (2H, m), 3.717 (3H, s) 3.95-4.05 (H, m), 5.05-5.15 (3H, m).
Step 3: 3-Hydroxy-7,11,15-trimethylhexadeca-6,10,14-trienoic acid
A solution of methyl 3-hydroxy-7,11,15-trimethylhexadeca-6,10,14-trienoate (139 mg, 430 μmol), ethanol (1 mL) and sodium hydroxide (1N, 440 μL, 440 μmol) was stirred at room temperature for two-hours. The crude mixture was purified by flash chromatography on a 20 mm ID silica gel column. Elution of the column with choloform:acetic acid (40:1/v=v) gave title compound as a colorless gum.
Anal for C 19 H 32 O 3 .0.25 H 2 O:
Calc'd C, 72.91; H, 10.49.
Found: C, 73.20; H, 10.39.
H 1 NMR (300 MHz, CDCl 3 ): δ 1.599 (6H, s), 1.629 (3H,s), 1.682 (3H, s), 1.9-2.2 (12H, m), 2.45-2.65 (2H, m), 4.0-4.1 (H, m), 5.05-5.20 (3H, m).
EXAMPLE 2
Preparation of [2-Oxo-6,10,14-trimethylpentadeca-5,9,13-trienyl]phosphonic acid
Step 1: Dimethyl [2-Oxo-6,10,14-trimethylpentadeca-5,9,13-trienyl]-phosphonate
This compound was prepared exactly by the method described in Step 1 of Example 1 except that the methyl acetoacetate was replaced by dimethyl 2-oxopropylphosphonate. Thereby was obtained title compound after chromatography on a 30 mm ID silica gel column. Elution of the column with hexane:ethyl acetate:methanol (40:10:2/v:v:v) gave the pure title compound as a colorless gum.
H 1 NMR (300 MHz, CDCl 3 ): δ 1.56-1.68 (12H,m), 1.92-2.1 (8H, m), 2.25 (h, d, J=6Hz), 2.3 (H, d, J=6Hz), 2.64 (2H, t, J=6Hz), 3.08 (2H, d, J=24Hz), 3.785 (6H, d, J=12Hz), 5.06-5.16 (3H, m).
Step 2: [2-oxo-6,10,14-trimethylpentadeca-5,9,13-trienyl]phosphonic acid
2,4,6-Collidine (225 μL, 1.7 mmol) was added to a stirred solution of dimethyl [2-oxo-6,10,14-trimethyl-pendadeca-5,9,13-trienyl]phosphonate (315 mg, 850 μmol) in chloroform (5 mL) at 0° C. under Ar atmosphere and this was followed by trimethylsilyl bromide (450 μL, 3.4 mmol). The cooling bath was removed and the clear solution was stirred at ambient temperature for 18 hours. The reaction mixture was evaporated, toluene (3 mL) was added and the mixture was again evaporated to remove any traces of trimethylsilyl bromide or HBr. Distributed white residue between 0.1N HCl (10 mL) and ethyl acetate (40 mL) at 0° C. The organic layer was separated, washed with cold water (3×10 mL), dried, filtered and evaporated. The crude product was purified by flash chromatography on a 20 mm ID Dowex 50 w-x-y column. Elution of the column with 25% aqueous methanol gave title compound after lypohilization of the appropriate fractions as a light brown gum.
Anal. for C 18 H 31 O 4 P.H 2 O:
Calc'd: C, 59.98; H, 9.32.
Found: C, 60.34; H, 9.21.
H 1 NMR (300 MHz, CD 3 OD): δ 1.60 (6H,s), 1.63 (3H, s), 1.67 (3H, s), 1.94-2.12 (8H, m), 2.24 (H, d, J=6Hz), 2.28 (H, d, J=6Hz), 2.68 (2H, t, J=6Hz), 3.06 (2H, d, J=24Hz), 5.05-5.15 (3H, m).
EXAMPLE 3
Preparation of [2-Hydroxy-6,10,14-trimethylpentadeca-5,9,13-trienyl]phosphonic acid
This compound was prepared similarly by the method described in Step 2 of Example 1 except that methyl 3-oxo-7,11,15-trimethylhexadeca-6,10,14-trienoate was replaced by dimethyl [2-oxo-6,10,14-trimethyl-pentadeca-5,9,13-trienyl]phosphonate and the product from this reaction was used in the hydrolysis step similarly to the method used in Step 2 in Example 2 to give, after lyophilization, title compound as a nearly colorless gum.
Anal. for C 18 H 33 O 4 P.0.5 H 2 O:
Calc'd: C, 61.17; H, 9.69.
Found: C, 61.22; H, 9.67.
H 1 NMR (300 MHz, CD 3 OD): δ 1.60 (6H,s), 1.63 (3H, s), 1.67 (3H, s), 1.86-2.2 (14H, m), 3.9-4.0 (H, m), 5.05-5.2 (3H, m).
EXAMPLE 4
Preparation of [1-Acetyl-4,8,12-trimethyltrideca-3,7,11-trienyl]phosphonic acid
Step 1: Dimethyl [1-acetyl-4,8,12-trimethyltrideca-3,7,11-trienyl]phosphonate
Dimethyl 2-oxopropylphosphonate (560 μL, 4.0 mmol) was added dropwise to a stirred suspension of sodium hydride (50% oil suspension, prewashed with hexane) (210 mg, 4.8 mmol) in anhydrous THF (15 mL) at 20° C. under an Argon atmosphere. The resulting slurry was stirred at 20° C. for 2 hours to allow for complete formation of the sodio derivative and then treated dropwise with farnesyl bromide (1.14 mL, 4.2 mmol). The cloudy yellow mixture was stirred at 20° C. for 2 hours and then quenched with saturated NH 4 Cl solution. The resulting mixture was washed with water, dried, filtered and evaporated to give the crude product which was purified by flash chromatography on a silica gel column. Elution of the column with hexane:ethyl acetate:methanol (40:10:1, v:v:v) gave the title compound as gum.
H 1 NMR (300 MHz, CDCl 3 ): δ 1.53-1.7 (12H, m), 1.93-2.1 (8H, m), 2.28 (3H, s) 2.4-2.55 (H, m), 2.63.-2.8 (H, m), 3.13-3.6 (H, m), 3.78 (6H, d, J=9Hz), 4.95-5.13 (3H, m).
Step 2: [1-Acetyl-4,8,12-trimethyltrideca-3,7,11-trienyl]phosphonic acid
This compound was prepared exactly by the method described in Step 2 of Example 2 except that dimethyl [2-oxo-6,10,14-trimethylpentadeca-5,9,13-trienyl]phosphonate was replaced by dimethyl [1-acetyl-4,8,12-trimethyltrideca-3,7,11-trienyl]phosphonate. Thereby was obtained title compound as a colorless gum.
Anal. for C 18 H 31 O 4 P.0.65 CH 3 OH:
Calc'd: C, 61.66; H, 9.32.
Found: C, 61.66; H, 9.34.
H 1 NMR (300 MHz, CD 3 OD): δ 1.59 (6H,s), 1.65 (3H, s), 1.67 (3H, s), 1.9-2.12 (8H, m), 2.25 (3H, s), 2.36-2.50 (H, m), 2.62-2.82 (H, m), 3.1-3.27 (H,m), 5.0-5.17 (3H, m).
EXAMPLE 5
Preparation of [2-[(E,E)-3,7,11-Trimethyl-2,6,10-dodecatrienylamino]-2-oxo-ethyl]phosphonic acid
Step 1: (E,E)-3,7,11-Trimethyl-2,6,10-dodecatrienylazide
A mixture of (E,E)-3,7,11-trimethyl-2,6,10-dodecatrienyl bromide (1.5 g, 5.26 mmol) and sodium azide (0.68 g, 10.5 mmol) in DMF (20 mL) was stirred at room temperature for 0.5 hours, then poured into cold water and extracted with ether. The ethereal extract was washed with brine, dried, filtered and evaporated to yield a residue. Purification of the residue by flash chromatography on a silica gel column, using hexane as the eluant, afforded the title compound as an oil (1.2 g, 4.85 mmol, 92%).
NMR (CDCl 3 ): δ 5.35 (H, t, J=7Hz), 5.10 (2H, m), 3.78 (2H, d, J=7Hz), 1.9-2.2 (8H, m), 1.72 (3H, s), 1.68 (3H, s) 1.60 (6H, s).
Step 2: Diethyl Carboxymethylphonate
Sodium hydroxide (0.54 g, 13.4 mmol) in water (2 mL) was added to a stirred solution of triethyl phosphonoacetate (2 g, 8.9 mmol) in ethanol (10 mL). The resulting mixture was stirred for 1 hour, then acidified with concentrated hydrochloric acid (12N, ca. 40 drops by transfer pipette). The solvents were evaporated under vacuum and the residue was treated with methylene chloride and anhydrous MgSO 4 . The inorganic salts were filtered off and the filtrate was concentrated in vacuo to give the title compound as an oil (1.7 g, 8.7 mmol, 98%).
NMR (CDCl 3 ): δ 8.87 (H, bs), 4.2 (4H, m), 3.06 (2H, s), 1.34 (6H, t, J=7Hz).
Step 3: (E,E)-3,7,11-trimethyl-2,6,10-dodecatrienylamine.
Water (46 μL) was added to a stirred mixture of (E,E)-3,7,11-trimethyl-2,6,10-dodecatrienylazide (0.8 g, 3.2 mmol) and triphenylphosphine (0.94 g, 3.62 mmol) in THF (3 mL) and stirred at room temperature overnight. An additional amount of water (46 ML) was added and stirred for another two hours. The reaction mixture was evaporated to dryness and the residue was redissolved in methylene chloride, then MgSO 4 was added and filtered. The filtrate was concentrated in vacuo to give the crude title compound as an oily solid which was used in the next step without purification.
Step 4: Diethyl [2-[(E,E)-3,7,11-trimethyl-2,6,10-dodecatrienyl-amino]-2-oxo-ethyl]phophonate
To a stirred solution of the crude (E,E)-3,7,11-trimethyl-2,6,10-dodecatrienyl-amine prepared from the previous reaction and diethyl carboxymethylphonate (0.63 g, 3.2 mmol) and DMF (6 mL) was added 1-hydroxybenzotriazole (0.49 g, 3.2 mmol) and 1-ethyl-3-(3-dimethylaminopropyl)carbodimide hydrochloride (0.61 g, 3.2 mmol). The resulting mixture was treated with triethylamine to adjust its pH value to 8-8.5, then stirred at room temperature overnight. The reaction mixture was poured into 10% citric acid solution and extracted with ethyl acetate. The organic extract was washed with sodium bicarbonate solution and brine, dried and filtered. Evaporation of the filtrate gave a residue which was purified by flash chromatography on a silica gel column. Elution of the column with 15% acetone in methylene choride provided the title compound (0.325 g, 0.81 mmol, 25% over two steps) as a viscous oil.
NMR (CDCl 3 ): δ 6.64 (H, bs), 5.20 (H, t, J=7Hz), 5.08 (2H, t, J=7Hz), 4.15 (4H, m), 3.87 (2H, t, J=7Hz), 2.88 (H, s), 2.80 (H, s), 2.0 (8H, m), 1.68 (3H, s), 1.60 (3H, s), 1.34 (6H, t, J=7Hz).
Step 5: [2-[(E,E)-3,7,11-Trimethyl-2,6,10-dodecatrienylamino]-2-oxo-ethyl]phosphonic acid
Diethyl [2-[(E,E)-3,7,11-trimethyl-2,6,10-dodecatrienylamino]-2-oxo-ethyl]phosphonate (0.325 g, 0.81 mmol) was deprotected in a similar fashion as that described in Step 2 of Example 2. The reaction mixture was diluted with toluene, then evaporated. This process was repeated two more times. The final residue was treated with diluted hydrochloride acid (0.1N) and extracted with ethyl acetate. The extract was washed with water three times, then dried and filtered. Evaporation of the filtrate afforded the title compound (0.14 g, 0.38 mmol, 47%) as a amorphous powder.
Anal for C 17 H 32 NO 5 P.H 2 O:
Calc: C, 56.49; H, 8.93; N, 3.88.
Found: C, 56.46; H, 8.30; N, 4.10.
NMR (CD 3 OD): δ 5.13 (H, t, J=7Hz), 5.0 (2H, m), 3.70 (2H, d, J=7Hz), 2.72 (H, s), 2.65 (H, s), 1.8-2.1 (8H, m), 1.60 (3H, s), 1.57 (3H, s), 1.48 (6H,s).
EXAMPLE 6
Preparation of [(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]thiomethyl-phosphonic acid
Step 1: (Benzyloxymethoxy)methyl-tri-(n-butyl)tin
n-Butyl lithium (1.6M in hexane, 16 mL, 25 mmol) was added under nitrogen to a stirred solution of di-isopropylamine (2.88, 28 mmol) in THF (50 mL) at 0° C. The resulting mixture was stirred at 0° C. for 15 min. then added tri-(n-butyl)tin (6.5 ml, 25 mmol) and stirred at 0° C. for 0.5 hours followed by the addition of paraformaldehyde (0.8 g, 25 mmol). The resulting mixture was stirred at 0° C. for 5 minutes, then warmed to room temperature and stirring continued for 1.5 hours. The reaction mixture was poured into cold water and extracted with ether. The ethereal extract was dried, filtered and evaporated to yield a residue (ca. 7.4 g) which was redissolved in methylene chloride (45 mL) and treated with di-isopropylethylamine (9 mL) and benzyl chloromethyl ether (6 mL). The resulting mixture was stirred at room temperature overnight. The reaction mixture was poured into ice chilled diluted hydrochloric acid and extracted with ether. The extract was washed with water, dried, filtered and evaporated to afford an oily residue, which was purified by flash chromatography on a silica gel column. Elution of the column with hexane:ether (50:1, v:v) provided the title compound (8.6 g, 19.5 mmol, 78%) as a colorless oil.
NMR (CDCl 3 ) δ 7.25-7.4 (5H, m), 4.66 (2H, s), 4.56 (2H, s), 3.82 (2H, t, J=8Hz), 1.55 (6H, m), 1.3 (6H, m), 0.9 (15H, m).
Step 2: Benzyl [(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyloxy]methyl ether
n-Butyl lithium (1.6M in hexane, 8.6 mL, 13.8 mmol) was added under nitrogen to a stirred solution of (benzyloxymethoxy)methyl-tri-(n-butyl) tin (6.1 g, 13.8 mmol) in THF (56 mL) at -78° C. The resulting mixture was stirred at -78° C. for 10 min, then added a solution of (E,E)-3,7,11-trimethyl-2,6,10-dodecatrienylbromide (3.5 g, 12.3 mmol) in THF (4 mL) via a dropping funnel. The resulting mixture was stirred at -78° C. for 0.5 hours, then poured into cold water and extracted with ether. The ethereal extract was dried, filtered and evaporated to afford a residue, which was purified by flash chromatography on a silica gel column. Elution of the column with hexane:ether (25:1, v:v) provided the title compound as a colorless oil (2.39 g, 6.7 mmol, 54.5%).
NMR (CDCl 3 ) δ 7.25-7.4 (5H, m), 5.17 (H, t, J=7Hz), 5.10 (2H, m), 4.78 (2H, s), 4.62 (2H, s), 3.60 (2H, t, J=7 Hz), 2.33 (2H, q, J=7 Hz), 2.0 (8H, m), 1.67 (3H, s), 1.63 (3H, s), 1.59 (6H, s).
Step 3: (E,E)-4,8,12-trimethyl-3,7,11-tridecatrienol
Benzyl [(E,E)-4,8,12-trimethyl-3,7,11-trienyloxy]methyl ether (2.50 g, 7.0 mmol) was added to a 3-necked Bantam-ware, equipped with a mechanical stirrer and filled with ca.60 mL of liquid ammonia. The resulting mixture was stirred at -78° C. while spheres of sodium (total weight ca 1.2 g) was added during a period of 1.5 hours. At this point, TLC analysis of an aliquot indicated the incompletion of the reaction. Therefore, THF (25 ML) was added to increase the fluidity of the reaction mixture followed by the treatment of an additional amount of sodium (ca 0.7 g). Then, it gave a persistent blue color of the reaction mixture. The cooling bath was removed and the reaction mixture was allowed to warm to room temperature. Ammonia was evaporated during the overnight standing. Ethanol (20 mL) was added to the reaction flask, stirred for 10 min, then added water (10 mL) and ether (50 mL). After 5 minute stirring, the mixture was poured into cold water and extracted with ether. The organic layer was separated, dried and filtered. Evaporation of the filtrate gave the title compound (1.66 g, 7.0 mmol, 100%) as a colorless oil.
NMR (CDCl 3 ) δ 5.15-5.20 (3H, m), 3.62 (2H, t, J=7Hz), 2.30 (2H, q, J=7Hz), 1.9-2.2 (8H, m), 1.69 (3H, s), 1.65 (3H, s), 1.60 (6H, s).
Step 4: (E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl tosylate
Tosylchloride (3.51 g, 9 mmol) was added to a stirred solution of (E,E)-4,8,12-trimethyl-3,7,11-tridecatrienol (1.66 g, 7 mmol) in pyridine (30 mL) at 0° C. The resulting mixture was placed in a refrigerator overnight, then poured into cold water and extracted with ether. The ethereal extract was washed with diluted hydrochloric acid to remove pyridine. After drying and filtration, the filtrate was evaporated to afford the title compound as an oil which was used in the next step without purification.
NMR (CDCl 3 ) δ 7.79 (2H, d, J=7Hz), 7.33 (2H, d, J=7Hz), 5.07 (2H, q, J=7Hz), 4.96 (H, t, J=7Hz), 3.97 (2H, t, J=7Hz), 2.44 (3H, s), 2.35 (2H, q, J=7Hz), 1.9-2.1 (8H, m), 1.69 (3H, s), 1.60 (3H, s), 1.58 (3H, s), 1.56 (3H, s).
Step 5: (E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl iodide
The (E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl tosylate obtained from previous step was dissolved in acetone (50 mL), then added sodium iodide (3.30 g, 22 mmol) and the resulting mixture was stirred at room temperature for 0.5 hours followed by heating at reflux for 3 hours. After cooling, the reaction mixture was poured into cold aqueous sodium thiosulfate solution and extracted with ether. The ethereal extract was washed with water, dried and filtered. Evaporation of the filtrate left a residue which was purified by flash chromatography on a silica gel column. Elution of the column with Hexane:ether (50:1, v:v) provided the title compound (1.85 g, 5.34 mmol, 76% for two steps) as a colorless oil.
NMR (CDCl 3 ) δ 5.1 (3H, m), 3.12 (2H, t, J=7Hz), 2.60 (2H, q, J=7Hz), 1.95-2.15 (5H, m), 1.69 (3H, s), 1.61 (3H, s), 1.60 (6H, s).
Step 6: Diethyl Acetylthiomethylphosphonate
To s stirred solution of diethyl idomethylphophonate (1.0 g, 3.6 mmol) in DMF (10 mL) was successively added cesium carbonate (1.30 g, 4 mmol) and thiolacetic acid (0.285 ml, 0.304 g, 4 mmol). The resulting mixture was stirred at room temperature under nitrogen overnight. The reaction mixture was poured into cold water (60 mL) and extracted with ether. The ethereal extract was washed with water (40 mL), dried, filtered and evaporated to yield an oily residue. The original aqueous phase and the washing were then combined and extracted with methylene chloride twice (2×50 mL) and ether once (50 mL). These extracts were combined, dried and filtered. The filtrate was concentrated on a rotary evaporator, then under high vacuum to give an oily residue. The two residue were combined and purified by flash chromatography on a silica gel column. Elution of the column with methylene chloride:acetone (10:1, v:v) afforded the title compound (0.726 g, 3.21 mmol, 89%) as a colorless oil.
NMR (CDCl 3 ) δ 4.16 (4H, m), 3.27 (H, s), 3.20 (H, s), 2.40 (3H, s), 1.33 (6H, t, J=7Hz).
Step 7: Diethyl [(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]thiomethylphosphonate
Solid sodium hydroxide (0.14 g, 3.5 mmol) was added to a stirred solution of diethyl acetylthiomethylphosphonate (0.59 g, 2.5 mmol) in ethanol (10 mL). The resulting mixture was stirred at room temperature under nitrogen until all the sodium hydroxide dissolved, then added a solution of (E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl iodide (0.84 g, 2.4 mmol) in ethanol (2 mL). The resulting mixture was stirred at room temperature under nitrogen overnight. The reaction mixture was poured into cold water and extracted with ether. The ethereal extract was washed with water, dried, filtered and evaporated to give a residue, which was purified by flash chromatography on a silica gel column. Elution of the column with methylene:acetate (10:1, v:v) afforded the title compound (0.91 g, 2.26 mmol, 94%) as a colorless oil.
NMR (CDCl 3 ) δ 5.17 (H, t, J=7Hz), 5.10 (2H, m), 4.17 (4H, m), 2.65-2.80 (4H, m), 2.30 (2H, q, J=7Hz), 1.9-2.1 (8H, m), 1.68 (3H, s), 1.62 (3H, s), 1.60 (6H, s), 1.35 (6H, t, J=7Hz).
Step 8: [(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]thiomethylphosphonic acid
Diethyl [(E,E)-4,8,12-trimethyl-3,7,11 -tridecatrienyl]thiomethylphosphonate (0.256 g, 0.636 mmol) was deprotected in a similar fashion as that described in Step 2 of Example 2. The reaction mixture was added toluene (3 mL), then evaporated in vacuo. This process was repeated two more times. The final residue was treated with diluted hydrochloride acid (0.1N) at 0° C., then extracted with ethylacetate. The extract was washed with water the three time (3×10 ML). After drying and filtration, filtrate was concentrated in vacuo to give the title compound (0.1 g, 0.29 mmol, 45%) as a gum.
Anal for C 17 H 31 O 3 PS.0.6 H 2 2O:
Calcd C, 57.15; H, 9.09.
Found C, 57.00; H, 9.27.
NMR (CDCl 3 ) δ 5.1-5.2 (3H, m), 3.6-3.8 (4H, m), 2.29 (2H, q, J=7Hz), 1.9-2.1 (8H, m), 1.68 (3H, s), 1.63 (3H, s), 1.61 (6H, s).
EXAMPLE 7
Preparation of 3-[(E,E)-3,7,11-trimethyl-2,6,10-dodecatrienylamino]-3-oxo-propionic acid
Step 1: Ethyl 3-[(E,E)-3,7,11-trimethyl-2,6,10-decatrienylamino]-3-oxo-propionate
The reaction was performed in a similar manner as that described in Step 4 of Example 4 but using malonic acid monoethyl ester instead of diethyl carboxymethylphosphonate. The title compound was obtained as a colorless oil.
NMR (CDCl 3 ) δ 7.00 (H, bs), 5.23 (H, t, J=7Hz), 5.12 (2H, m), 4.20 (2H, q, J=7Hz), 3.90 (2H, t, J=7Hz), 3.32 (2H, s), 1.9-2.1 (5H, m), 1.70 (6H, s), 1.61 (6H, s).
Step 2: 3-[(E,E)-3,7,11-trimethyl-2,6,10-dodecatrienylamino]-3-oxo-propionic acid
Sodium hydroxide (1N, 0.68 mL, 0.68 mmol) was added to a stirred solution of ethyl 3-[(E,E)-3,7,11-trimethyl-2,6,10-dodecatrienylamino]-3-oxopropionate (0.115 g, 0.34 mmol) in ethanol (2 mL) at 0° C. The resulting mixture was stirred at 0° C. for 5 minutes, then warmed to room temperature and stirred for 0.5 hours. The reaction mixture was poured into brine, acidified with hydrochloric acid (5%) and extracted with ethyl acetate. The extract was washed with brine, dried, filtered and evaporated to afford the title compound (80 mg, 0.26 mmol, 76%) as a gum.
Anal for C 18 H 29 NO 3 :
Calcd: C, 70.32; H, 9.51; N, 4.56.
Found: C, 70.70; H, 9.48; N, 4.80.
NMR (CDCl 3 ) δ 5.20 (H, t, J=7Hz), 5.10 (2H, t, J=7Hz), 3.92 (2H, t, J=7hZ), 3.30 (2H, s), 1.9-2.15 (8H, m), 1.68 (6H, s), 1.60 (6H, s).
EXAMPLE 8
Preparation of [2-[(E,E)-3,7,11-Trimethyl-2,6,10-dodecatrienylamino]-2-oxo-ethyl]phosphonic acid monomethyl ester, potassium salt
Step 1: Dimethyl Carboxymethylphosphonate
The title compound was prepared in a similar fashion as that described in Step 2 of Example 5 except triethyl phosphonoacetate being replaced by trimethyl phosphonoacetate. NMR (CDCl 3 ) δ 3.86 (3H, s), 3.83 (3H, s), 3.07 (H, s), 3.00 (H, s).
Step 2: Dimethyl [2-[(E,E)-3,7,11-trimethyl-2,6,10-dodecatrienylamino]-2-oxo-ethyl]phosphonate
The title compound was prepared in a similar manner as that described in Step 4 of Example 5 except that dimethyl carboxymethylphosphonate was used instead of diethyl carboxymethylphosphonate. NMR (CDCl 3 ) δ 6.50 (H, bs), 5.21 (H, t, J=7Hz), 5.10 (2H, t, J=7 Hz), 3.88 (2H, t, J=7 Hz), 3.82 (3H, s), 3.78 (3H, s), 2.88 (H, s), 2.82 (H, s), 1.9˜2.1 (8H, m), 1.67 (6H, s), 1.60 (6H, s).
Step 3: [2-[(E,E)-3,7,11-Trimethyl-2,6,10-dodecatrienylamino]-2-oxoethyl]phosphonic acid monomethyl ester, potassium salt
Potassium hydroxide (1N, 0.25 ml) was added to a stirred solution of dimethyl [2-[(E,E)-3,7,11-trimethyl-2,6,10-dodecatrienylamino]-2-oxo-ethyl]-phosphonate in methanol (1 ml) and water (0.75 ml). The resulting mixture was heated at 65°-70° C. for 1.75 hours. After cooling, the mixture was evaporated in vacuo to leave a residue. The residue was applied to a column packed with CHP20P. The column was eluted successively with water (20×12 ml) and 20% acetonitrile (20×12 ml) and the fractions were analyzed by HPLC. The fractions of high purity of the title compound were combined and lyophilized. The residue was redissolved in methanol and transferred to a small vial. The solvent was evaporated by blowing nitrogen gas to the solution, then dried under high vacuum to provide the title compound as a gum.
Anal. for C 18 H 31 NKO 4 P:
Calcd: C, 54.66; H, 7.90; N, 3.54.
Found: C, 54.71; H, 7.80; N, 3.37.
NMR (CD 3 OD) δ 5.24 (H, t, J=7 Hz), 5.10 (2H, q, J=7 Hz), 3.80 (2H, d, J=6 Hz), 3.60 and 3.57 (3H combined, 2s) 2.67 (H, s), 2.60 (H, s), 1.9˜2.2 (8H, m), 1.68 (3H, s), 1.66 (3H, s), 1.60 (6H, s).
EXAMPLE 9
Preparation of [2-[(E,E)-3,7,11-trimethyl-2,6,10-dodecatrienylamino]-1-oxo-methyl]phosphonic acid
Step 1: Dimethyl [2-[(E,E)-3,7,11-trimethyl-2,6,10-dodecatrienylamino]-1-oxo-methyl]phosphonate
A mixture of (E,E)-3,7,11-trimethyl-2,6,10-dodecatrienylamine (Ca. 2.63 mmol, its preparation described in Step 3 of Example 5) and trimethyl phosphonoformate (0.44 g, 2.63 mmol) in toluene (4 ml) was heated at reflux for 3 h. After cooling, the reaction mixture was concentrated in vacuo and the residue was purified by flash chromatography on a silica gel column. Elution of the column with methylene chloride, then acetone in methylene chloride (2% to 10%) to afford the title compound (96 mg, 0.27 mmol, 10%) as an oil. NMR (CDCl 3 ) δ 6.90 (H, bs), 5.20 (H, t, J=7 Hz), 5.10 (2H, t, J=7 Hz), 3.94 (2H, m), 3.90 (3H, s), 3.86 (3H, s), 1.9˜2.15 (8H, m), 1.67 (6H, s), 1.60 (6H, s).
Step 2: [2-[(E,E)-3,7,11-trimethyl-2,6,10-dodecatrienylamino]-1-oxo-methyl]-phosphonic acid
Dimethyl [2-[(E,E)-3,7,11-trimethyl-2,6,10-dodecatrienylamino]-1-oxo-methyl]-phosphonate was deprotected in a similar fashion as that described in Step 2 of Example 2. The reaction mixture was diluted with toluene (3 ml), then evaporated to dryness. This process was repeated twice and the final residue was dissolved in methanol (2 ml) and treated with potassium hydroxide (1N, 0.57 ml). After 20 min stirring, the mixture was concentrated and the residue was applied to a column packed with CHP20P. The column was eluted successively with water (20×12 ml) and 20% acetonitrile in water, the fractions were analyzed by HPLC. The fractions of high purity of the title compound were combined and lyophilized. The residue was dissolved in methanol and transferred to a vial. The solvent was removed by evaporation followed by drying under high vacuum to afford the title compound as a gum.
NMR (CD 3 OD) δ 7.53 (H, s), 5.24 (H, t, J=7 Hz), 5.10 (2H, q, J=7 Hz), 3.86 (2H, d, J=6 Hz), 1.9˜2.15 (8H, m), 1.70 (3H, s), 1.67 (3H, S), 1.60 (6H, s).
EXAMPLE 10
Preparation of [1-Hydroxy-(E,E)-3,7,11-trimethyl-2,6,10-dodecatrienyl]phosphonic acid
Step 1: Dimethyl [1-hydroxy-(E,E)-3,7,11-trimethyl-2,6,10-dodecatrienyl]phosphonate
To a stirred solution of farnesal (245 mg, 1.11 mmol) in acetonitrile (1.1 ml) under argon at room temperature (r.t), was added triethylamine (0.31 ml, 2.22 mmol) and dimethyl phosphite (0.153 ml, 1.67 mmol) and the resulting mixture stirred at r.t. for 24 hr. The reaction mixture was concentrated in vacuo, the resulting residue was chromatographed over silica gel eluted with ethyl acetate to afford the title compound as a colorless oil: NMR (CDCl 3 ) δ 1.60 (6H, s), 1.68 (3H, s), 1.71 (3H, d, J=3.1 Hz), 1.80-2.30 (9H, m), 3.80 (6H, m), 4.69 (1H, dt, J=9 and 5.4 Hz), 5.00-5.20 (2H, m), 5.34 (1H, m).
Step 2: [1-Hydroxy-(E,E)-3,7,11-trimethyl-2,6,10-dodecatrienyl]phosphonic acid
To a stirred solution of dimethyl [1-hydroxy-(E,E)-3,7,11-trimethyl-2,6,10-dodecatrienyl]phosphonate (67 mg, 0.203 mmol) and 2,4,6-collidine (0.107 ml, 0.81 mmol)in dichloromethane (3 ml) under argon at 0° C., was added trimethylsilyl bromide (0.107 ml, 0.8 mmol) and the resulting mixture stirred at 0° C. for 30 min and then at r.t. for 5 hrs. The resulting white suspension was diluted with toluene (10 ml) and the solvent evaporated in vacuo, the resulting white solid was dissolved in ethylacetate and water and the pH was adjusted to pH=3 by the addition of 1M HCl solution. The organic layer was separated, dried (MgSO 4 ) and evaporated to afford a pale yellow solid. The-solid was washed with dichloromethane (2×5 ml) and the white solid filtered off and dried in vacuo to afford the title compound.
NMR (DMSO-d6) δ 1.55 (6H, s), 1.56 (3H, s), 1.60 (3H, d, J=2.0 Hz), 1.80-2.20 (9H, m), 4.24 (1H, dd, J=9.5 and 10.5 Hz), 5.00-5.30 (3H, m).
Anal. Calcd for C 15 H 27 O 4 P.0.25 H 2 O: C, 58.71; H, 9.03.
Found: C, 58.72: H, 8.94.
EXAMPLE 11
Preparation of [1-Hydroxy-(E,E)-5,9,13-trimethyl-4,8,12-tetradecatrienyl]phosphonic acid
Step 1: (E,E)-4,8,12-Trimethyl-3,7,11-tridecatrienal
A solution of (E,E)-4,8,12-trimethyl-3,7,11-tridecatrienol (400 mg, 1.59 mmol) in acetonitrile (5 ml) was added to a slurry of N-methymorpholine N-oxide (280 mg, 2.38 mmol) and powdered 4A molecular sieves in acetonitrile (10 ml) and the mixture stirred at r.t. for 10 min. Tetrapropylammonium perruthenate (28 mg, 0.00795 mmol) was added in one portion and the resulting dark green slurry stirred at r.t for 1 hr. The reaction mixture was filtered through a plug of silica gel eluting with ethylacetate and the filtrate evaporated in vacuo. The resulting oil was chromatographed over silica gel eluting with diethylether:hexanes (1:10, v:v) to afford the title compound (200 mg, 50%) as a clear colorless oil.
NMR (CDCl 3 ) δ 1.59 (6H, s) 1.63 (3H, s), 1.68 (3H, s), 1.9-2.2 (8H, m) 2.33 (2H, brq, J=7 Hz), 2.46 (2H, tt, J=1.6 and 7.0 Hz), 5.00-5.20 (3H, m), 9.76 (1H, t, J=1.6 Hz).
Step 2: Dimethyl [1-hydroxy-(E,E)-5,9,13-trimethyl-4,8,12-tetradecatrienyl]phosphonate
To a stirred solution of (E,E)-4,8,12-trimethyl-3,7,11-tridecatrienal (200 mg, 0.81 mmol) in acetonitrile (0.8 ml) under argon at r.t., was added triethylamine (0.22 ml, 1.61 mmol) and dimethyl phosphite (0.11 ml, 1.21 mmol) and the resulting mixture stirred at r.t. for 4 hr. The reaction mixture was concentrated in vacuo, and the resulting residue chromatographed over silica gel eluted with ethyl acetate to afford the title compound as a colorless oil.
NMR (CDCl 3 ) δ 1.60 (6H, s), 1.63 (3H, s), 1.68 (3H, s), 1.72-1.85 (2H, m) 1.90-2.40 (10H, m), 3.59 (1H, m) 3.80 (3H, d, J=11 Hz), 3.81 (3H, d, J=11 Hz) 3.89 (1H, m), 5.00-5.20 (3H, m).
Step 3: [1-Hydroxy-(E,E)-5,9,13-trimethyl-4,8,12-tetradecatrienyl]phosphonic acid
To a stirred solution of dimethyl[1-hydroxy-(E,E)-5,9,13-trimethyl-4,8,12-tetradecatrienyl]phosphonate (98 mg, 0.253 mmol) and 2,4,6-collidine (0.134 ml, 1.014 mmol) in dichloromethane (3 ml) under arson at 0° C., was added trimethylsilyl bromide (0.134 ml, 1.013 mmol) and the resulting mixture stirred at 0° C. for 30 min. and then at r.t. for 5 hr. The resulting white suspension was diluted with toluene (10 ml) and the solvent evaporated in vacuo, the resulting white solid was dissolved in ethylacetate and water and the pH was adjusted to 3 by the addition of 1M HCl solution. The organic layer was separated, dried (Na 2 SO 4 ) and evaporated to afford a glassy residue. The solid was washed with acetonitrile (2×5 ml) and the white solid filtered off and dried in vacuo to afford the title compound.
NMR (DMSO-d6) δ 1.55 (6H, s), 1.56 (3H, s), 1.62 (3H, s), 1.80-2.20 (13H, m), 3.42 (1H, m), 5.00-5.20 (2H, m).
EXAMPLE 12
Preparation of [1-Hydroxy-(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]phosphonic acid
Step 1: Diethyl (t-Butyldimethylsiloxy)methylphosphonate
To a stirred solution of diethyl hydroxylmethylphosphonate (2.13 g, 12.7 mmol), triethylamine (2.12 ml, 15.2 mmol) and dimethylaminopyridine (77 mg, 0.63 mmol) in dichlormethane at 0° C. under argon, at r.t., was added t-butyldimethylsilyl chloride (1.85 g, 12.8 mmol) in dichloromethane (5 ml). After 14 hr the resulting slurry was poured into water (100 ml) and extracted with dichloromethane (2×100 ml). The organic extracts were dried (Na 2 SO 4 ), concentrated in vacuo and the resulting oil chromatographed on silica gel eluted with ethylacetate:hexanes (1:1, v:v) to afford the title compound as a clear oil.
NMR (CDCl 3 ) δ 0.09 (6H, s), 0.89 (9H, s), 1.33 (6H, t, J=7.1 Hz), 3.91 (1H, d, J=8.5 Hz,), 4.14 (2H, q, J=7.1 Hz), 4.17 (2H, q, J=7.1 Hz).
Step 2: Diethyl [1-(t-Butyldimethylsiloxy)-(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]phosphonate
To a stirred solution of the diethyl (t-butyldimethylsiloxy)methylphosphonate (562 mg, 2.0 mmol) in THF (5 ml) under argon at -78° C. was added n-BuLi (0.84 ml of a 2.5M solution in hexanes, 2.1 mmol) and the resulting mixture stirred at -78° C. for 15 min. Farnesyl bromide (0.542 ml, 2.0 mmol) was added to the mixture over 5 min and the solution stirred a further 1 hr at -78° C. and then allowed to warm to r.t. The reaction mixture was poured into saturated NaHCO 3 solution and the organic solvent evaporated in vacuo, the residue was extracted into ethylacetate and washed with brine, dried (MgSO 4 ) and concentrated in vacuo and the resulting oil chromatographed on silica gel eluted with ethylacetate:hexanes (3:7, v:v). to afford the title compound as an oil.
NMR (CDCl 3 ) δ 0.00 (3H, s), 0.06 (3H, s) 0.82 (9H, s), 1.25 (3H, t, J=7 Hz) 1.26 (3H, t, J=7 Hz) 1.52 (6H, s), 1.56 (3H, s), 1.61 (3H, s), 1.90-2.10 (8H, m) 2.10-2.30 (2H, m), 3.84 (1H, m), 4.00-4.10 (4H, m), 5.00-5.15 (2H, m), 5.15 (1H, brt, J=7 Hz).
Step 3: Diethyl [1-hydroxy-(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]phosphonate
To a solution of the diethyl [1-(t-butyldimethylsiloxy)-(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]phosphonate (55 mg, 0.113 mmol) in THF (1 ml), under argon, at 0° C. was added tetrabutylammonium fluoride (0.113 ml of a 1.0M solution in THF, 0.113 mmol), and the mixture stirred at 0° C. for 1 hr. The solvent was evaporated in vacuo and the residue chromatographed on silica gel eluted with ethylacetate:hexanes, (3:1, v:v) to afford the title compound (37 mg 88%) as an oil.
NMR (CDCl 3 ) δ 1.34 (6H, brt, J=7 Hz), 1.60 (6H, s), 1.65 (3H, s), 1.68 (3H, s), 1.90-2.20 (8H, m), 2.30-2.60 (2H, m), 2.8 (1H, br s), 3.86 (1H, dt J=8.9 and 4.6 Hz) 4.17 (2H, q, J=7.1Hz), 4.19 (2H, q, J=7.1 Hz), 5.00-5.15 (2H, m), 5.25 (1H, brt, J=7 Hz).
Step 4: [1-Hydroxy-(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]phosphonic acid
To a stirred solution of diethyl [1-hydroxy-(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]phosphonate (37 mg, 0.0993 mmol) and 2,4,6-collidine (0.052 ml, 0.397 mmol) in dichloromethane (3 ml) under argon at 0° C., was added trimethylsilyl bromide (0.052 ml, 0.397 mmol) and the resulting mixture stirred at 0° C. for 30 min and then at r.t. for 4 hr. The resulting white suspension was diluted with toluene (10 ml) and the solvent evaporated in vacuo. The resulting white solid was dissolved in ethylacetate and water and the pH was adjusted to 3 by the addition of 1M HCl solution. The organic layer was separated and dried (MgSO 4 ) and evaporated to afford a clear oil. Addition of acetonitrile 2 ml precipitated the title compound as an off white solid which was removed by filtration and dried in vacuo.
NMR (DMSO-d6) δ 1.55 (9H, s), 1.62 (3H, s), 1.80-2.40 (11H, m), 3.40 (1H, m), 5.00-5.15 (2H, m), 5.25 (1H, m). Mass:m/e 315 (M-H + ).
EXAMPLE 13
Preparation of [2-Acetamido-(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]phosphonic acid
Step 1: Dimethyl [2-hydroxy-(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]phosphonate
n-Butyllithium (0.698 ml of a 2.5M solution in hexanes, 1.75 mmol) was added to a stirred solution of dimethyl methylphosphonate (0.189 ml, 1.75 mmol) in THF (4 ml), under argon at -78° C. The resulting colorless solution was stirred at this temperature for 20 min. Farnesal (350 mg, 1.59 mmol) in THF (4 ml) was added over 5 min and the resulting mixture stirred a further 30 min and then treated with saturated sodium bicarbonate solution (5 ml) and allowed to warm to r.t. The THF was evaporated in vacuo and the aqueous extracted twice with ethylacetate, washed with brine, dried (MgSO 4 ) and concentrated in vacuo. The residue was chromatographed on silica gel eluted with ethylacetate to afford the title compound as an oil.
NMR (CDCl 3 ) δ 1.59 (6H, s), 1.68 (3H,s), 1.70 (3H, s), 1.80-2.20 (1H, m) 3.0 (1H, d, J=2.7 Hz), 3.76 (3H, d, J=11 Hz) 3.77 (3H, d, J=10.8 Hz) 4.80 (1H, m), 5.10 (2H, m), 5.25 (1H, brd, J=9.5 Hz).
Step 2: Dimethyl [2-amino-(E,E) -4,8,12-trimethyl-3,7,11-tridecatrienyl]phosphonate
To a stirred solution of the dimethyl [2-hydroxy-(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]phosphonate (174 mg, 0.505 mmol), triphenylphosphine (197 mg, 0.758 mmol) and phthalidide (89 mg, 0.606 mmol) under argon at r.t. in THF (1.6 ml) was added diethylazodicarboxylate (0.119 ml, 0.759 mmol) over 2 min. After 2 hrs the reaction mixture was concentrated in vacuo and chromatographed on silica gel gradient eluted with ethyl acetate:hexanes (1:1, v:v) to (3:2, v:v) to afford the phthalimide derivative (181 mg, 0.382 mmol) contaminated with triphenylphospine oxide which was not further purified. The phthalimide derivative (181 mg, 0.382 mmol), hydrazine (0.12 ml, 3.82 mmol) in methanol (3.8 ml) was stirred under argon at r.t. for 20 min and then heated at reflux for 24 hr. Upon cooling a white precipitate was obtained and removed by filtration. The filtrate was concentrated in vacuo and chromatographed on silica gel eluted with methylene chloride:methanol:ammomiun hydroxide (95:5:0.2, v:v:v) to afford the title compound as an oil.
NMR (CDCl 3 ) δ 1.61 (6H, s), 1.68 (6H, s), 1.80-2.20 (12H, m), 3.76 (6H, d, J=10 Hz) 4.07 (1H, m), 5.00-5.20 (3H, m).
Step 3: Dimethyl[2-acetamido-(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]phosphat
To a solution of dimethyl [2-amino-(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]phosphonate (50 mg, 0.145 mmol) dimethylaminopyridine (9 mg, 0.073 mmol) and triethylamine (0.061 ml, 0.435 mmol) at r.t. under argon was added acetic anhydride (0.041 ml, 0.435 mmol). After 30 min. the reaction was concentrated in vacuo and chromatographed on silica gel eluting with methanol:dichloromethane, 3:97, v:v to afford the title product as an oil.
NMR (DMSO-d6) δ=1.55 (6H, s), 1.64 (6H, s), 1.75 (3H, s) 1.80-220 (10H, m), 3.55 (3H, s), 3.6 (3H, s) 4.73 (1H, m) 5.00-5.15 (2H, m), 888 (1H, d, J=8 Hz).
Step 4: [2-Acetamido-(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]phosphonic acid
To a stirred solution of dimethyl [2-acetamido-(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]phosphonate (39 mg, 0.101 mmol) and 2,4,6-collidine (0.054 ml, 0.404 mmol) in dichloromethane (2.5 ml) under argon at 0° C., was added trimethylsilyl bromide (0.054 ml, 0.404 mmol) and the resulting mixture stirred at 0° C. for 30 min and then at r.t. for 5 hr. The resulting white suspension was diluted with toluene (10 ml) and the solvent evaporated in vacuo. The resulting white solide was dissolved in ethylacetate and water and the pH was adjusted to 3 by the addition of 1M HCl solution. The organic layer was separated, dried (Na 2 SO 4 ) and evaporated to afford a clear oil, which was dissolved in hexanes and treated with 10 drops of ammonium hydroxide, the precipitate was removed by filtration and dried in vacuo to afford the title compound as an off white solid.
NMR (DMSO-d6) δ 1.54 (6H, s), 1.61 (3H, s), 1.62 (3H, s), 1.73 (3H, s), 1.80-2.10 (10H, m), 4.72 (1H, m), 5.00-5.15 (2H, m), 6.92 (1H, s), 7.10 (1H, s) 7.27 (1H, s), 7.78 (1H, d, J=8 Hz)
Anal Calcd for C 18 H 35 NO 4 P 1.01 H 2 O, 0.92 NH 3 : C, 55.25; H, 9.47; N, 6.90.
Found: C, 55.23; H, 9.47; N, 6.90.
EXAMPLE 14
Preparation of [2-Hydroxy-(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]phosphonic acid, Ammonium salt
Dimethyl [2-hydroxy-(E,E)-4,8,12-trimethyl-3,7,11-tridecatrienyl]-phosphonate was deprotected in a similar fashion as described in Step 2 of Example 2 to afford [2-hydroxy-(E,E)-4-8,12-trimethyl-3,7,11-tridecatrienyl]phosphonic acid. This acid was dissolved in methanol, treated with ammonium hydroxide and the title compound precipitated out as a white solid.
NMR (DMSO-d6) δ 7.32 (H, s), 7.16 (H, s), 6.98 (H, s), 4.95-5.2 (3H, m), 4.51 (H, m), 1.8-2.2 (11H, m), 1.62 (3H, s), 1.60 (3H, s), 1.55 (6H, s).
Anal Calcd for C 16 H 29 O 4 P.1.73 NH 3 .0.43 H 2 O: C, 54.34; H, 9.99; N, 6.86.
Found: C, 54.33; H, 9.75; N, 6.88.
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The present invention is directed to farnesyl pyrophosphate analogs which inhibit farnesyl-protein transferase (FTase) and the farnesylation of the oncogene protein Ras. The invention is further directed to chemotherapeutic compositions containing the compounds of this invention, and methods for inhibiting farnesyl-protein transferase and the farnesylation of the oncogene protein Ras.
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This application is a divisional of Ser. No. 09/338,213 Jun. 22, 1999. Now U.S. Pat. No. 6,269,666.
BACKGROUND OF THE INVENTION
The present invention relates to automatic washers, either of the front-loading or top-loading types, and more particularly to an improved washing system and control therefor.
Automatic clothes washers generally include fluid handling systems for filling a washer tub with a wash fluid consisting of a water and detergent solution, tumbling or agitating a wash load of fabrics for a period of time, then draining the wash fluid from the tub. A portion of the washing part of the cycle may include a spray treatment or pretreatment of the fabrics while the basket is spinning. A subsequent rinse with fresh water and draining of the rinse water are also provided. All or part of the rinse cycle may include a spray rinse of the fabrics while the basket is spinning at high speed.
Spray treatment of fabrics during the wash cycle therefore is known. Spray treatment may be desirable in a clothes washer because of known benefits such as improved washing performance and reduced energy and water usage. An example of a clothes washer having spray treatment is disclosed in U.S. Pat. No. 5,271,251 for example, assigned to the assignee of the present invention. In this example, however, a probe sensor provides a signal for the purpose of maintaining a predetermined water level during recirculation. Alternatively, a pressure dome or temperature thermistor may be used to detect the water level and a determination may be made for the level of water to be used in the following swirl portion of the cycle. However, there is no determination made of the amount of fabric load contained within the washer using the on or off times of the inlet valve or valves or the information provided by the pressure sensor.
There are known disadvantages to spray treatment as well. One undesirable condition which has been found to occur during a spray pretreatment portion of the wash cycle is ‘suds lock’. When this condition occurs, contact of the fluid with the spinning basket acts to further increase the amount of suds which thus raises the height of the sudsy fluid toward the basket. The eventual result of this unstable process is that suds build up beyond the bottom of the basket and climb between the sides of the basket and tub. This large amount of suds acting between the spinning basket and the fixed tub produces a significant drag force on the basket. This drag force is large enough to cause the clutch to slip and thus causing the basket to slow down considerably. This slipping of the clutch due to excessive suds between the spinning basket and the tub is called ‘suds lock’.
Certain combinations of environmental factors have been found to increase the likelihood of suds lock. Such combinations of very small loads or no load, very large doses of detergent, liquid detergent, type of detergent and soft water have been found to increase the formation of suds during the spray pretreat cycle. Also, if the means by which the amount of water controlled during the spray pretreatment cycle is not robust, suds lock may be more likely. To guard against both worst case conditions or machine degradation over time, a control for sensing suds lock and controlling the machine based on suds lock information is desirable.
U.S. Pat. No. 4,784,666, assigned to the assignee of the present application, discloses a high performance washing process for vertical axis automatic washers which includes the recirculation of wash fluid prior to the agitate portion of the wash cycle. That patent describes, as a particular embodiment of the invention, to load a charge of detergent into the washer along with a predetermined amount of water, preferably prior to admitting a clothes load into the basket to assure that the concentrated detergent solution will initially be held in a sump area of the wash tub so that the detergent will be completely dissolved or mixed into a uniform solution before being applied to the clothes load. It is also suggested that the addition of an anti foaming agent may be desirable. No particular arrangement is provided for mixing the detergent and water to provide a uniform solution, nor is any particular means described for assuring that the amount of wash liquid within the tub during the spin wash portion of the wash cycle is an appropriate amount which is slightly in excess of the saturation level for the clothes load.
U.S. Pat. Nos. 5,219,370 and 5,233,718, assigned to the assignee of the present invention, disclose variations on a high performance washing process for vertical or horizontal axis automatic washers which include the recirculation of wash fluid prior to the agitate portion of the wash cycle or other washing or rinsing steps. The primary means for controlling water input into the systems is to detect water level using a liquid level sensor. It is suggested that a pressure dome sensor may be used to detect an oversudsing condition, however this would be performed in conjunction with usage of the liquid level sensor, which is not provided for in the present invention. These patents allow for the possibility of indirectly inferring the water level in the tumble portion of the cycle based on the sensed level of detergent liquor in the pretreatment portion, unlike the present invention which determines the amount of clothes load and possibility of suds lock.
SUMMARY OF INVENTION
The present invention provides a control for sensing the state of the washing machine during a pretreatment cycle having a combined spray and high speed spin. During such a pretreatment cycle the washer is susceptible to the possible occurrence of a suds lock condition, which may be detected and handled by the present invention. This can be accomplished by a variety of sensing techniques, through which the possible or imminent occurrence of suds lock can be determined or inferred, including sensing the condition of the wash liquid or the washing machine components. A suds lock condition may even be anticipated and avoided by the present invention. Further, by knowing that a suds lock condition is occurring or is likely to occur, the spray pretreatment portion of the wash cycle can be preterminated and the rest of the cycle can be continued. Alternatively, adding of water may be discontinued. By following a suds lock condition immediately with a deepfill of the tub of the automatic washer, suds buildup within the basket can be minimized.
By using the same technique of measuring suds lock, the size of the load can also be ascertained. This information can thus be applied to control the rest of the cycle. For example, the automatic deepfill water level and relative agitation rate can be altered according to the sensed size of the load. In the present invention, the load size is determined regardless of the types of fabric materials contained in the load. As well, in certain load conditions such as large loads, the deepfill portion may be slightly altered in order to optimize and maximize the wash performance. This may be performed not only as a result of detecting the load size but also as a result of user control inputs.
Furthermore, the control may be used to detect special conditions, for example unusually wet laundry at the outset of the wash cycle or failure in some aspect of the wash cycle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a partially cut away automatic washer containing recirculation hardware embodying the principles of the present invention.
FIG. 2 is a schematic diagram of an automatic washer portraying in fluid circuit form the recirculation hardware and control arrangement embodying the principles of the present invention.
FIG. 3 is a block diagram of the process for controlling the spray pretreatment portion of the wash cycle based on monitoring the condition of suds lock occurrence.
FIG. 4 a is a block diagram of an automatic washer containing recirculation hardware using flow rate information to control the amount of water added during the spray pretreatment portion of the wash cycle.
FIG. 4 b is a block diagram of an automatic washer containing recirculation hardware using height of water in the tub sump information to control the amount of water added during the spray pretreatment portion of the wash cycle.
FIG. 5 is a plot displaying the typical form by which the inlet valve is controlled based on measured information.
FIG. 6 is a block diagram of the general process for determining whether suds lock has occurred based on criteria and suds lock measure information.
FIG. 7 is a block diagram that shows the components which make up the drive system and the corresponding means for measuring the existence of suds lock through each component.
FIG. 8 is a block diagram that shows the measuring of the existence of suds lock through measuring the height of suds in the tub/basket.
FIG. 9 is a plot displaying the process by which the inlet valve is controlled based on measured information for the special case of having too much added water in the system at the start of the cycle.
FIG. 10 is a plot displaying the process by which the inlet valve is controlled based on measure information for the special case of never satisfying the measure due to some failure condition in the machine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 a washing machine is generally shown at 10 which has a tub 12 with a vertical agitator 14 therein, a water supply 15 , a power supply (not shown), an electrically driven motor 16 operably connected via a transmission 20 to the agitator 14 and controls 18 including a presettable sequential control device 22 for use in selectively operating the washing machine 10 through a programmed sequence of washing, rinsing and extracting steps. A water level setting control 18 is provided for use in conjunction with control device 22 . A fully electronic control having an electronic display (not shown) may be substituted for control device 22 . The control device 22 is mounted to a panel 24 of a console 26 on the washing machine 10 . A rotatable and perforate wash basket 28 is carried within the tub 12 and has an opening 36 which is accessible through an openable top lid 30 of the washer 10 . Tub ring 37 is positioned overlying wash basket 28 and tub 12 .
The invention disclosed herein is not necessarily limited to implementation in a vertical axis washing machine as shown in the figures. Inasmuch as the invention is a washing machine having a unique control and recirculating spray wash arrangement, the invention may be equally applied in a horizontal or tilted axis washing machine. Moreover, in the specific application of the invention in a vertical axis washing machine, the invention may be practiced in a variety of machines which may include different motor and transmission arrangements, pumps, recirculation arrangements, agitators or impellers, or controls.
A sump hose 40 is fluidly connected to a sump (not shown) contained in a lower portion of tub 12 for providing a wash fluid recirculating source. Pressure dome 42 receives the recirculating fluid which exits via recirculating spray nozzle hose 48 which is fluidly connected to recirculating spray nozzle 32 . A pressure sensor or transducer 46 detects fluid pressure within pressure dome 42 and provides an output signal via lines 47 to the control, the signal varying dependent upon the sensed dynamic pressure. A second air dome 50 having a deepfill pressure sensor or transducer optionally provides a second pressure signal indicating static pressure to the control via lines 52 .
As described herein, a pressure sensor may be a pressure switch having predetermined pressure levels that, within certain limits, will provide one or more signals to control 22 that a certain pressure has been achieved. Depending on the presence or absence of such signals, the control will receive and store or process such information, as is well known. Alternatively, a transducer may be used to sense pressure and provide a signal of varying frequency or voltage to control 22 indicating the pressure levels detected.
In FIG. 2 a schematic diagram further describes an example of a washing machine incorporating the present invention. Hot water inlet 11 and cold water inlet 13 are controlled by hot water valve 17 and cold water valve 19 , respectively. Valves 17 and 19 are selectably openable to provide fresh water to feed line 60 . A spray nozzle valve 21 is fluidly connected to feed line 60 for selectably providing fresh water to tub 12 when desired. This fresh water is delivered by fresh water spray nozzle 31 via fresh water hose 33 . Valves 17 and 19 are openable individually or together to provide a mix of hot and cold water to a selected temperature.
Upon opening one or both of valves 17 and 19 , fresh water is selectably provided to a series of dispenser valves via feed line 60 . Valve 62 selectably provides fresh water to detergent dispenser 63 , valve 64 selectably provides fresh water to bleach dispenser 65 , and valve 66 selectably provides fresh water to softening agent dispenser 67 .
As further shown in FIG. 2, the washing machine includes a wash liquid recirculation system. In order to recirculate wash liquid for the recirculating spray wash, tub sump 41 collects wash liquid and is fluidly connected to pump 23 by sump hose 40 . Pump 23 is selectably operational to pump liquid from tub sump 41 via pump outlet hose 25 either to recirculating hose 27 or drain hose 29 depending on the position of bidirectional valve 30 . Recirculating hose 27 provides recirculating wash liquid to pressure dome 42 , the wash liquid exiting the pressure dome 42 via recirculating spray nozzle hose 48 and being emitted to the wash basket 28 via recirculating spray nozzle 32 .
Pressure dome 42 provides a head of pressure varying dependent upon the amount of wash liquid contained in the recirculating wash system by maintaining a captured dome of air in communication with the recirculating wash liquid. The pressure dome 42 provides a channel for the captured air to keep in contact with pressure sensor 46 via pressure line 45 .
Pressure sensor 46 provides optionally either an on/off or a varying or dynamic signal to control 22 via lines 47 , the signal varying dependent on the sensed pressure of the recirculating wash liquid. Control 22 also optionally receives a static pressure signal from deepfill transducer dome 50 via lines 52 for signaling the level of wash liquid within wash tub 12 , however the invention disclosed herein may be practiced without use of a deepfill pressure dome. Control 22 is further operable to receive input signals via lines 49 , including signals from valves 21 , 62 , 64 and 66 providing on and off times for these valves.
By sensing the air pressure within pressure dome 42 , the amount of recirculating wash liquid in the washing machine may be inferred. This information is useful to determine the amount of free water in the washing machine during a recirculating wash. Thereby, the amount of clothing in the washing machine may be inferred, which information is useful in order to minimize water and energy usage during a spray pretreatment cycle, stain cycle or other recirculating wash cycle, and further during later or other portions of the cycle. Also, the suds lock condition, or absence thereof during portions of a cycle may be determined. Suds lock may be prevented by limiting recirculating wash liquid to slightly in excess of clothes saturation.
A basic process for the new control scheme of the spray pretreatment portion of the wash cycle is shown in the block diagram 100 in FIG. 3 . The process begins at the commencement of spray treatment 102 by starting monitoring of the suds lock algorithm 104 . The process simply either completes the full cycle if suds lock does not occur or skips through the rest of the pretreatment cycle and onto the next step 106 in the case that suds lock should occur. This process 100 is independent of the method by which the existence of suds lock is determined.
Several methods can be applied in order to ascertain the existence of suds lock. FIG. 4 a displays a block diagram 108 of the automatic washer containing recirculation hardware where a measure based on the flow rate of the wash liquid recirculation line is used to ascertain when water is added to the recirculation system. The flow rate can be measured in one of a number of known ways. A flow washer 68 contained in detergent dispenser valve 63 controls the flow rate within a predetermined range for a variety of predictable inlet water pressures. Limiting flow in this manner allows the flow rate to be inferred based upon the on time of the inlet valve. A flow meter may also be used. Finally, the deep fill rate may also be discerned.
This intermittent process is due to the dry clothes load absorbing water into the load and thus the system requiring more water to regain the necessary flow rate. A similar approach is shown in a block diagram 110 in FIG. 4 b which shows that determining when water needs to be added to the system can be performed by any of various techniques capable of measuring the height of the wash fluid in the sump portion of the tub. Alternatively, a pressure sensor may be used to determine whether one or more predetermined pressure levels have been reached. In either case, if the control determines that the necessary wash fluid amount recirculating within the washer is satisfied, the control discontinues adding water by intermittent closing of the water inlet valve.
Detecting Load Size During Pretreatment Portion of Cycle
Using either of these means shown in FIGS. 4 a or 4 b to control the process of adding water to the system, an alternating pattern of the times for the addition of water to the system and not adding water to the system can be gained. FIG. 5 shows such a typical pattern or profile 112 relating to the on and off periods of the inlet valve for the spray pretreatment portion of the automatic wash cycle, based on whether the water level or water pressure detecting means is satisfied. Preferably, the control determines the necessary amount of wash liquid as that amount which is slightly in excess of the saturation level for the clothes load.
Accordingly, as the pretreatment portion of the cycle proceeds as shown in FIG. 5, the control continually monitors the inlet on or off times or both on and off times, or the pressure or water level signals which are used to control the inlet on, off or on and off times. This information, as discussed later herein, may be used to determine whether the clothes washer is experiencing a suds lock condition or some other abnormal condition if the information is outside a certain expected range. As well, however, this information may be used to determine the load size being washed, so that the pretreatment cycle and later portions of the wash cycle may be altered and preferably optimized or adapted to effectively complete the cleaning and rinsing of the clothes, but no more in order to avoid suds lock.
Pretreatment Cycle Control Based on Load Size Measurement
By using the measure of load size during the pretreatment cycle, the rest of the pretreatment cycle can be optimized based on the load size information. After the desired water level or pressure is detected as initially satisfied by the control 22 , the washing machine is allowed to continue the normal pretreatment cycle where water is added to the system as requested by the control system for a first predetermined time. The control then identifies the load size in a manner as previously discussed. The inlet valve may be shut off regardless of whether water is called for by the control system when a second predetermined time is reached. This second predetermined time may be defined based on the load size measure. At this time, the pretreatment step is completed and the machine proceeds through the rest of the cycle. The process of not adding water will aid the system in avoiding suds lock which increases the performance of the cycle.
In another example of optimizing the rest of the pretreatment cycle based on the load size information, the control system determines the total water fill times at preselected intervals. Depending on the total water fill time, a preselected overall cycle time for pretreatment is performed, during which water may be added. The cycle is further optimized by taking into consideration the water level and cycle selected by the user, so that the washer may perform not only according to the load size detected but in accordance with the demands of the user.
Total Cycle Control based on Load Size Measurement
From the various means of determining load size during the pretreatment portion of the cycle, this information can be applied to control other portions of the cycle. In previous washers, the load size or water level input on the console is the input used to control the amount of water added to the system in the deep fill and the relative agitation rate based on the type of cycle chosen. In the present invention, the load size determined from the pretreatment step can be applied in a similar way to determine water amounts and control the agitation performed during the rest of the wash cycle. For example, the load size information can be used to determine the agitation length and rate, to determine the deep fill wash length, spin time and speed, the deep fill or spray rinse length, spin time and speed, or the number of rinses.
An automatic washer incorporating the present invention may preferably include traditional user control inputs such as cycle, water temperature and water level. Although the input by the consumer may be taken into consideration to affect the cleaning cycle, the control selectively processes the previously mentioned inlet on, off or on and off, water level or pressure information independently of such user input to determine the size of the clothes load. It is noted that the type of clothes, particularly the variety of materials providing the makeup of the clothes is not of critical importance once the pretreatment cycle is completed, since the load size information gained during the pretreatment cycle is all that is needed to continue the wash process. However, the user input may be considered as part of an algorithm such that the performance of the washer, for example the length of wash time, is not greatly different than consumer expectations for a selected input.
In another example of optimizing the rest of the wash cycle based on detected load size, it is a known problem in a vertical axis washer to turn over a large clothes load approaching 17 pounds during a deep fill wash. One difficulty is that after filling the washer to the maximum level and beginning agitation, the large items in the load such as sheets, tablecloths or towels may be displaced above the waterline by the agitator, which physically lowers the water level in the tub. The lowering of the water level in the tub can be anticipated by control 22 or detected via a pressure sensor 46 or 50 and compensated for by adding water to return to the maximum level.
Alternatively, to address the aforementioned problem, a delayed fill may be used. When the user selects a heavy duty cycle along with maximum water level, for example the water level in the deep fill wash is initially brought to a level slightly below the maximum. The clothes load will be partially submerged, with a portion of the load remaining dry or at most partially saturated on the surface. At this water level, the agitator is allowed to commence turning and will easily pull the dry clothing from the top of the load, moving the clothes down the center of the basket and up the outside in the normal motion. After an initial preselected period, long enough to allow the load to be fully wetted and largely submerged, the washing machine may be filled to the maximum level followed by additional agitation or while continuing to agitate. The preceding process assures that normal rollover of the wash load is achieved as quickly as possible despite the large load.
Suds Lock Measuring
FIG. 6 displays a block diagram 118 of the general process for determining whether suds lock has occurred based on selected criteria and suds lock measure information. This diagram is independent of chosen measurement technique. Several sets of criteria are satisfactory for the case of using information about the inlet water valve cycling information measurement of suds lock. The following table contains several functional criteria:
TABLE
Suds Lock Criteria Table for Inlet Water Valve Based Measures.
Suds Lock Measure
Suds Lock Criteria
Case (1)
t on (0)
10-20 sec.
Case (2)
t on (0)/(t on (1))
N
Case (3)
t on (0)/(t on (1) + t on (2))
N
Case (4)
t on (0)/(t on (1) + t on (2) + t on (3))
N
The optimum value for N is approximately 2. The algorithm also incorporates a minimum time, t min — check , which to start checking for suds lock to occur. This time could be set between 0 sec and 40 sec. In addition to satisfying the suds lock criteria, there also is a time t on — min which sets a minimum time of addition which it must be above to be considered as suds lock condition. Typical ranges for this are between 2 to 4 sec.
Other ways exist for detecting suds lock in the washing machine. FIG. 7 displays a block diagram 120 that shows the components which make up the drive system and the corresponding means for detecting the existence of suds lock through each component. For the basket, the means for detecting the existence of suds lock 122 may be summarized as follows.
A first suds lock detection method is by measurement of the basket RPM (by magnetic, optical or ultrasonic means) after the basket is brought up to normal operating speed. When basket reduces RPM by 70% from the steady state value, suds lock has occurred.
A second suds lock detection method is by measurement of the basket or tub acceleration after the basket is brought up to normal operating speed. Vibration of the basket or tub should be fairly constant or increasing during the spray pretreatment portion of the cycle unless suds lock occurs.
For the drive system, the means for detecting the existence of suds lock 124 may be summarized as follows.
A first suds lock detection method is by measuring the temperature of the clutch. When a suds lock condition occurs, the temperature of the clutch will increase significantly during suds lock condition. A second suds lock detection method is by measuring torque on drive components. When a suds lock condition occurs, a significant drop in torque will occur.
For the motor, motor control and supply power, the means for detecting the existence of suds lock 126 , 128 and 129 may be summarized as follows. A first suds lock detection method is by measurement of motor RPM using a tachometer which is built into the motor. When the basket reduces RPM by 70% from steady state value, suds lock has occurred. A second suds lock detection method is by measurement of the current or wattage going to the motor measured at motor. When current or wattage increase by a given percentage, suds lock has occurred.
A third suds lock detection method is by measurement of total current or wattage going to the entire machine, since motor current is by far most significant component. When current or wattage increase by a given percentage, suds lock has occurred. A fourth suds lock detection method is by measurement using an opto coupler for obtaining information about drop in the torque draw of the motor. A fifth suds lock detection method is by measurement using a ferrite core sensor for obtaining information about the drop in the torque draw of the motor. In the latter two methods, when torque drops by a given amount, suds lock has occurred.
In addition to measurements which can be made on the drive system, measurement of the height of the suds in the system can be made. FIG. 8 displays a block diagram 130 illustrating the components which are to be observed, that is the tub or the basket, and the means for detecting the existence of suds lock through each component. Specific embodiments of such techniques to measure the height of the suds during a spray pretreatment portion of the wash cycle may include a) providing a conductivity strip along the side of the basket; b) ultrasonic measurement, or c) optical measurement. Feedback provided to the control in each case indicates an oversuds condition, from which it may be inferred that suds lock has occurred.
Special Conditions
In addition to the occurrence of suds lock, there are a few special conditions which can as be detected by the control. Although other detection means may be used, in these examples the control monitors the inlet valve on time over a prescribed check time. One such condition occurs when the machine is started in pretreatment portion of the cycle with much more water than necessary. FIG. 9 displays the process by which the inlet valve is controlled based on measure information for the special case of having too much added water in the system at the start of the cycle. This condition can occur for the reasons that the user starts the machine into normal deepfill (without prefill), then stops the machine after a good amount of water has filled the machine (over 2 gallons) and the machine is switched and restarted in pretreatment cycle; the user puts a very soggy clothes load into the machine or the user physically adds water into the machine with the load.
For all these conditions, the time by which the machine calls for water will be very small. Thus by monitoring the time by which the control system calls for water with respect to some length of checking time, this condition can be ascertained. If such a case should occur, the pretreatment cycle may be ended and the rest of the cycle is continued.
Another special condition can be detected by the primary means of monitoring the inlet valve on time over a prescribed check time. One such condition may occur when the washing machine is in the recirculating spray pretreatment portion of the cycle and the machine continuously calls for water without stopping.
FIG. 10 displays a graphic depiction 140 of the process by which the inlet valve is controlled based on measured information in the special case where the recirculation flow in the system at the start of the cycle is not satisfied for some finite period of time. In addition to sensing this condition based on the recirculation flow being not satisfied, additional information can be gained from the deepfill pressure transducer for the air dome 50 in the tub.
For the case where the deepfill pressure transducer does not sense the existence of a sizable amount of water in the tub, a variety of machine conditions may be a cause. Under the category of washing machine component failures, the failures can include a sizable leak in the tub or the recirculation or drain hose system; one or more bad inlet valves not adding water to system, or a recirculation diverter valve failed or stuck in the drain direction. Under the category of non-washing machine component failures might be a long fill due to very low line pressure.
For the case where the deepfill pressure transducer is sensing the existence of a sizable amount of water in the tub, the following machine conditions may be a cause, all of which are washing machine component failures. The failures can include a bad recirculation pressure switch, a pump or motor failure, a severe recirculation line clog or the recirculation pressure hose is disconnected.
In case of such failure, the control 22 will end the cycle and indicate the failure condition to the consumer.
As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that we wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of the contribution to the art.
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This invention relates a control for an automatic washer incorporating a spray pretreatment or stain care cycle. In order to manage the occurrence of the condition of suds lock, the state of the washing machine related to the suds lock condition during spray pretreatment is determined by one or more of a number of methods. With this information concerning the state of the spray pretreatment process, the occurrence of suds lock can be ascertained and the cycle can be controlled accordingly to minimize negative effects resulting from a prolonged suds lock condition. Additionally, with certain information related to the occurrence of suds lock, steps can be taken during the spray pretreatment portion of the cycle to avoid the condition of suds lock altogether. Using the same primary process for measuring suds lock, load size can also be ascertained. Information about load size can be used to control the wash cycle.
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CROSS REFERENCE TO RELATED APPLICATION
This is a continuation-in-part of Ser. No. 08/087,510 filed Jul. 2, 1993, now abandoned, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates a method of reducing levels of TNF.sub.α in a mammal and to compounds and compositions useful therein.
TNF.sub.α, or tumor necrosis factor α, is a cytokine which is released primarily by mononuclear phagocytes in response to various immunostimulators. Excessive or unregulated TNF.sub.α production has been implicated in a number of disease conditions. These include endotoxemia and/or toxic shock syndrome (Tracey et al., Nature 330, 662-664 (1987) and Hinshaw et al., Circ. Shock 30, 279-292 (1990)); cachexia (Dezube et al., Lancet, 335 (8690), 662 (1990)); and Adult Respiratory Distress Syndrome where TNF.sub.α concentration in excess of 12,00 pg/ml have been detected in pulmonary aspirates from ARDS patients {Millar et al., Lancet 2(8665), 712-714 (1989)}. Systemic infusion of recombinant TNF.sub.α also resulted in changes typically seen in ARDS {Ferrai-Baliviera et al., Arch. Surg. 124(12), 1400-1405 (1989)}.
TNF.sub.α appears to be involved in bone resorption diseases, including arthritis where it has been determined that when activated, leukocytes will produce a bone-resorbing activity, and data suggest that TNF.sub.α contributes to this activity. {Bertolini et al., Nature 319, 516-518 (1986) and Johnson et al., Endocrinology 124(3), 1424-1427 (1989).}It has been determined that TNF.sub.α stimulates bone resorption and inhibits bone formation in vitro and in vivo through stimulation of osteoclast formation and activation combined with inhibition of osteoblast function. Although TNF.sub.α may be involved in many bone resorption diseases, including arthritis, the most compelling link with disease is the association between production of TNF.sub.α by tumor or host tissues and malignancy associated hypercalcemia {Calci. Tissue Int. (US) 46(Suppl.), S3-10 (1990)}. In Graft versus Host Reaction, increased serum TNF.sub.α levels have been associated with major complication following acute allogenic bone marrow transplants {Holler et al., Blood, 75(4), 1011-1016 (1990)}.
Cerebral malaria is a lethal hyperacute neurological syndrome associated with high blood levels of TNF.sub.α and the most severe complication occurring in malaria patients. Levels of serum TNF.sub.α correlated directly with the severity of disease and the prognosis in patients with acute malaria attacks {Grau et al., N. Engl. J. Med. 320(24), 1586-1591 (1989)}.
TNF.sub.α also plays a role is the area of chronic pulmonary inflammatory diseases. The deposition of silica particles leads to silicosis, a disease of progressive respiratory failure caused by a fibrotic reaction. Antibody to TNF.sub.α completely blocked the silica-induced lung fibrosis in mice {Pignet et al., Nature, 344:245-247 (1990)}. High levels of TNF.sub.α production (in the serum and in isolated macrophages) have been demonstrated in animal models of silica and asbestos induced fibrosis {Bissonnette et al., Inflammation 13(3), 329-339 (1989)}. Alveolar macrophages from pulmonary sarcoidosis patients have also been found to spontaneously release massive quantities of TNF.sub.α as compared with macrophages from normal donors {Baughman et al., J. Lab. Clin. Med. 115(1), 36-42. (1990)}. TNF.sub.α is also implicated in the inflammatory response which follows reperfusion, called reperfusion injury, and is a major cause of tissue damage after loss of blood flow {Vedder et al., PNAS 87, 2643-2646 (1990)). TNF.sub.α also alters the properties of endothelial cells and has various pro-coagulant activities, such as producing an increase in tissue factor pro-coagulant activity and suppression of the anticoagulant protein C pathway as well as down-regulating the expression of thrombomodulin {Sherry et al., J. Cell Biol. 107, 1269-1277 (1988)}. TNF.sub.α has pro-inflammatory activities which together with its early production (during the initial stage of an inflammatory event) make it a likely mediator of tissue injury in several important disorders including but not limited to, myocardial infarction, stroke and circulatory shock. Of specific importance may be TNF.sub.α -induced expression of adhesion molecules, such as intercellular adhesion molecule (ICAM) or endothelial leukocyte adhesion molecule (ELAM) on endothelial cells {Munro et al., Am. J. Path. 135(1), 121-132 (1989)}.
Moreover, it now is known that TNF.sub.α is a potent activator of retrovirus replication including activation of HIV-1. {Duh et al. , Proc. Nat. Acad. Sci. 86, 5974-5978 (1989); Poll et al., Proc. Nat. Acad. Sci. 87, 782-785 (1990); Monto et al., Blood 79, 2670 (1990); Clouse et al., J. Immunol. 142, 431-438 (1989); Poll et al., AIDS Res. Hum. Retrovirus, 191-197 (1992)}. At least three types or strains of HIV have been identified, i.e., HIV-1, HIV-2 and HIV-3. As a consequence of HIV infection, T-cell mediated immunity is impaired and infected individuals manifest severe opportunistic infections and/or unusual neoplasms. HIV entry into the T lymphocyte requires T lymphocyte activation. Other viruses, such as HIV-1, HIV-2 infect T lymphocytes after T cell activation and such virus protein expression and/or replication is mediated or maintained by this T cell activation. Once an activated T lymphocyte is infected with HIV, the T lymphocyte must continue to be maintained in an activated state to permit HIV gene expression and/or HIV replication. Monokines, specifically TNF.sub.α, are implicated in activated T-cell mediated HIV protein expression and/or virus replication by playing a role in maintaining T lymphocyte activation.
AIDS results from the infection of T lymphocytes with Human Immunodeficiency Virus (HIV). At least three types or strains of HIV have been identified, i.e., HIV-1, HIV-2 and HIV-3. As a consequence of HIV infection, T-cell mediated immunity is impaired and infected individuals manifest severe opportunistic infections and/or unusual neoplasms. HIV entry into the T lymphocyte requires T lymphocyte activation. Other viruses, such as HIV-1, HIV-2 infect T lymphocytes after T cell activation and such virus protein expression and/or replication is mediated or maintained by such T cell activation. Once an activated T lymphocyte is infected with HIV, the T lymphocyte must continue to be maintained in an activated state to permit HIV gene expression and/or HIV replication. Monokines, specifically TNF.sub.α, are implicated in activated T-cell mediated HIV protein expression and/or virus replication by playing a role in maintaining T lymphocyte activation. Therefore, interference with monokine activity such as by inhibition of monokine production, notably TNF.sub.α, in an HIV-infected individual aids in limiting the maintenance of T lymphocyte caused by HIV infection. Monocytes, macrophages, and related cells, such as kupffer and glial cells, have also been implicated in maintenance of the HIV infection. These cells, like T cells, are targets for viral replication and the level of viral replication is dependent upon the activation state of the cells. (Rosenberg et al., The Immunopathogenesis of HIV Infection, Advances in Immunology, 57 (1989)). Monokines, such as TNF.sub.α, have been shown to activate HIV replication in monocytes and/or macrophages {Poli et al. Proc. Natl. Acad. Sci., 87, 782-784 (1990)}, therefore, inhibition of monokine production or activity aids in limiting HIV progression as stated above for T cells. Additional studies have identified TNF.sub.α as a common factor in the activation of HIV in vitro and has provided a clear mechanism of action via a nuclear regulatory protein found in the cytoplasm of cells (Osborn, et al., PNAS 86 2336-2340). This evidence suggests that a reduction of TNF.sub.α synthesis may have an antiviral effect in HIV infections, by reducing the transcription and thus virus production.
AIDS viral replication of latent HIV in T cell and macrophage lines can be induced by TNF.sub.α {Folks et al., PNAS 86, 2365-2368 (1989)}. A molecular mechanism for the virus inducing activity is suggested by TNF.sub.α 's ability to activate a gene regulatory protein (NFkB) found in the cytoplasm of cells, which promotes HIV replication through binding to a viral regulatory gene sequence (LTR) {Osborn et al., PNAS 86, 2336-2340 (1989)}. TNF.sub.α in AIDS associated cachexia is suggested by elevated serum TNF.sub.α and high levels of spontaneous TNF.sub.α production in peripheral blood monocytes from patients {Wright et al. J. Immunol. 141(1), 99-104 (1988)}.
TNF.sub.α has been implicated in various roles with other viral infections, such as the cytomegalia virus (CMV), influenza virus, adenovirus, and the herpes family of viruses for similar reasons as those noted.
Efforts directed to the suppression of the effects of TNF.sub.α have ranged from the utilization of steroids such as dexamethasone and prednisolone to the use of both polyclonal and monoclonal antibodies {Beutler et al., Science 234, 470-474 (1985); WO 92/11383}.
DETAILED DESCRIPTION
The present invention is based on the discovery that a class of non-polypeptide imides more fully described herein appear to inhibit the action of TNF.sub.α.
A first aspect of the present invention pertains to compounds of the formula: ##STR1## in which Z is ##STR2##
in which
R 1 is the divalent residue of (i) pyridine, (ii) pyrrolidine, (iii) imidizole, (iv) naphthalene, (v) thiophene, or (vi) a straight or branched alkane of 2 to 6 carbon atoms, unsubstituted or substituted with phenyl or phenyl substituted with nitro, cyano, trifluoromethyl, carbethoxy, carbomethoxy, carbopropoxy, acetyl, carbamyl, acetoxy, carboxy, hydroxy, amino, alkyl of 1 to 4 carbon atoms, alkoxy of 1 to 4 carbon atoms, or halo, wherein the divalent bonds of said residue are on vicinal ring carbon atoms;
R 2 is --CO-- or --SO 2 --;
R 3 is (i) phenyl substituted with nitro, cyano, trifluoromethyl, carbethoxy, carbomethoxy, carbopropoxy, acetyl, carbamoyl, acetoxy, carboxy, hydroxy, amino, alkyl of 1 to 4 carbon atoms, alkoxy of 1 to 4 carbon atoms, or halo, (ii) pyridyl, (iii) pyrrolyl, (iv) imidazolyl, (v) naphthyl, (vi) thienyl, (vii) quinolyl, (viii) furyl, or (ix) indolyl;
R 4 is alanyl, arginyl, glycyl, phenylglycyl, histidyl, leucyl, isoleucyl, lysyl, methionyl, prolyl, sarcosyl, seryl, homoseryl, threonyl, thyronyl, tyrosyl, valyl, benzimidol-2-yl, benzoxazol-2-yl, phenylsulfonyl, methylphenylsulfonyl, or phenylcarbamoyl; and
n has a value of 1, 2, or 3.
More particularly, a first preferred subclass pertains to compounds of the formula: ##STR3##
in which R 1 is the divalent residue of (i) pyridine, (ii) pyrrolidine, (iii) imidizole, (iv) naphthalene, (v) thiophene, or (vi) a straight or branched alkane of 2 to 6 carbon atoms, unsubstituted or substituted with phenyl or phenyl substituted with nitro, cyano, trifluoromethyl, carbethoxy, carbomethoxy, carbopropoxy, acetyl, carbamyl, acetoxy, carboxy, hydroxy, amino, alkyl of 1 to 4 carbon atoms, alkoxy of 1 to 4 carbon atoms, or halo, wherein the divalent bonds of said residue are on vicinal ring carbon atoms; R 2 is --CO-- or --SO2--; and n has a value of 1, 2, or 3.
Preferred compounds of Formula IA include those in which R 1 is a divalent residue of pyridine, naphthalene or imidazole, R 2 is --CO--, and n is 2.
A second preferred subclass pertains to compounds of the formula: ##STR4##
in which R 3 is (i) phenyl substituted with nitro, cyano, trifluoromethyl, carbethoxy, carbomethoxy, carbopropoxy, acetyl, carbamoyl, acetoxy, carboxy, hydroxy, amino, alkyl of 1 to 4 carbon atoms, alkoxy of 1 to 4 carbon atoms, or halo, (ii) pyridyl, (iii) pyrrolyl, (iv) imidazolyl, (v) naphthyl, (vi) thienyl, (vii) quinolyl, (viii) furyl, (ix) indolyl, or (x) ##STR5##
in which R 8' is hydrogen or alkyl of 1 to 4 carbon atoms, and R 9' is hydrogen, alkyl of 1 to 4 carbon atoms, COR 10 or --SO 2 R 10 in which R 10 is hydrogen alkyl of 1 to 4 carbon atoms, or phenyl; and
n has a value of 1, 2, or 3.
Preferred compounds of Formula IB are those wherein R 3 is trifluoromethylphenyl, cyanophenyl, methoxyphenyl, fluorophenyl, or furyl, and n is 2.
A third preferred subclass pertains to compounds of the formula: ##STR6##
in which R 4 is alanyl, arginyl, glycyl, phenylglycyl, histidyl, leucyl, isoleucyl, lysyl, methionyl, prolyl, sarcosyl, seryl, homoseryl, threonyl, thyronyl, tyrosyl, valyl, benzimidol-2-yl, benzoxazol-2-yl, phenylsulfonyl, methylphenylsulfonyl, or phenylcarbamoyl, and n has a value of 1, 2, or 3.
Preferred compounds of Formula IC are those wherein R 4 is phenylsulfonyl or 2-amino-3-phenylpropanoyl and n is 2.
A second aspect of the present invention pertains to compounds of the formula: ##STR7##
in which R 5 is (i) o-phenylene, unsubstituted or substituted with nitro, cyano, trifluoromethyl, carbethoxy, carbomethoxy, carbopropoxy, acetyl, carbamoyl, acetoxy, carboxy, hydroxy, amino, alkyl of 1 to 4 carbon atoms, alkoxy of 1 to 4 carbon atoms, or halo, or (ii) the divalent residue of pyridine, pyrrolidine, imidizole, naphthalene, or thiophene, wherein the divalent bonds are on vicinal ring carbon atoms;
R 6 is --CO--, --CH 2 --, or --SO 2 --;
R 7 is (i) hydrogen, (ii) straight or branched alkyl of 1 to 6 carbon atoms, (iii) pyridyl, (iv) phenyl or phenyl substituted with one or two substituents selected from the group consisting of nitro, cyano, trifluoromethyl, carbethoxy, carbomethoxy, carbopropoxy, acetyl, carbamoyl, acetoxy, carboxy, hydroxy, amino, alkyl of 1 to 4 carbon atoms, alkoxy of 1 to 4 carbon atoms, or halo, (v) alkyl of 1 to 4 carbon atoms, (vi) benzyl unsubstituted or substituted with one or two substituents selected from the group consisting of nitro, cyano, trifluoromethyl, carbethoxy, carbomethoxy, carbopropoxy, acetyl, carbamoyl, acetoxy, carboxy, hydroxy, amino, alkyl of 1 to 4 carbon atoms, alkoxy of 1 to 4 carbon atoms, or halo, and (vi) --(C m H 2m )--CO--R 11 .
each of R 11 and R 12 , independently of the other, is --OH or ##STR8##
each of n and m, independently of the other, has a value of 0, 1, 2, or 3;
R 8' is hydrogen or alkyl of 1 to 4 carbon atoms; and
R 9' is hydrogen, alkyl of 1 to 4 carbon atoms, --COR 10 , or --SO 2 R 10 in which is hydrogen, alkyl of 1 to 4 carbon atoms, or phenyl.
A first preferred subclass of Formula II pertains to compounds of the formula: ##STR9##
in which R 5 is (i) o-phenylene, unsubstituted or substituted with nitro, cyano, trifluoromethyl, carbethoxy, carbomethoxy, carbopropoxy, acetyl, carbamoyl, acetoxy, carboxy, hydroxy, amino, alkyl of 1 to 4 carbon atoms, alkoxy of 1 to 4 carbon atoms, or halo, or (ii) the divalent residue of pyridine, pyrrolidine, imidizole, naphthalene, or thiophene, wherein the divalent bonds are on vicinal ring carbon atoms;
R 6 is --CO--, --CH 2 --, or --SO 2 --;
R 7 is (i) hydrogen, (ii) straight or branched alkyl of 1 to 6 carbon atoms, (iii) pyridyl, (iv) phenyl or phenyl substituted with one or two substituents selected from the group consisting of nitro, cyano, trifluoromethyl, carbethoxy, carbomethoxy, carbopropoxy, acetyl, carbamoyl, acetoxy, carboxy, hydroxy, amino, alkyl of 1 to 4 carbon atoms, alkoxy of 1 to 4 carbon atoms, or halo, (v) imidazol-4-yl-methyl, and (vi) ##STR10## each of n and m, independently of the other, has a value of 0, 1, 2, or 3; each of R 8 and R 8' , independently of the other, is hydrogen or alkyl of 1 to 4 carbon atoms; and each of R 9 and R 9' , independently of the other, is hydrogen, alkyl of 1 to 4 carbon atoms, --COR 10 or --SO 2 R 10 in which R 10 is hydrogen, alkyl of 1 to 4 carbon atoms, or phenyl.
Preferred compounds of Formula IIA are those in which R 5 is o-phenylene, R 6 is --CO--; R 7 is phenyl, substituted phenyl or pyridyl; n is 0 or 1, and each of R 8 and R 9 is hydrogen.
A second preferred subclass of Formula II pertains to compounds of the formula: ##STR11##
in which R 5 is (i) o-phenylene, unsubstituted or substituted with nitro, cyano, trifluoromethyl, carbethoxy, carbomethoxy, carbopropoxy, acetyl, carbamoyl, acetoxy, carboxy, hydroxy, amino, alkyl of 1 to 4 carbon atoms, alkoxy of 1 to 4 carbon atoms, or halo, or (ii) the divalent residue of pyridine, pyrrolidine, imidizole, naphthalene, or thiophene, wherein the divalent bonds are on vicinal ring carbon atoms;
R 6 is --CO--, --CH 2 --, or --SO 2 --;
R 7 is (i) hydrogen, (ii) straight or branched alkyl of 1 to 6 carbon atoms, (iii) pyridyl, (iv) phenyl or phenyl substituted with one or two substituents selected from the group consisting of nitro, cyano, trifluoromethyl, carbethoxy, carbomethoxy, carbopropoxy, acetyl, carbamoyl, acetoxy, carboxy, hydroxy, amino, alkyl of 1 to 4 carbon atoms, alkoxy of 1 to 4 carbon atoms, or halo, (v) alkyl of 1 to 4 carbon atoms, (vi) benzyl unsubstituted or substituted with one or two substituents selected from the group consisting of nitro, cyano, trifluoromethyl, carbethoxy, carbomethoxy, carbopropoxy, acetyl, carbamoyl, acetoxy, carboxy, hydroxy, amino, alkyl of 1 to 4 carbon atoms, alkoxy of 1 to 4 carbon atoms, or halo, and (vi) --(C m H 2 m)--CO-R 11 in which R 11 is --OH or ##STR12##
each of n and m, independently of the other, has a value of 0, 1, 2, or 3;
R 8' is hydrogen or alkyl of 1 to 4 carbon atoms; and
R 9' is hydrogen, alkyl of 1 to 4 carbon atoms, --COR 10 , or --SO 2 R 10 in which R 10 is hydrogen, alkyl of 1 to 4 carbon atoms, or phenyl.
Preferred compounds of Formula IIB are those in which R 5 is o-phenylene, R 6 is --CO--; R 7 is phenyl, substituted phenyl or pyridyl; and n is 0 or 1.
Typical compounds of this invention include 2-(2,6-dioxo-3-piperidinyl)-4-azaisoindoline-1,3-dione, 2-(2,6-dioxo-3-piperidinyl)-benzo[e]isoindoline-1,3-dione, 5-(2,6-dioxo-3-piperidinyl)-pyrrolo[3,4-d]imidazole-4,6-dione, 3-(trifluoromethylphenylcarboxamido)piperidine-2,6-dione,3-(cyanophenylcarboxamido) piperidine-2,6-dione, 3-(methoxyphenylcarboxamido) piperidine-2,6-dione, 3-(3-pyridylcarboxamido)-piperidine-2,6-dione, 3- (2-furylcarboxamido) piperidine-2,6-dione, 3-phenylsulfonamidopiperidine-2,6-dione, 3-(2-amino-3-phenylpropaneamido)-piperidine-2,6-dione, 2-phthalimido-2-phenylacetamide, 3-phthalimido-3-phenylpropanamide, 2-phthalimido-3-phenylpropanamide, 2-phthalimido-3-(4hydroxy)phenylpropanamide, 3-phthalimido-3-phenylpropionic acid, 2-phthalimido-2-(4-hydroxyphenyl)acetic acid, 2-phthalimido-2-phenylacetic acid, 2-phthalimido-2-(4-fluorophenyl)acetic acid, 2-phthalimido-2-(2-fluorophenyl)acetic acid, 2-phthalimido-2-(4-fluorophenyl)acetamide, 2-phthalimido-3-phenylpropionic acid, 2-phthalimido-4-methylpentanoic acid, 3-phenylcarboxamidopiperidine-2,6-dione, 2-phthalimidoacetamide, 3-phthalimidopropanamide, 3-phthalimidoimidazoline-2,5-dione, 3-phenylcarboxamidopropanamide, 2-phthalimido-3-carbamoylpropionic acid, 2-(1,3-dioxo-4-azaisoindolinyl)-3-carbamoylpropionic acid, 3-(1,3-dioxo-4-azaisoindolinyl)piperidine-2,6-dione, 2 -(1,3-dioxo-4-azaisoindolinyl)-acetamide, 3-phthalimido-3-carbamoylpropionic acid, 4-phthalimidobutyramide, and 4 -phthalimidobutyric acid.
The term alkyl as used herein denotes a univalent saturated branched or straight hydrocarbon chain. Unless otherwise stated, such chains can contain from 1 to 18 carbon atoms. Representative of such alkyl groups are methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl, tertbutyl, pentyl, isopentyl, neopentyl, tert-pentyl, hexyl, isohexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, and the like. When qualified by "lower", the alkyl group will contain fro 1 to 6 carbon atoms. The same carbon content applies to the parent term "alkane" and to derivative terms such as "alkoxy".
The compounds can be used, under the supervision of qualified professionals, to inhibit the undesirable effects of TNF.sub.α. The compounds can be administered orally, rectally, or parenterally, alone or in combination with other therapeutic agents including antibiotics, steroids, etc., to a mammal in need of treatment. Oral dosage forms include tablets, capsules, dragees, and similar shaped, compressed pharmaceutical forms. Isotonic saline solutions containing 20-100 mg/ml can be used for parenteral administration which includes intramuscular, intrathecal, intravenous and intraarterial routes of administration. Rectal administration can be effected through the use of suppositories formulated from conventional carriers such as cocoa butter.
Dosage regimens must be titrated to the particular indication, the age, weight, and general physical condition of the patient, and the response desired but generally doses will be from about 10 to about 500 mg/day as needed in single or multiple daily administration. In general, an initial treatment regimen can be copied from that known to be effective in interfering with TNF.sub.α activity for other TNF.sub.α mediated disease states by the compounds of the present invention. Treated individuals will be regularly checked for T cell numbers and T4/T8 ratios and/or measures of viremia such as levels of reverse transcriptase or viral proteins, and/or for progression of monokine-mediated disease associated problems such as cachexia or muscle degeneration. If no effect is soon following the normal treatment regimen, then the amount of monokine activity interfering agent administered is increased, e.g., by fifty percent a week.
The compounds of the present invention also can be used topically in the treatment or prophylaxis of topical disease states mediated or exacerbated by excessive TNF.sub.α production, respectively, such as viral infections, such as those caused by the herpes viruses, or viral conjunctivitis, etc.
The compounds also can be used in the veterinary treatment of mammals other than in humans in need of inhibition of TNF.sub.α production. TNF.sub.α mediated diseases for treatment, therapeutically or prophylactically, in animals include disease states such as those noted above, but in particular viral infections. Examples include feline immunodeficiency virus, equine infectious anaemia virus, caprine arthritis virus, visna virus, and maedi virus, as well as other lentiviruses.
Certain of these compounds possess centers of chirality and can exist as optical isomers. Both the racemates of these isomers and the individual isomers themselves, as well as diastereomers when then are two chiral centers, are within the scope of the present invention. The racemates can be used as such or can be separated into their individual isomers mechanically as by chromatography using a chiral absorbant. Alternatively, the individual isomers can be prepared in chiral form or separated chemically from a mixture by forming salts with a chiral acid, such as the individual enantiomers of 10-camphorsulfonic acid, camphoric acid, alpha-bromocamphoric acid, methoxyacetic acid, tartaric acid, diacetyltartaric acid, malic acid, pyrrolidone-5-carboxylic acid, and the like, and then freeing one or both of the resolved bases, optionally repeating the process, so as obtain either or both substantially free of the other; i.e., in a form having an optical purity of >95%.
The compounds can be prepared using methods which are known in general for the preparation of imides. However, the present invention also pertains to an improvement in the formation of the final compounds, as discussed below in greater detail.
An N-alkoxycarbonylimide and an amine thus are allowed to react in the presence of a base such as sodium carbonate or sodium bicarbonate substantially as described by Shealy et al., Chem. & Ind., (1965) 1030-1031) and Shealy et al., J. Pharm. Sci. 57, 757-764 (1968) to yield the N-substituted imide. Alternatively, a cyclic acid anhydride can be reacted with an appropriate amine to form an imide. Formation of a cyclic imide also can be accomplished by refluxing a solution of an appropriately substituted dicarboxylic acid monoamide in anhydrous tetrahydrofuran with N,N'-carbonyldiimidazole. In contrast to prior art methods which produced a yield of less than 50%, this reaction produces yields in excess of 60%, in some cases greater than 90%. This reaction also has broader applicability, being useful not only in the preparation of compounds of the present invention but also in the preparation of known compounds such as thalidomide.
Inhibition of TNF.sub.α by these compounds can be conveniently assayed using anti-TNF.sub.α antibodies. For example, plates (Nunc Immunoplates, Roskilde, DK) are treated with 5 μg/mL of purified rabbit anti-TNF.sub.α antibodies at 4° C. for 12 to 14 hours. The plates then are blocked for 2 hours at 25° C. with PBS/0.05% Tween containing 5 mg/mL BSA. After washing, 100 μL of unknowns as well as controls are applied and the plates incubated at 4° C. for 12 to 14 hours. The plates are washed and assayed with a conjugate of peroxidase (horseradish) and mouse anti-TNF.sub.α monoclonal antibodies, and the color developed with o-phenylenediamine in phosphatecitrate buffer containing 0.012% hydrogen peroxide and read at 492 nm.
The following examples will serve to further typify the nature of this invention but should not be construed as a limitation in the scope thereof, which scope is defined solely by the appended claims.
EXAMPLE 1
A stirred suspension of (S)-glutamine (14.6 g, 100 mmol) and 2,3-pyridinedicarboxylic anhydride (14.9 g, 100 mmol) in 100 mL of acetic acid is heated and refluxed for 1 hour. The reaction solution is cooled to form a solid. The solid is removed by filtration and washed with acetic acid to yield 7.11 g (26%) of 2-(1,3-dioxo-4-azaisoindolin-2yl)glutaramic acid. The product can be further purified by slurring in 700 mL of refluxing ethanol, cooling, filtering, and drying to produce a white powder with a melting point of 222°-226° C.; 1 H NMR (DMSO-d 6 ) δ 13.25 (br s, 1 H, COOH), 9.04 (dd, 1 H, J=1.2, 4.9 Hz, pyr), 8.37 (dd, 1 H, J =1.2, 7.8 Hz, pyr), 7.85 (dd, 1 H, J=4.9, 7.8 Hz, pyr), 7.20 (s, 1 H, CONH 2 ), 6.73 (s, 1 H, CONH 2 ), 4.83 (dd, 1 H, J=10.2, 4.8 Hz, CHN), 2.55-1.90 (m, 4 H, CH 2 CH 2 ); 13 C NMR (DMSO-d 6 ) δ1173.22, 170.21, 165.8, 165.7, 155.4, 150.9, 131.7, 128.3, 126.9, 51.5, 31.4, 24.0.
Utilization of asparagine in place of glutamine produces 2-(1,3-dioxo-4-azaisoindolin-2-yl)-malonamic acid.
By substituting equivalent amounts of 2,3-naphthalenedicarboxylic anhydride and 4,5-imidazoledicarboxylic anhydride for 2,3-pyridinedicarboxylic anhydride in the foregoing procedure, there are respectively obtained 2-(1,3-dioxobenzo[e]isoindolin-2-yl)glutaramic acid and 2-(4,6-dioxopyrrolo[3,4-d]imidazol-5-yl)glutaramic acid.
EXAMPLE 2
A stirred suspension of 1.39 g, 5.01 mmol, of 2-(1,3-dioxo-4-azaisoindolin-2-yl)glutaramic acid (see Example 1), N,N'-carbonyldiimidazole (0.890 g, 5.49 mmoL) and N,N-dimethylaminopyridine (0.005 g, 0.04 mmoL) in 20 mL of tetrahydrofuran is refluxed for 15 hours. The reaction slurry is cooled and the solid removed by filtration and washed with minimal tetrahydrofuran. 2-(2,6-Dioxo-3-piperidinyl)-4-azaisoindoline-1,3-dione (0.859 g, 66%) is recovered as a white powder. 1 H NMR (DMSO-d6) 6 11.18 (s, 1 H, NHCO), 9.04 (d, 1 H, J=5.0 Hz, pyr), 8.39 (d, 1 H, J=7.7 Hz, pyr), 7.86 (dd, 1 H, J=5.0, 7.7 Hz, pyr), 5.25 (dd, 1 H, J=15.3, 13 Hz, 1 H, CHCO), 3.05-2.75 (m, 1 H, CH 2 CO), 2.75 (m, 2 H, CH 2 CO, CH 2 ), 2.20-2.00 (m, 1 H, CH 2 CO, CH 2 ); 13 C NMR (DMSO-d6) 6 172.6, 169.6, 165.4, 155.3, 150.8, 131.7, 128.2, 126.9, 49.0, 30.8, 21.8. Anal. Calcd for Cl 2 H 9 N 3 O 4 . Theory 55.60, 3.50, 16.21. Found 55.50, 3.53, 16.11.
Substitution of 2-(1,3-dioxo-4-azaisoindolin-2-yl)malonamic acid in the foregoing procedure yields 2-(2,5-dioxo-3-pyrrolidinyl)-4-azaisoindoline-1,3-dione.
By substituting equivalent amounts of 2-(1,3-dioxobenzo[e]isoindolin-2-yl)glutaramic acid and 2-(4,6-dioxopyrrolo[3,4-d]imidazol-5-yl)glutaramic acid in the foregoing procedure, there are respectively obtained 2-(2,6-dioxo-3-piperidinyl)-benzo[e]isoindoline-1,3-dione and 5-(2,6-dioxo-3-piperidinyl)-pyrrolo[3,4-d]imidazole-4,6-dione.
EXAMPLE 3
A solution of L-glutamine (2.92 g, 20.0 mmoL) and sodium hydroxide (20 mmoL) in water is added to a stirred solution of phenylisocyanate (2.4 g, 2.2 mL, 20 mmoL) in acetonitrile (40 mL). The reaction mixture is stirred for 45 hours and is partially concentrated to remove acetonitrile. The reaction mixture is washed with ethyl acetate (2 x 25 mL each). The pH of the reaction mixture is adjusted to 1-2 with 4N hydrochloric acid. The slurry of the reaction mixture is filtered and the solid washed and dried to yield 4.70 g of N-phenyl-N'-(4-carboxybutyramide)urea (89%) as a white powder.
By substituting 4-trifluoromethylphenylisocyanate, 3-cyanophenylisocyanate, 2-methoxyphenylisocyanate, fur-2-ylisocyanate, and pyrid-3-ylisocyanate for phenylisocyanate in the foregoing procedure, there are respectively obtained N-(4-trifluoromethylphenyl)-N'-(4-carboxybutyramide)urea, N-(3-cyanophenyl)-N'-(4-carboxybutyramide)urea, N-(2-methoxy-phenyl)-N'-(4-carboxybutyramide)urea, N-(fur-2-yl)-N'-(4-carboxybutyramide)urea, and N-(pyrid-3-yl)-N'-(4-carboxybutyramide)urea.
EXAMPLE 4
N-Phenyl-N'-(4-carboxybutyramide)urea (2.00 g, 7.54 mmoL) is mixed with carbonyldiimidazole (1.24 g, 7.95 mmoL) in tetrahydrofuran (30 mL) is heated and refluxed for 16 hours. The reaction mixture is concentrated and the residue slurried in water (25 mL). The resulting slurry is filtered and the solid is washed with water and air dried to yield 0.63 g of 3-phenylcarboxamidopiperidine-2,6-dione which can be alternatively named as N-phenyl-N'-(2-glutarimide)urea as a white flocculent powder. After being allowed to stand, the filtrate is refiltered to yield 0.70 g of additional material. 1 H NMR (DMSO-d 6 ) 6 8.51 (s, 1H, CONHCO), 7.6-7.2 (m, 6 H, Ar, ArNH), 6.83 (s, 1 H, NHCH), 4.26 (t, 1 H, CHCO), 2.4-1.8 (m, 4 H, CH 2 CH 2 ); 13 C NMR (DMSO-d 6 ) δ 173.2, 155.6,, 132.2, 128.7, 127.7, 126.7, 55.7, 29.8, 27.2. Anal. Calcd for C 12 H.sub. 13 N 3 O 3 . Theoretical: C, 58.29; H, 5.29; N, 16.99. Found: C, 58.12; H, 5.17; N, 17.02.
By substituting N-(4-trifluoromethylphenyl)-N'-(4-carboxybutyramide)urea, N-(3-cyanophenyl)-N'-(4-carboxybutyramide)urea, N-(2-methoxyphenyl)-N'-(4-carboxybutyramide)urea, N-(fur-2-yl)-N'-(4-carboxybutyramide)urea, and N-(pyrid-3-yl)-N'-(4-carboxybutyramide)urea for N-phenyl-N'-(4-carboxybutyramide)urea in the foregoing procedure, there are respectively obtained 3-(4-trifluoromethylphenylcarboxamido)piperidine-2,6-dione, 3-(3-cyanophenylcarboxamido)-piperidine-2,6-dione, 3-(2-methoxyphenylcarboxamido)piperidine-2,6-dione, 3-(fur-2-ylcarboxamido)piperidine-2,6-dione, and 3-(pyrid-3-ylcarboxamido)piperidine-2,6-dione.
EXAMPLE 5
To a stirred mixture of phenylglycine (3.0 g, 20 mmoL) and sodium carbonate (2.23 g, 21 mmoL) in 450 mL of water is added N-carbethoxyphthalimide (4.38 g, 20 mmoL). After 45 minutes, the reaction slurry is filtered. The filtrate is stirred and the pH adjusted to 1-2 with 4N hydrochloric acid. After 1 hour, the resulting slurry is filtered and the solid washed with water. The solid is dried in vacuo (60° C., <1 mm) to afford 2.88 g (51%) of 2-phthalimido-2-phenylacetic acid, which can be alternatively named as N-phthaloylphenylglycine, as a white powder.
Use of β-phenyl-β-alanine, β-phenyl-β-alanine, histidine, and tyrosine in place of phenylglycine in the procedure of this example yields respectively 3-phthalimido-3-phenylpropionic acid, 2-phthalimido-3-phenylpropionic acid, 2-phthalimido-3-imidazolylpropionic acid, and 2-phthalimido-3-(4-hydroxyphenyl)propionic acid.
EXAMPLE 6
To a stirred mixture of 2-phthalimido-2-phenylacetic acid (2.50 g, 8.89 mmoL) in tetrahydrofuran (50 mL) is added carbonyldiimidazole (1.50 g, 9.25 mmoL) and a few crystals of 4-dimethylaminopyridine. The reaction is then heated to 50° C. for 45 minutes. After the reaction mixture cools to room temperature, 1 mL of concentrated ammonium hydroxide is added via syringe. The reaction is stirred for 1 hour, then diluted with 50 mL of water and partially concentrated to remove the majority of the tetrahydrofuran. The resulting slurry is filtered and the solid washed with copious amounts of water. The solid is dried in vacuo (60° C., <1 mm) to afford 1.9 g (76%) of 2-phthalimido-2-phenylacetamide, which may be alternatively named as N-phthaloylphenylglycinamide, as an off-white powder: mp 218°-2201/2° C.; 1 H NMR (DMSO-d 6 ) δ 9.00-7.75 (m, 4 H, Ar), 7.61 (br s, 1 H, CONH 2 ), 7.55-7.20 (m, 6 H, Ar, CONH 2 ), 5.82 (s, 1 H, CHCO 2 ); 13 C NMR (DMSO-d 6 ) δ 168.2, 167.1, 135.6, 134.5, 131.4, 129.4, 127.9, 127.7, 123.1, 56.3. Anal (C 16 H 12 N 2 O 3 ), C, H, N.
Use of 3-phthalimido-3-phenylpropionic acid, 2-phthalimido-3-phenylpropionic acid, 2-phthalimido-3-imidazolylpropionic acid, and 2-phthalimido-3-(4-hydroxyphenyl)propionic acid in place of 2-phthalimido-2-phenylacetic acid in the procedure of this example yields respectively 3-phthalimido-3-phenylpropanamide, 2-phthalimido-3-phenylpropanamide, 2-phthalimido-3-imidazolylpropanamide, and 2-phthalimido-3-(4-hydroxy)phenylpropanamide.
EXAMPLE 7
To a stirred mixture of β-alanine (4.45 g, 50.0 mmoL) and sodium carbonate (5.35 g, 50.5 mmoL) in 100 mL of water is added N-carbethoxyphthalimide (10.95 g, 50.0 mmoL). After 1.5 hour, the reaction slurry is filtered. The filtrate is stirred and the pH adjusted to 1-2 with 4N hydrochloric acid. After 15 minutes, the resulting slurry is filtered and the solid washed with water. The solid is dried in vacuo (60° C., <1 mm) to afford 6.96 g (64%) of N-phthaloyl-β-alanine, which can be alternatively named as 3-phthalimidopropionic acid, as a white powder.
EXAMPLE 8
To a stirred solution of N-phthaloyl-β-alanine (2.19 g, 10.0 mmoL) in tetrahydrofuran (25 mL) is added carbonyldiimidazole (1.62 g, 10.0 mmoL) and a few crystals of 4-N,N-dimethylaminopyridine followed by 15 mL of tetrahydrofuran. The reaction is then heated to 40°-45° C. for 1 hour. After the reaction mixture cools to room temperature, 1 mL of concentrated ammonium hydroxide is added via syringe. The reaction is stirred for 20 minutes and the resulting slurry filtered and the solid washed with tetrahydrofuran. The solid is dried in vacuo (60° C., <1 mm) to afford 1.72 g (79%) of N-phthaloyl-β-alanine amide, which can be alternatively named as 3-phthalimidopropanamide, as a white powder: mp 252°-253° C.; 1 H NMR (DMSO-d6) δ 8.00-7.70 (m, 4 H, Ar), 7.45 (br s, 1 H, CONH 2 ), 6.89 (br s, 1 H, CONH 2 ), 3.78 (t, 2 H, J=7 Hz, CH 2 CO), 2.43 (t, 2 H, CH 2 ); 13 C NMR (DMSO-d 6 ) δ 171.5, 167.6, 134.2, 131.6, 122.9, 34.1, 33.5. Anal. Calcd for C 11 H 10 N 2 O 3 . Theoretical: C, 60.55; H, 4.62; N, 12.84. Found: C, 60.49; H, 4.59; N, 12.82.
EXAMPLE 9
To a stirred solution of glycinamide hydrochloride (2.20 g, 20.0 mmoL) and sodium carbonate (2.54 g, 24 mmoL) in 25 mL of water is added N-carbethoxyphthalimide (4.38 g, 20.0 mmoL). The resulting suspension is stirred for 1.5 hour and then filtered to afford 3.22 g (79%) of the crude product as a white powder. The crude product is slurried in 200 mL of refluxing ethanol. The resulting suspension after cooling to room temperature is filtered and the solid dried in vacuo (60° C., <1 mm) to afford 2.65 g (65%) of N-phthaloylglycinamide as a white powder: mp 199°-201° C.; 1 H NMR (DMSO-d 6 ) δ 8.00-7.8 (m, 4 H, Ar), 7.70 (br s, 1 H, CONH 2 ), 7.26 (br s, 1 H, CONH 2 ), 4.16 (s, 2 H, CH 2 ); 13 C NMR (DMSO-d 6 ) δ 167.8, 167.5, 134.4, 131.7, 123.1, 39.9. Anal. Calcd for C 11 H10N 2 O 3 . Theoretical: C, 60.55; H, 4.62; N, 12.84. Found: C, 60.49; H, 4.59; N, 12.82.
EXAMPLE 10
To a stirred solution of L-glutamine (43.8 g, 300 mmoL) and sodium carbonate (33.4 g, 315 mmoL) in 750 mL of water is rapidly added N-carbethoxyphthalimide [65.8 (97% pure, 67.8 g), 300 mmoL] as a solid. After 1 hour, the reaction mixture is filtered to remove unreacted N-carbethoxyphthalimide. The pH of the stirred filtrate is adjusted to 3-4 with 4N hydrochloric acid. The mixture is then seeded with N-phthaloyl-L-glutamine and the pH adjusted to 1-2 with 4N hydrochloric acid. The resulting slurry is stirred for 1 hour. The slurry is filtered and the solid washed with copious amounts of water. The solid is air-dried and then dried in vacuo (60° C., <1 mm) overnight to afford 49.07 g (59%) of N-phthaloyl-L-glutamine, which can be alternatively named as 2-phthalimidoglutaramic acid, as a white powder.
EXAMPLE 11
A stirred mixture of N-phthaloyl-L-glutamine (48.0 g, 174 mmoL), carbonyldiimidazole (30.43 g, 188 mmoL), and 4-dimethylaminopyridine (0.105 g, 0.861 mmoL) in anhydrous tetrahydrofuran (300 mL) is heated to reflux for 16 hours. The reaction slurry is filtered and the solid washed with methylene chloride (200 mL). The solid is air-dried and then dried in vacuo (60° C., <1 mm) to afford 40.40 g (90%) of thalidomide as a white powder. 1 H NMR (DMSO-d 6 ) δ 11.16 (s, 1 H, NH), 8.05-7.80 (br s, 4 H, Ar), 5.18 (dd, 1 H, J=12, 5 Hz, CHCO), 3.05-2.85 (m, 1 H, CH 2 CO), 2,70-2.45 (m, 2 H, CH 2 CH 2 ), 2.15-2.00 (M, 1 H, CH 2 ). 13 C NMR (DMSO-d 6 ) δ 172.8, 169.8, 167.1, 134.9, 131.2, 123.4, 49.0, 30.9, 22.0.
EXAMPLE 12
A stirred suspension of (S)-glutamine (14.6 g, 100 mL) and pyridine-2,3-dicarboxylic anhydride (14.9 g, 100 mmol) in 100 mL of acetic acid is heated at reflux for 1 hour. The resulting solution is allowed to cool. The solid which forms upon cooling is filtered and the solid washed with acetic acid and dried to afford 7.11 g (26%) of crude product. The crude product is slurried in 700 mL of refluxing ethanol, the suspension cooled, and the slurry collected by filtration and dried to afford 6.10 g (23%) of N-quinolinylglutamine, which can be alternatively named as 2-(1,3-dioxo-4-azaisoindol-2-yl)-3-carbamoylpropionic acid, as a white powder. mp 222°-226° C.; 1 H NMR (dmso-d 6 ) δ 13.25 (br s, 1 H, COOH), 9.04 (dd, 1 H, J=1.2, 4.9 Hz, pyr), 8.37 (dd, 1 H, J=1.2, 7.8 Hz, pyr), 7.85 (dd, 1 H, J=4.9, 7.8 Hz, pyr), 7.20 (s, 1 H, CONH 2 ), 6.73 (s, 1 H, CONH 2 ), 4.83 (dd, 1 H, J=10.2, 4.8 HZ, CHN), 2.55-1.90 (m, 4 H, CH 2 CH 2 ); 13 C NMR (dmso-d 6 ) 6 1173.22, 170.21, 165.8, 165.7, 155.4, 150.9, 31.7, 128.3, 126.9, 51.5, 31.4, 24.0.
EXAMPLE 13
A stirred suspension of N-quinolinylglutamine (1.39 g, 5.01 mmol), carbonyldiimidazole (0.890 g, 5.49 mmol), and N,N-dimethylpyridine (0.005 g, 0.04 mmol) in 20 mL of tetrahydrofuran is heated at reflux for 15 hours. After cooling, the reaction slurry is filtered and the solid washed with minimal tetrahydrofuran to afford, after drying 0.859 g (66%) of N-quinolinylglutarimide, which can be, alternatively named as 3-(1,3-dioxo-4-azaisoindol-2-yl)-2,6-dioxopiperidine, as a white powder: 1 H NMR (dmso-d 6 ) δ 11.18 (s, 1 H, NHCO), 9.04 (d, 1 H, J=5.0 Hz, pyr), 8.39 (d, 1 H, J=7.7 Hz, pyr), 7.86 (dd, 1 H, J=5.0, 7.7 Hz, pyr), 5.25 (dd, 1 H, J=15.3 , 13 Hz, 1 H, CHCO), 3.05-2.75 (m, 1 H, CH 2 CO), 2.75 (m, 2 H, CH 2 CO, CH 2 ), 2.20-2.00 (m, 1 H, CH 2 CO, CH 2 ); 13 C NMR (dmso-d 6 ) δ 172.6, 169.6, 165.4, 155.3, 150.8, 131.7, 128.2, 126.9, 49.0, 30.8, 21.8. Anal. Calculated for C 12 H 9 N 3 O 4 . Theory 55.60, 3.50, 16.21. Found 55.50, 3.53, 16.11.
EXAMPLE 14
To a stirred mixture of phenylglycine (3.0 g, 20 mmol) and sodium carbonate (2.23 g, 21 mmol) in 450 mL of water is added N-carbethoxyphthalimide (4.38 g, 20 mmol). After 45 minutes, the reaction slurry is filtered. The filtrate is stirred and the pH adjusted to 1-2 with 4N hydrochloric acid. After 1 hour, the resulting slurry is filtered and the solid washed with water. The solid is dried in vacuo (60° C., <1 mm) to afford 2.88 g (51%) of 2-phthalimidophenylacetic acid as a white powder.
By employing (R)-phenylglycine, there is obtained (R)2-phthalimido-phenylacetic acid, as a white powder: mp 175°-177° C.; 1 H NMR (dmso-d 6 , 250 M Hz) δ 12.50 (br s, 1H), 7.95-7.85 (m, 4H), 7.55-7.28 (m, 5H), 6.04 (s, 1H); 13 C NMR (dmso-d 6 ) δ 168.9, 166.9, 135.0, 134.9, 131.0, 129.1, 128.1, 127.9, 123.5, 56.1. Anal. Calculated for C 16 H 11 NO 4 . Theoretical: C, 68.32; H, 3.94; N, 4.98. Found: C, 68.32; H, 3.85; N, 4.95.
Likewise from (S)-phenylglycine, there is obtained (S)-2-phthalimido-phenylacetic acid as a white powder: mp 180°-184° C.; 1 H NMR (dmso-d 6 , 250 M Hz) δ 12.5 (br s, 1H), 7.95 7.85 (m, 4H) , 7.55-7.28 (m, 5H) , 6.04 (s, 1H); 13 C NMR (dmso-d 6 ) δ 168.9, 166.9, 135.0, 134.9, 130.9, 129.1, 128.1, 127.9, 123.5, 55.1. Anal. Calculated for C 16 H 11 NO 4 . Theoretical: C, 68.32; H, 3.94; N, 4.98. Found: C, 68.14; H, 3.87; N, 4.96.
EXAMPLE 15
To a stirred solution of N-phthaloylglycine (2.50 g, 8.89 mmol) in tetrahydrofuran (50 mL) is added carbonyldiimidazole (1.50 g, 9.25 mmol) and a few crystals of 4-N,N-dimethylaminopyridine. The reaction is then heated to 50° C. for 45 minutes. After the reaction mixture had cooled to room temperature, 1 mL of concentrated ammonium hydroxide is added via syringe. The reaction is stirred for 1 hour, then diluted with 50 mL of water and partially concentrated to remove the majority of the tetrahydrofuran. The resulting slurry was filtered and the solid washed with copious amounts of water. The solid was dried in vacuo (60° C., 1 mm) to afford 1.9 g (76%) of 2-phthalimido-2-phenylacetamide as an off-white powder: mp 218°-220° C.; 1 H NMR (dmso-d 6 ) δ 9.00-7.75 (m, 4 H, Ar), 7.61 (br s, 1 H, CONH 2 ), 7.55-7.20 (m, 6 H, Ar, CONH 2 ), 5.82 (s, 1 H, CHCO 2 ); 13 C NMR (dmso-d 6 ) 6 168.2, 167.1, 135.6, 134,5, 131.4, 129.4, 127.9, 127.7, 123.1, 56.3.
EXAMPLE 16
To a stirred mixture of β-alanine (4.45 g, 50.0 mmol) and sodium carbonate (5.35 g, 50.5 mmol) in 100 mL of water is added N-carbethoxyphthalimide (10.95 g, 50.0 mmol). After 1.5 hour, the reaction slurry is filtered. The filtrate is stirred and the pH adjusted to 1-2 with 4N hydrochloric acid. After 15 minutes, the resulting slurry is filtered and the solid washed with water. The solid is dried in vacuo (60° C., <1 mm) to afford 6.96 g (64%) of N-phthaloyl-β-alanine, which can be alternatively named as 3-phthalimido-3-phenylpropionic acid, as a white powder.
EXAMPLE 17
To a stirred solution of N-phthaloyl-β-alanine (2.19 g, 10.0 mmol) in tetrahydrofuran (25 mL) is added carbonyldiimidazole (1.62 g, 10.0 mmol) and a few crystals of 4-N,N-dimethylaminopyridine, followed by 15 mL of tetrahydrofuran. The mixture is heated at 40°-45° C. for 1 hour. After the reaction mixture is cooled to room temperature, 1 mL of concentrated ammonium hydroxide is added via syringe. The reaction is stirred for 20 minutes and the resulting slurry is filtered and the solid washed with tetrahydrofuran. The solid is dried in vacuo (60° C., <1 mm) to afford 1.72 g (79%) of N-phthaloyl-β-alanine amide, which can be alternatively named as 3-phthalimidopropionic acid, as a white powder: mp 252°-253° C.; 1 H NMR (dmso-d 6 ) δ 8.00-7.70 (m, 4 H, Ar), 7.45 (br s, 1 H, CONH 2 ), 6.89 (br s, 1 H, CONH.sub. 2), 3.78 (t, 2 H, J=7 Hz, CH 2 CO), 2.43 (t, 2 H, CH 2 ); 13 C NMR (dmso-d 6 ) δ 171.5, 167.6, 134.2, 131.6, 122.9, 34.1, 33.5. Anal. Calculated for C 11 H 10 N 2 O 3 . Theoretical: C, 60.55; H, 4.62; N, 12.84. Found: C, 60.49; H, 4.59; N, 12.82.
EXAMPLE 18
To a stirred solution of glycinamide hydrochloride (2.20 g, 20.0 mmol) and sodium carbonate (2.54 g, 24 mmol) in 25 mL of water is added N-carbethoxyphthalimide (4.38 g, 20.0 mmol). The resulting suspension is stirred for 1.5 hour and then filtered to afford 3.22 g (79%) of crude product as a white powder. The crude product is slurried in 200 mL of refluxing ethanol and, after cooling to room temperature, the resulting suspension is filtered and the solid dried in vacuo (60° C., <1 mm) to afford 2.65 g (65%) of N-phthaloylglycinamide, which can be alternatively named as phthalimidoacetamide, as a white powder: mp 199°-201° C.; 1H NMR (dmso-d 6 ) δ 8.00-7.8 (m, 4 H, Ar), 7.70 (br s, 1 H, CONH 2 ), 7.26 (br s, 1 H, CONH 2 ), 4.16 (s, 2 H, CH 2 ); 13 C NMR (dmso-d 6 ) δ 167.8, 167.5, 134.4, 131.7, 123.1, 39.9. Anal. Calculated for C 11 H 10 N 2 O 3 . Theoretical: C, 60.55; H, 4.62; N, 12.84. Found: C, 60.49; H, 4.59; N, 12.82.
EXAMPLE 19
By following the procedure of Example 17 but utilizing an equivalent amount of 4-aminobutyric acid, there is obtained a 67% yield of 4-phthalimidobutyric acid as a white powder: mp 108°-111° C.; 1 H NMR (dmso-d 6 ) δ 12.10 (s, 1 H),, 7.92°-7.75 (m, 4 H, Ar), 3.62 (t, J=6.8 Hz, 2 H), 2.29 (t, J=7.2 Hz, 2 H), 1.90-1.76 (m, 2 H); 13 C NMR (dmso-d 6 ) δ 173.8, 167.9, 134.2, 131.6, 122.9, 36.8, 30.9, 23.3.
EXAMPLE 20
By following the procedure of Example 15 but utilizing an equivalent amount of 4-phthalimidobutyric acid, there is obtained 4-phthalimidobutyramide as a white powder in a 23% yield: mp 159.5°-161.5° C.; 1 H NMR (dmso-d 6 ) δ 8.0-7.7 (m, 4 H, Ar), 3.58 (t, J=6.9 Hz, 2 H), 2.09 (t, 2 H), 1.92-1.70 (m, 2 H); 13 C NMR (dmso-d 6 ) 6 173.3, 167.9, 134.2, 131.6, 122.9, 37.1. 32.3, 23.9.
EXAMPLE 21
By following the procedure of Example 18 but employing N-carbethoxyphthalimide and (S)-phenylalaninamide hydrochloride, there is obtained (S)-2-phthalimido-3-phenylpropionamide which can be recrystallized from ethanol to afford white crystals: mp 211°-215° C.; 1 H NMR (dmso-d 6 ) δ 7.92 (s, 5 H, Ph), 7.72, 7.33 (2 s, 2 H), 7.2-7.0 (m, 4 H, Ar), 4.92 (dd, 1 H, J=12, 4.5 Hz), 3.52 (dd, 1 H, J=4.3, 13.9), 3.35 (dd, 1 H, J=12, 13.9); 13 C NMR (dmso-d 6 ) δ 169.6, 167.4, 137.7, 134.3, 131.2, 128.5, 128.1, 126.3, 122.9, 54.2, 33.7.
EXAMPLE 22
To a stirred solution of d,l-phenylalanine (4.17 g, 25.0 mmol) and sodium carbonate (2.78 g, 26.25 mmol) in 50 mL of water is added N-carboethoxyphthalimide (5.65 g, 25.0 mmol). The resulting slurry is stirred for 1.5 hour and filtered. The pH of the filtrate is adjusted to 1-2 with 4 N hydrochloric acid with stirring. After 20 minutes, the slurry is refiltered and the solid washed with water. The solid is dried in vacuo (60° C., <1 mm) to afford 5.44 g (74%) of 2-phthalimido-3-phenylpropionic acid as a white powder: mp 165°-169° C.; 1 H NMR (dmso-d 6 , 250 M Hz) δ 12.5(br s, 1H), 7.84(s, 4H), 7.23-7.06 (m, 5H), 5.13 (dd, 1H, J=5.0), 3.26-3.05 (m, 2H); 13 C NMR (250 MHz, dmso-d 6 ) δ 170.0, 167.0, 137.2, 134.8, 130.6, 128.6, 128.2, 126.5, 123.3, 52.8, 33.8. Anal. Calculated for C 17 H 13 NO 4 . Theoretical: C, 69.15; H, 4.44; N, 4.74. Found: C, 69.07; H, 4.34; N, 4.78.
EXAMPLE 23
To a stirred solution of 2-phthalimido-3-phenylpropionic acid (2.95 g, 10.0 mmol) in tetrahydrofuran (25 mL) are added carbonyldiimidazole (1.62 g, 10.0 mmol) and a few crystals of 4-N,N-dimethylaminopyridine, followed by 15 mL of tetrahydrofuran. The reaction mixture is stirred at room temperature for 45 minutes and 1 mL of concentrated ammonium hydroxide then is added. After 10 minutes, the reaction mixture is diluted with 50 mL water and the resulting slurry is partially concentrated to remove the tetrahydrofuran and filtered. The solid is washed with water and dried in vacuo (60° C., <1 mm) to afford 2.46 g (84%) of 2-phthalimido-3-phenylpropionamide as a white powder: mp 224°-226° C.; 1 H NMR (dmso-d 6 , 250 MHz) δ 7.79 (s, 4 H, Ar), 7.71 (br s, 1 H, CONH 2 ), 7.32 (br s, 1 H, CONH 2 ), 7.20-7.02 (m. 5H, Ar), 5.06-4.98 (m, 1H), 3.56-3.25 (m, 2H); 13 C NMR (dmso-d 6 , 250 MHz) δ: 169.6, 168.0, 137.1, 134.3, 131.2, 129.5, 128.1, 126.3, 122.9, 54.2, 33.7. Anal. Calculated for C 17 H 14 N 2 O 3 . Theoretical: C, 69.38; H,4.79; N, 9.52. Found: C, 69.37; H, 4.73; N, 9.43.
EXAMPLE 24
To a stirred solution of 4-fluorophenyglycine (3.38 g, 20.0 mmol) and sodium carbonate in 450 mL of 2:1 water:acetonitrile is added N-carbethoxyphthalimide (4.38 g, 20 mmol). After 1 hour, the reaction mixture is partially concentrated to remove the acetonitrile. The resulting slurry is filtered and the pH of the stirred filtrate is adjusted to 1-2 with 4 N hydrochloric acid and then stirred for an additional 30 minutes and filtered. The solid is air-dried and then dried in vacuo (60° C., <1 mm) to afford 4.55 g (76%) of 2-phthalimido-2-(4-fluorophenyl)acetic acid as a white powder: mp 180°-183° C.; 1 H NMR (dmso-d 6 , 250 MHz) δ 8.10-7.80 (m, 4 H), 7.65-7.45 (m, 4 H), 7.3-7.10 (t, 2 H), 6.10 (s, 1 H); 13 C NMR (dmso-d 6 , 250 MHz) δ168.9, 166.9, 163.6, 159.7, 135.0, 131.4, 131.3 (m), 130.9, 123.5, 115.0, 114.7, 54.4. Anal. Calculated for C 16 H 10 NO 4 F. Theoretical: C, 64.22; H, 3.37; N, 4.68. Found: C, 64.13; H, 3.33; N, 4.63.
Similarly prepared from 2-fluorophenylglycine is 2-phthalimido-2-(2-fluorophenyl)acetic acid as a white solid: mp 174.5°-180.5° C.; 1 H NMR (dmso-d 6 ) δ 13.8 (br s, 1 H), 7.65-7.15 (m, 4H), 6.18 (s, 1 H); 13 C NMR (dmso-d 6 ) δ 168.1, 166.8, 162.1, 158.2, 135.0, 130.9, 130.8, 130.5, 130.4, 124.1. 123.6, 121.8, 121.6, 115.3, 114.9, 48.9. Anal. Calculated for C 16 H 10 NO 4 F. Theoretical: C, 64.22; H, 3.37; N, 4.68. Found: C, 63.93; H, 3.27; N, 4.68.
EXAMPLE 25
Similarly prepared according to the procedure of Example 23 from 2-phthalimido-2-(4-fluorophenyl)acetic acid, carbonyldiimidazole, 4-N,N-dimethylaminopyridine and concentrated ammonium hydroxide is 2-phthalimido-2-(4-fluorophenyl)acetamide which can be recrystallized from tetrahydrofuran to afford 0.76 g (51%) of the product as white crystals: mp 180°-183° C.; 1 H NMR (dmso-d 6 ) δ 8.00-7.55 (m, 4 H), 7.64 (s, 1 H), 7.60-7.40 (m, 3 H), 7.25-7.05 (m, 2 H), 5.83 (s, 1 H). Anal. Calculated for C 16 H 11 N 2 O 3 F. Theoretical: C, 64.43; H, 3.72; N, 9.39. Found: C, 64.16; H, 3.62; N, 9.18.
Likewise from 2-phthalimido-2-(2-fluorophenyl)acetic acid there is obtained 2-phthalimido-2-(2-fluorophenyl)acetamide as small white crystals: mp 197°-201° C.; 1H NMR (dmso-d 6 ) δ 8.05-7.75 (m, 5 H), 7.65-7.05 (m, 5 H), 6.06 (s, 1 H), 13 C NMR (dmso-d 6 ) δ 167.4, 166.9, 162.2, 158.3, 134.6, 131.3, 131.2, 131.1, 130.2, 130.0, 123.9, 123.8, 123.2, 122.4, 115.1, 114.8, 49.9.
EXAMPLE 26
To a stirred solution of d,l-leucine (3.31 g, 25.0 mmol) and sodium carbonate (2.78 g, 26.25 mmol) in 50 mL of water is added N-carboethoxyphthalimide (5.65 g, 25.0 mmol). After 1 hour at room temperature, the reaction slurry is filtered, the filtrate stirred, and the pH adjusted to 1-2 with 4N hydrochloric acid. The mixture is stirred overnight, the resulting slurry is filtered, and the solid washed with water and dried in vacuo (60° C., <1 mm) to afford 5.32 g (81%) of the 2-phthalimido-4-methylpentanoic acid as a white powder: mp 134°-137° C.; 1 H NMR (dmso-d 6 , 250 M Hz) δ 12.50 (br s, 1H), 8.00-7.80 (m, 4H), 4.79 (dd, 1H, J=4.3), 2.28-2.10 (m, 1H), 1.94-1.77 (m, 1H), 1.51-1.34 (m, 1H), 0.89 (d, 3H, J=4.4), 0.86 (d, 3H, J=4.5); 13 C NMR (dmso-d 6 ) δ 170.8, 167.4, 134.8, 131.1, 123.3, 50.2, 36.7, 24.6, 23.0, 20.8. Anal. Calculated for C 14 H 15 NO 4 . Theoretical: C, 64.36; H, 5.74; N, 5.36. Found: C, 64.18; H, 5.73; N, 5.98.
EXAMPLE 27
To a stirred solution of 2-phthalimido-4-methylpentanoic acid (1.32 g, 5.0 mmol) in tetrahydrofuran (25 mL) are added carbonyldiimidazole (0.81 g, 5.0 mmol) and a few crystals of 4-N,N-dimethylaminopyridine followed by 15 mL of tetrahydrofuran. The reaction mixture is stirred at room temperature for 1 hour, then 1 mL of concentrated ammonium hydroxide is added. After 10 minutes, the reaction mixture is diluted with 50 mL water. The resulting slurry is partially concentrated to remove the tetrahydrofuran and filtered. The solid is washed with water and dried in vacuo (60° C., <1 mm) to afford 1.16 g (89%) of 2-phthalimido-4-methylpentanamide as a white powder: mp 173°-176° C.; 1 H NMR (dmso-d 6 , 250 MHz) δ 7.95-7.79 (m, 4 H, Ar), 7.61 (br s, 1 H, CONH 2 ), 7.22 (br s, 1 H, CONH 2 ), 4.73- 4.60 (m, 1 H ), 2.30-2.10 (m, 1 H), 1.95-1.80 (m, 1H), 1.45-1.25 (m, 1H); 13 C NMR (dmso-d 6 ) δ: 170.4, 167.7, 134.4, 131.5, 123.1, 51.3, 36.4, 24.7, 23.2, 20.6. Anal. Calculated for C 14 H 16 N 2 O 3 . Theoretical: C, 64.60; H, 6.20; N, 10.76. Found: C, 64.63; H, 6.11; N, 10.70.
EXAMPLE 28
To a stirred solution of histidine (3.17 g, 20.0 mmol) and sodium carbonate (2.23 g, 21 mmol) in 50 mL of water is added N-carboethoxyphthalimide (4.52 g, 20.0 mmol). After 1.5 hour, the reaction slurry is filtered. The filtrate is stirred and the pH adjusted to 1-2 with 4N hydrochloric acid. The resulting slurry is filtered and the solid washed with water and dried in vacuo (60 C, <1 mm) to afford 3.65 g (64%) of 2-phthalimido-3-(imidazol-4-yl)propionic acid as a white powder: mp 280°-285° C.; 1 H NMR (dmso-d 6 , 250 M Hz) δ12.5 (br s, 1H), 7.90-7.60 (m, 6H), 6.80(s, 1H), 4.94 (t, 1H, J=7.8), 3.36 (d, 2H, J=7.8); 13 C NMR (dmso-d 6 ) δ 170.1, 167.1, 134.8, 134.6, 133.2, 131.1, 123.2, 116.3, 52.4, 25.8; Anal. Calculated for C 14 H 11 N 3 O 4 . Theoretical: C, 58.95; H, 3.89; N, 14.73. Found: C, 58.80; H, 3.88; N, 14.66.
EXAMPLE 29
To a stirred mixture of 3-amino-3-(4-methoxyphenyl)propionic acid (1.95 g, 10.0 mmol) and sodium carbonate (1.11 g, 10.5 mmol) in 200 mL of acetonitrile-water 1:1 is added N-carboethoxyphthalimide (2.26 g, 10.0 mmol). After 1 hour, the reaction slurry is filtered. The filtrate is concentrated to remove the acetonitrile and the pH adjusted to 1-2 with 4 N hydrochloric acid and stirred over night. The resulting slurry is filtered and the solid washed with water. The solid is dried in vacuo (60 C, <1 mm) to afford 2.82 g (87%) of the 3-phthalimido-3-(4-methoxyphenyl)propionic acid as a white powder: mp 160°-164° C.; 1 H NMR (dmso-d 6 , 250 MHz) δ 12.5 (br s, 1H), 7.95-7.80 (m, 4 H), 7.36 (d, 2 H, J=8.7), 6.92 (d, 2 H, J=8.4 Hz), 5.18-5.10 (m, 1 H), 3.70-3.15 (m, 2 H); 13 C NMR (dmso-d 6 ) δ 171.7, 167.6, 158.6, 134.6, 131.0, 130.8, 128.3, 123.1, 113.9, 55.0, 49.6, 35.9. Anal. Calculated for C 18 H 15 NO 5 . Theoretical: C, 66.46; H, 4.63; N, 4.31. Found: C, 66.25; H, 4.65; N, 4.28.
Similarly from 3-amino-3-(3-methoxyphenyl)propionic acid there is obtained 3-phthalimido-3-(3-methoxyphenyl)propionic acid as white crystals: mp 111°-115° C.; 1 H NMR (dmsod 6 , 250 MHz) 6 12.5 (br s, 1H), 7.94-7.81 (m, 4 H), 7.32-7.23 (m, 1H), 7.02-6.85 (m, 3 H), 5.70-5.60 (m, 1 H), 3.77-3.67 (s, 3H), 3.56-3.15 (m, 2 H); 13 C NMR (dmso-d 6 ) δ 171.6, 167.6, 159.2, 140.4, 134.7, 131.0, 129.7, 123.2, 119.0, 112.9, 112.7, 54.9, 50.0, 35.8.
Likewise from 3-amino-3-(2-methoxyphenyl)propionic acid there is obtained 3-phthalimido-3-(2-methoxyphenyl)propionic acid as a white powder: mp 163°-168 ° C.; 1 H NMR (dmso-d 6 , 250 MHz) δ 12.5 (br s, 1H), 7.95-7.80 (m, 4 H), 7.45-6.90 (m, 4H), 6.05-5.92 (m, H), 3.78 (s, 3H) 3.55-3.05 (m, 2 H); 13 C NMR (dmso-d 6 ) 171.7, 167.5, 156.1, 134.5, 131.0, 128.9, 127.3, 126.1, 123.0, 120.1, 111.0, 55.5, 45.3, 35.1.
EXAMPLE 30
By following the procedure of Example 27 utilizing 3-phthalimido-3-(4-methoxyphenyl)propionic acid, there is obtained 3-phthalimido-3-(4-methoxyphenyl)propionamide as a white powder: mp 183°-188° C.; 1 H NMR (dmso-d 6 , 250 MHz) δ 7.90-7.75 (m, 4 H, Ar), 7.58 (br s, 1 H, CONH 2 ), 7.38 (d, 2H, J=8.6 ), 6.91 (d, 3H, J=8.6), 5.73 (t, 1H, J=7.8), 3.23(d, 2H, J=7.9); 13 C NMR (dmso-d 6 ) δ: 171.2, 167.6, 158.5, 134.5, 131.3, 131.2, 128.4, 123.0, 113.7, 55.0, 49.9, 36.8.. Anal. Calculated for C 18 H 16 N 2 O 4 . Theoretical: C, 66.66; H,4.97; N, 8.64. Found: C, 66.27; H, 5.04; N, 8.40.
EXAMPLE 31
To a stirred mixture of 3-amino-3-(4-cyanophenyl)propionic acid (3.80 g, 20.0 mmol) and sodium carbonate (2.23 g, 21 mmol) in 100 mL of water is added N-carboethoxyphthalimide (4.52 g, 20.0 mmol). After 2 hour, the reaction slurry is filtered and the pH of the stirred filtrate adjusted to 1-2 with 4 N hydrochloric acid. The resulting gel is extracted with ethyl acetate (3×30 mL). The extract is dried over magnesium sulfate and concentrated in vacuo. The crude product is recrystallized from 10% aqueous acetonitrile and then recrystallized from 20% aqueous methanol. The product is dried in vacuo (60° C., <1 mm) to afford 1.5 g (23%) of 3-phthalimido-3-(4-cyanophenyl)propionic acid as a white powder: mp 134°-137° C.; 1 H NMR (dmso-d 6 , 250 MHz) δ 12.5 (br s, 1H), 7.95-7.56 (m, 8 H),. 5.76 (t, 1 H, J=7.7), 3.57-3.15 (m, 2 H); 13 C NMR (dmso-d 6 ) δ 171.5, 167.6, 144.2, 134.8, 132.6, 131.1, 128.1, 123.3, 118.5, 49.7, 35.5.
Likewise from 3-amino-3-(3-cyanophenyl)propionic acid there is obtained 3-phthalimido-3-(3-cyanophenyl)propionic acid as a white powder: mp 172°-175° C.; 1 H NMR (dmso-d 6 , 250 MHz) δ 12.5 (br s, 1H), 8.05-7.51 (m, 8 H), 5.82-5.70 (m, 1 H), 3.63-3.20(m, 2 H); 13 C NMR (dmso-d 6 ) δ 171.5, 167.6, 140.3, 134.6 132.0, 131.5, 131.2, 130.7, 129.8, 123.22, 118.5, 111.6, 49.3, 35.6.
EXAMPLE 32
By following the procedure of Example 27 utilizing 3-phthalimido-3-(4-cyanophenyl)propionic acid, there is obtained 3-phthalimido-3-(4-cyanophenyl)propionamide as a white powder: 1 H NMR (dmso-d 6 , 250 MHz) δ 8.05-7.50 (m, 9 H), 6.97 (s, 1 H), 5.87-5.72 (m, 1 H), 3.44-3.12 (m, 2 H); 13 C NMR (dmso-d 6 ) δ 170.8, 167.6, 144.6, 134.6, 132.4, 131.1, 127.9, 123.2, 118.5, 110.3, 49.8, 36.4.
Similarly from 3-phthalimido-3-(3-cyanophenyl) propionic acid (1.60 g, 5.0 mmol), there is obtained 3-phthalimido-3-(3-cyanophenyl)propionamide as a white powder: mp 217°-220° C.; 1 H NMR (dmso-d 6 , 250 MHz) δ 8.05-7.40 (m, 9 H), 6.99 (br s, 1 H), 5.90-5.75 (m, 1H ), 3.50-3.10 (m, 2H); 13 C NMR (dmso-d 6 ) δ: 171.0, 167.7, 140.8, 134.6, 132.2, 131.5, 131.4, 130.8, 129.9, 123.2, 118.7,111.5, 49.7, 36.7.
EXAMPLE 33
To a stirred solution of phenyl isocyanate (2.2 mL, 2.4 g, 20 mmol) in acetonitrile (40 mL) is added a solution of L-glutamine (2.92 g, 20.0 mmol) and sodium hydroxide (20 mmol) in water (20 mL). The reaction mixture is stirred for 45 hours, partially concentrated to remove the acetonitrile, and washed with ethyl acetate (2×25 mL). The pH of the aqueous layer is adjusted to 1-2 with 4N hydrochloric acid, the resulting thick slurry filtered, and the solid washed with water and air-dried to afford 4.70 g (89%) yield of 2-(N-phenyluriedo)-4-carbamoylbutyric acid as a white powder.
2-(N-phenyluriedo)-4-carbamoylbutyric acid (2.00 g, 7.54 mmol) and carbonyldiimidazole (1.24 g, 7.95 mmol) in tetrahydrofuran (30 mL) are heated at reflux for 16 hours. The reaction mixture is concentrated and the residue slurried in water (25 mL), the slurry filtered, and the solid washed with water and air-dried to afford 0.63 g of N-phenyl-N'-(1,6-dioxopiperidin-2-yl)urea. After sitting, filtration of the filtrate afforded 0.70 g (38%) of the product as a white flocculent powder: 1 H NMR (dmso-d 6 ) δ 8.51 (s, 1 H, CONHCO), 7.6-7.2 (m, 6 H, Ar, ArNH), 6.83 (s, 1 H, NHCH), 4.26 (t, 1 H, CHCO), 2.4-1.8 (m, 4 H, CH 2 CH 2 ); 13 C NMR (dmso-d 6 ) δ 173.2, 155.6, 132.2, 128.7, 127.7, 126.7, 55.7, 29.8, 27.2. Anal. Calculated for C 12 H 13 N 3 O 3 . Theoretical: C, 58.29; H, 5.29; N, 16.99. Found: C, 58.12; H, 5.17; N, 17.02.
EXAMPLE 34
Tablets, each containing 50 mg of active imide ingredient, can be prepared in the following manner:
______________________________________Constituents (for 1000 tablets)______________________________________active imide ingredient 50.0 glactose 50.7 gwheat starch 7.5 gpolyethylene glycol 6000 5.0 gtalc 5.0 gmagnesium stearate 1.8 gdemineralised water q.s.______________________________________
The solid ingredients are first forced through a sieve of 0.6 mm mesh width. The active imide ingredient, the lactose, the talc, the magnesium stearate and half of the starch then are mixed. The other half of the starch is suspended in 40 ml of water and this suspension is added to a boiling solution of the polyethylene glycol in 100 ml of water. The resulting paste is added to the pulverulent substances and the mixture is granulated, if necessary with the addition of water. The granulate is dried overnight at 35° C., forced through a sieve of 1.2 mm mesh width and compressed to form tablets of approximately 6 mm diameter which are concave on both sides.
EXAMPLE 35
Tablets, each containing 100 mg of active imide ingredient, can be prepared in the following manner:
______________________________________Constituents (for 1000 tablets)______________________________________active imide ingredient 100.0 glactose 100.0 gwheat starch 47.0 gmagnesium stearate 3.0 g______________________________________
All the solid ingredients are first forced through a sieve of 0.6 mm mesh width. The active imide ingredient, the lactose, the magnesium stearate and half of the starch then are mixed. The other half of the starch is suspended in 40 ml of water and this suspension is added to 100 ml of boiling water. The resulting paste is added to the pulverulent substances and the mixture is granulated, if necessary with the addition of water. The granulate is dried overnight at 35° C., forced through a sieve of 1.2 mm mesh width and compressed to form tablets of approximately 6 mm diameter which are concave on both sides.
EXAMPLE 36
Tablets for chewing, each containing 75 mg of active imide ingredient, can be prepared in the following manner:
______________________________________Composition (for 1000 tablets)______________________________________active imide ingredient 75.0 gmannitol 230.0 glactose 150.0 gtalc 21.0 gglycine 12.5 gstearic acid 10.0 gsaccharin 1.5 g5% gelatin solution q.s.______________________________________
All the solid ingredients are first forced through a sieve of 0.25 mm mesh width. The mannitol and the lactose are mixed, granulated with the addition of gelatin solution, forced through a sieve of 2 mm mesh width, dried at 50° C. and again forced through a sieve of 1.7 mm mesh width. The active imide ingredient, the glycine and the saccharin are carefully mixed, the mannitol, the lactose granulate, the stearic acid and the talc are added and the whole is mixed thoroughly and compressed to form tablets of approximately mm diameter which are concave on both sides and have a breaking groove on the upper side.
EXAMPLE 37
Tablets, each containing 10 mg of active imide ingredient, can be prepared in the following manner:
______________________________________Composition (for 1000 tablets)______________________________________active imide ingredient 10.0 glactose 328.5 gcorn starch 17.5 gpolyethylene glycol 6000 5.0 gtalc 25.0 gmagnesium stearate 4.0 gdemineralised water q.s.______________________________________
The solid ingredients are first forced through a sieve of 0.6 mm mesh width. Then the active imide ingredient, lactose, talc, magnesium stearate and half of the starch are intimately mixed. The other half of the starch is suspended in 65 ml of water and this suspension is added to a boiling solution of the polyethylene glycol in 260 ml of water. The resulting paste is added to the pulverulent substances, and the whole is mixed and granulated, if necessary with the addition of water. The granulate is dried overnight at 35° C., forced through a sieve of 1.2 mm mesh width and compressed to form tablets of approximately 10 mm diameter which are concave on both sides and have a breaking notch on the upper side.
EXAMPLE 38
Gelatin dry-filled capsules, each containing 100 mg of active imide ingredient, can be prepared in the following manner:
______________________________________Composition (for 1000 capsules)______________________________________active imide ingredient 100.0 gmicrocrystalline cellulose 30.0 gsodium lauryl sulphate 2.0 gmagnesium stearate 8.0 g______________________________________
The sodium lauryl sulphate is sieved into the active imide ingredient through a sieve of 0.2 mm mesh width and the two components are intimately mixed for 10 minutes. The microcrystalline cellulose is then added through a sieve of 0.9 mm mesh width and the whole is again intimately mixed for 10 minutes. Finally, the magnesium stearate is added through a sieve of 0.8 mm width and, after mixing for a further 3 minutes, the mixture is introduced in portions of 140 mg each into size 0 (elongated) gelatin dry-fill capsules.
EXAMPLE 39
A 0.2% injection or infusion solution can be prepared, for example, in the following manner:
______________________________________active imide ingredient 5.0 gsodium chloride 22.5 gphosphate buffer pH 7.4 300.0 gdemineralised water to 2500.0 ml______________________________________
The active imide ingredient is dissolved in 1000 ml of water and filtered through a microfilter. The buffer solution is added and the whole is made up to 2500 ml with water. To prepare dosage unit forms, portions of 1.0 or 2.5 ml each are introduced into glass ampoules (each containing respectively 2.0 or 5.0 mg of imide).
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Cyclic imides are inhibitors of tumor necrosis factor α and can be used to combat cachexia, endotoxic shock, and retrovirus replication. A typical embodiment is 2-(2,6-dioxo-3-piperidinyl)-4-azaisoindoline-1,3-dione.
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BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates to detection devices, and particularly to a printer interface detection device.
[0003] 2. Description of Related Art
[0004] Nowadays, as more databases and computer networks are interconnected, distributed multiple data systems and destinations are used to store information. Proper functioning of the printer interface of a computer becomes very important in such distributed resources. Generally, when a printer interface of a computer is tested for its functionality, a corresponding printer needs to be connected, which is inconvenient in a distributed arrangement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a schematic, isometric view of one embodiment of a printer interface detection device.
[0006] FIG. 2 is a schematic, isometric view of the printer interface detection device of FIG. 1 detecting a computer.
[0007] FIG. 3 is a circuit diagram of the printer interface detection device of FIG. 1 .
DETAILED DESCRIPTION
[0008] Referring to FIGS. 1-3 , an exemplary embodiment of a printer interface detection device 100 is used to simulate a printer to determine whether a printing function of a printer interface 32 of a computer 30 to be detected is normal. The printer interface detection device 100 includes a shell 1 , a printer interface 5 mounted on the shell 1 , a detection circuit 10 received in the shell 1 , two switches K 1 and K 2 mounted on the shell 1 , and first to third light emitting diodes (LEDs) D 1 -D 3 mounted on the shell 1 . The two switches K 1 and K 2 , and the first to third LEDs D 1 -D 3 are connected to the detection circuit 10 . The first LED D 1 , displays a power status of the printer interface detection device 100 . The second LED D 2 , displays a printing status of the printer interface detection device 100 . The third LED D 3 , displays a detection result of the printer interface detection device 100 , to allow determination of whether a printing function of the printer interface 32 of the computer 30 is normal.
[0009] The printer interface 5 is connects to the printer interface 32 of the computer 30 .
[0010] The printer interface 5 of the printer interface detection device 100 includes an initialization signal pin NIT, an acknowledgement signal pin ACK, a busy signal pin BUSY, a data signal pin DATA, and a strobe signal pin STROBE, corresponding to an initialization signal pin, an acknowledgement signal pin, a busy signal pin, a data signal pin, and a strobe signal pin of the printer interface 32 of the computer 30 respectively.
[0011] The detection circuit 10 includes a microcontroller 12 , resistors R 1 -R 4 , capacitors C 1 -C 3 , a crystal oscillator J, and a power source Vcc. The microcontroller 12 includes a reset pin RET, a power pin VCC, a ground pin GND, a plurality of input/output (I/O) pins P 1 . 0 , P 1 . 1 , P 1 . 2 , P 1 . 3 , P 1 . 6 , P 3 . 4 , and P 3 . 5 , an external crystal input pin XTAL 1 , and an external crystal output pin XTAL 2 . The reset pin RET of the microcontroller 12 is connected to a cathode of the capacitor C 1 , and is grounded via the resistor R 1 . An anode of the capacitor C 1 is connected to the power source Vcc. The switch K 1 is connected to the capacitor C 1 in parallel, to reset the microcontroller 12 . The power pin of the microcontroller 12 is connected to an anode of the first LED D 1 , and connected to the power source Vcc via the switch K 2 , to start the detection circuit 10 . A cathode of the first LED D 1 is grounded via the resistor R 2 . The I/O pin P 1 . 6 of the microcontroller 12 is connected to the initialization signal pin INIT of the printer interface 5 . The I/O pin P 1 . 3 of the microcontroller 12 is connected to the acknowledgement signal pin ACK of the printer interface 5 . The I/O pin P 1 . 2 of the microcontroller 12 is connected to the busy signal pin BUSY of the printer interface 5 . The I/O pin P 1 . 1 of the microcontroller 12 is connected to the strobe signal pin STROBE of the printer interface 5 . The I/O pin P 1 . 0 of the microcontroller 12 is connected to the data signal pin DATA of the printer interface 5 . The I/O pin P 3 . 4 of the microcontroller 12 is connected to an anode of the third LED D 3 . A cathode of the third LED D 3 is grounded via the resistor R 3 . The I/O pin P 3 . 5 of the microcontroller 12 is connected to an anode of the second LED D 2 . A cathode of the second LED D 2 is grounded via the resistor R 4 . The crystal oscillator J is connected between the external crystal input pin XTAL 1 and the external crystal output pin XTAL 2 . The external crystal input pin XTAL 1 is grounded via the capacitor C 2 . The external crystal output pin XTAL 2 is grounded via the capacitor C 3 . The crystal oscillator J, the capacitor C 2 , and the capacitor C 3 form a clock circuit. The ground pin GND is grounded. The initialization signal pin INIT, the acknowledgement signal pin ACK, the busy signal pin BUSY, and the strobe signal pin STROBE of the printer interface 5 can be triggered at a low level.
[0012] In use, the printer interface 5 of the printer interface detection device 100 is connected to the printer interface 32 of the computer 30 . The switch K 2 is turned on to initialize the detection circuit 10 . When the computer 30 identifies the printer interface detection device 100 , the computer 30 transmits a printing demand instruction to the printer interface detection device 100 via the data signal pin DATA. The microcontroller 12 receives the printing demand instruction, and directs the I/O pin P 1 . 1 to output a low level signal, as a first printing status signal, to the computer 30 via the strobe signal pin STROBE of the printer interface 5 , to notify the computer 30 that the printer interface detection device 100 is awaiting print data. The computer 30 transmits print data to the microcontroller 12 via the data signal pin DATA of the printer interface 5 . When the I/O pin P 1 . 0 of the microcontroller 12 receives the print data, the microcontroller 12 directs the I/O pin P 3 . 5 to output a high level signal to turn on the second LED D 2 to denote that the printer interface detection device 100 has started receiving the print data, and directs the I/O pin P 1 . 3 to output a low level signal, as a second printing status signal, to the computer 30 to notify the computer 30 that the printer interface detection device 100 has started receiving the print data. The microcontroller 12 directs the I/O pin P 1 . 2 to output a low level signal, as a third printing status signal, to the computer 30 via the busy signal pin ACK of the printer interface 5 after finishing receiving the print data, to notify the computer 30 that the printer interface detection device 100 has successfully received all print data and start printing.
[0013] When the printer interface detection device 100 has finished printing, the microcontroller 12 directs the I/O pin P 1 . 6 to output a low level signal, as a fourth printing status signal, to the computer 30 via the initialization signal pin NIT of the printer interface 5 , to notify the computer 30 that the printer interface detection device 100 has finished printing. The microcontroller 12 directs the I/O pin P 3 . 5 to output a low level signal to turn off the second LED D 2 to indicate that the printer interface detection device 100 has finished printing. The computer 30 determines whether the first to fourth printing statuses of the printer interface detection device 100 are consistent with printing statuses stored in the computer 30 . If so, the detection is successful and the computer 30 transmits an instruction to the microcontroller 12 via the data signal pin DATA of the printer interface 5 . The microcontroller 12 directs the I/O pin P 3 . 4 to output a high level signal to turn on the third LED D 3 to denote that the detection is successful and the printing function of the printer interface 32 of the computer 30 is normal. If the first to fourth printing statuses of the printer interface detection device 100 are not consistent with printing statuses stored in the computer 30 , the third LED D 3 remains unlit, denoting that the detection has failed and the printing function of the printer interface 32 of the computer 30 is abnormal.
[0014] It is to be understood, however, that even though numerous characteristics and advantages of the embodiments have been set forth in the foregoing description, together with details of the structure and function of the embodiments, the disclosure is illustrative only, and changes may be made in details, especially in matters of shape, size, and arrangement of parts within the principles of the embodiments to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A printer interface detection device includes a printer interface connected to a printer interface of a computer to be detected, a microcontroller, and an indicator. The printer interface includes a number of input/output (I/O) pins and a data signal pin connected to the corresponding pins of the microcontroller. The microcontroller outputs a plurality of printing status signals to the computer according to instructions from the computer. The computer compares whether the number of printing statuses are consistent with printing statuses stored in the computer, to determine whether a printing function of the printer interface of the computer is normal. When the printing function of the printer interface of the computer is normal, the indicator is lit.
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This invention is the result of a contract with the Department of Energy (Contract No. W-7405-ENG-36).
BACKGROUND OF THE INVENTION
The invention described herein is generally related to magnetic compasses. More particularly, this invention is related to remotely readable magnetic compasses.
In various applications there is a need for a directional compass which can be read from a remote location. For example, in the operation of remotely controlled submersible marine vehicles it is desirable to monitor the geographic orientation of the vehicle by means of a remotely readable compass located onboard the vehicle. Similarly, in oil and gas field well logging operations it is sometimes necessary to monitor the geographic orientation of a tool or down-hole instrumentation package. Remotely readable compasses are also useful in towed undersea hydrophone arrays used in marine geophysical research, in sonobuoys used in naval operations, and in remotely controlled airborne meteorological instruments.
Although it is considered to be a straightforward matter to design a remotely readable compass using various well-known electronic transducers and the like, there is a need in some applications for simpler yet more reliable assemblies. For example, there is a need in some applications, particularly in the undersea applications noted above, for a remotely readable compass which does not require a battery or other independent power supply, and which is free of other electronic components so as to be relatively immune to the effects of corrosion and electromagnetic interference.
Further, remotely controlled instrumentation packages are increasingly being connected to remote stations by means of optical fibers, which are light in weight, inexpensive, and less susceptible to the effects of salt water or electrical interference. As optical fibers become increasingly prevalent in instrumentation packages, it becomes increasingly desirable to eliminate electrical wires and cables altogether, so that communication can be simplified by the use of single multi-strand optical fiber cables.
SUMMARY OF THE INVENTION
Accordingly, it is an object and purpose of the present invention to provide an improved remotely readable magnetic compass.
It is also an object of the present invention to provide a remotely readable magnetic compass which contains no electrical components.
It is another object of the present invention to provide a remotely readable magnetic compass wherein compass orientation information is both detected and communicated by means of light beams transmitted through optical fibers.
Additional objects, advantages and novel features of the invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
SUMMARY OF THE INVENTION
To achieve the foregoing and other objects, and in accordance with the purpose of the present invention as embodied and broadly described herein, the present invention provides a remotely readable compass comprising a magnet which is rotatably mounted in a compass body so as to be freely rotatable with respect to the compass body. The compass further comprises a rotatable sheet polarizer which is affixed to the magnet so as to be rotatable with the magnet with respect to the compass body about a common axis of rotation. The compass further comprises first and second excitation optical fibers which are affixed to the compass body and which terminate adjacent the rotatable sheet polarizer so as to direct light beams propagated through the fibers onto the rotatable sheet polarizer. There are also first and second return optical fibers which are affixed to the compass body and which are positioned respectively opposite the rotatable sheet polarizer from the first and second excitation fibers, such that the return fibers receive light which is emitted from the excitation fibers and transmitted through the rotatable sheet polarizer. The compass further includes first and second fixed sheet polarizers. The first fixed sheet polarizer is affixed to the compass body so as to be optically interposed between the first excitation fiber and the first return fiber, and the second fixed sheet polarizer is affixed to the compass body so as to be interposed between the second excitation fiber and the second return fiber. The fixed sheet polarizers have optical axes which are oriented orthogonally with respect to one another. In operation, light is emitted from the excitation fibers and transmitted through the fixed sheet polarizers and the rotatable sheet polarizer, whereupon the light is attenuated to varying degrees depending upon the orientation of the rotatable sheet polarizer with respect to the two fixed sheet polarizers. The attenuated beams are received in the return fibers. By measuring the ratio of the intensities of the light beams in the two return fibers, the angular orientation of the magnet with respect to the compass body may be determined.
The compass may further include first and second semicircular opaque strips formed on the sheet polarizer. Each of the opaque strips is geometrically centered on the axis of rotation of the rotatable sheet polarizer. The strips are disposed at different radii from the axis of rotation of the rotatable sheet polarizer. Further, the opaque strips each extend through a circumferential angle of approximately 180°, and are offset from one another circumferentially by an angle of approximately 90°. A pair of third and fourth excitation optical fibers are affixed to the compass body and terminate adjacent the rotatable sheet polarizer so as to direct light beams emitted therefrom onto the sheet polarizer at radii which correspond respectively to the radii of the first and second opaque strips. There are also third and fourth return optical fibers affixed to the compass body opposite the rotatable sheet polarizer from the third and fourth excitation fibers, respectively. The return fibers are positioned so as to receive light emitted from the third and fourth excitation fibers and transmitted through the sheet polarizer. The rotatable sheet polarizer either transmits or occludes light emitted from the third and fourth excitation fibers, depending upon the orientation of the rotatable sheet polarizer and the magnet with respect to the compass body. By determining the transmission or occlusion of light emitted by the third and fourth excitation fibers, the quadrant in which the magnet and the rotatable sheet polarizer are oriented may be unequivocally determined. Thus, by measuring the ratio of the intensity of the light beams received in the first and second return fibers, and by further determining the occlusion or transmission of the light beams emitted by the third and fourth excitation fibers, an unequivocal determination can be made of the direction in which the compass body is pointing.
In a preferred embodiment of the invention, the magnet and the rotatable sheet polarizer are mounted in a gimbal arrangement in a liquid filled case, whereby the magnet and the rotatable sheet polarizer are maintained in a horizontal position and accommodate modest deviations in the orientation of the case from an upright position. The light beams in the four excitation fibers may be generated by means of a single light beam transmitted through a primary excitation fiber, by means of a set of three evanescent wave couplers which are suitably disposed so as to divide a single light beam in the primary excitation fiber into four substantially equal light beams for transmission through the four excitation fibers.
These and other aspects of the present invention will become more apparent upon consideration of the accompanying drawings and the following detailed description of a preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate a preferred embodiment of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:
FIG. 1 is a side view in cross section of a preferred embodiment of the fiber optic compass of the present invention;
FIG. 2 is an end view in cross section of the compass shown in FIG. 1, taken along section line 2--2 of FIG. 1;
FIG. 3 is a plan view in cross section of the compass shown in FIGS. 1 and 2, taken along section line 3--3 of FIG. 2;
FIG. 4 is an enlarged isometric view of a portion of the compass shown in FIGS. 1, 2 and 3; and
FIG. 5 is a plan view of the compass disk and gimbal, illustrating the general operation of the compass.
DETAILED DESCRIPTION OF THE INVENTION
A preferred embodiment of the fiber optic compass of the present invention is shown in FIGS. 1 through 4. The particular embodiment illustrated in the Figures and described below is particularly adapted for use in undersea applications, for example, in submersible vehicles or in sonobuoys.
The compass includes a square case 10 made of suitable polymeric material. A square cover plate 12 is affixed to the open top of the case 10 by means of screws 14 and is sealed by means of an O-ring 16. The case is filled with a suitable liquid 18, for example, silicone oil, which functions as a damping medium for the movable magnetic element of the compass, described below, and which also enables the case 10 to withstand high pressures in an undersea environment.
A circular outer gimbal ring 20 is pivotably attached to opposite side walls of the case 10 by means of two jewel bearing assemblies 22 and 24 (FIG. 2), such that the ring 20 can rotate about the axis of rotation passing through the bearing assemblies 22 and 24. Pivotably attached to the inside of the outer gimbal ring 20 is an inner gimbal 26, which is attached to the outer ring 20 by means of two jewel bearing assemblies 28 and 30.
The bearing assemblies 28 and 30 are positioned on the ring 20 so as to define an axis of rotation which is orthogonal to the axis of rotation defined by the jewel bearing assemblies 22 and 24, such that the inner gimbal 26 is rotatable in two degrees of freedom with respect to the case 10. Both the inner gimbal 26 and the outer gimbal 20 are formed of suitable polymeric materials so as to be neutrally buoyant in the damping liquid 18. Affixed to the upper surface of the inner gimbal 26 is a float 32, and affixed to the lower surface of the inner gimbal 26 is a counterweight 34. This arrangement results in the inner gimbal seeking to maintain a level of orientation, despite deviations in the orientation of the case 10 of as much as approximately 20° from the vertical.
The rotatable magnetic element of the compass includes a rotatable sheet polarizer which consists of a rigid circular disk 36. The disk 36 is rotatably mounted in a central opening in the inner gimbal 26. Affixed to the upper and lower surfaces of the disk 36 are bar magnets 38 and 40, respectively. The bar magnets 38 and 40 are oriented such that their north-south axes are parallel to one another and both extend in the same direction, so that the two magnets effectively function as a single bar magnet in the ordinary manner of a simple compass. The disk 36 and its magnets 38 and 40 are rotatably mounted in an opening in the inner gimbal 26 by means of upper and lower jewel bearing assemblies 42 and 44, respectively. More specifically, the bearing assembly 42 includes a conical bearing cup 42a which is affixed to the upper bar magnet 38 and which is centered on the center of the disk 36; and an adjustable threaded jewel bearing pin 42b which extends from a threaded bore in the upper surface of the inner gimbal 26. Likewise, the lower bearing assembly 44 is also centered on the center of the disk 36 and includes a bearing cup 44a and an associated jewel bearing pin 44b. The other jewel bearing assemblies 22, 24, 28 and 30, described above, are constructed in essentially the same fashion.
The disk 36 is made of a light polarizing material, for example, the sheet polarizer sold by Polaroid Corporation under its trademark Polaroid. The magnets 38 and 40 are oriented on the disk so that the optical axis of the polarizing disk 36 is parallel to the parallel north-south axes of the magnets. The diameter of the disk 36 is significantly larger than the length of the magnets 38 and 40. The outer portion of the disk passes through a pair of narrow, horizontal transverse slots 26a and 26b formed in the inner gimbal 26.
The outer portion of the disk 36 includes first and second opaque strips 46 and 48. Each strip is semicircular and extends exactly half way around the disk, that is, through an arc of 180° around the disk. The strips 46 and 48 are radially spaced from one another but are concentric with one another and are each centered on the geometric center of the disk 36. That is, the strips 46 and 48 are positioned at different radii on the disk, with the strip 46 being positioned adjacent the outer periphery of the disk, and the second strip 48 being positioned radially inward from the periphery of the disk. The strips may be made of any coating or other material which is substantially opaque to light.
Further, the strips are offset circumferentially from one another by 90°. More specifically, the first strip 46 terminates at ends which lie on a line that passes through the center of the disk and which is orthogonal to the north-south axis of the magnets 38 and 40, and which is also orthogonal to the optical axis of the polarizing disk 36. The second strip 48 terminates at ends which lie on a line that passes through the center of the disk and which is parallel to both the north-south axis of the magnets and the optical axis of the disk.
The compass may be connected to a remote station by means of an optical fiber cable 50 which contains five optical fibers; a primary transmission fiber 52 and four return fibers 54, 56, 58 and 60. The cable 50 passes through the wall of the compass body 10. Light is generated at the remote station and is transmitted to the compass by means of the primary transmission fiber 52. Light may be generated at the remote station by any suitable means, although it is considered that light emitting diodes (LED's) or laser diodes are the most effective means for this purpose. The light beam in fiber 52 is divided into four substantially equal light beams by means of three commercially available evanescent wave couplers 62, 64 and 66. Each wave coupler operates to divide the beam into two equal beams, so by utilizing three couplers disposed as shown the original beam is divided into four equal beams. Referring now particularly to FIG. 4, the four light beams are transmitted from the wave couplers 64 and 66 by means of four excitation optical fibers 68, 70. 72 and 74, which are embedded in and pass through the inner gimbal 26 so as to terminate at the lower surface of the slot 26a in the inner gimbal 26. Each of the fibers is terminated with a graded refractive index rod, only one of which is identified by the numeral 76. The graded index rods are all identical, are commercially available, and operate to collimate the beam emitted from the end of the attached fiber.
The four fibers 68-74 open onto the lower surface of the slot 26a at positions which correspond to four different radii of the disk 36. Specifically, the fiber 68 is positioned such that light emitted from the fiber 68 is directed onto the underside of the disk at a radius which is centered on the first opaque strip 46. The fiber 70 is positioned slightly closer to the center of the disk, such that light from fiber 70 is directed onto the disk 36 at a radius which corresponds with the second opaque strip 48.
The remaining two fibers 72 and 74 open onto the lower surface of the slot 26a at positions which are progressively closer to the center of the disk. The ends of the graded index rods which terminate the fibers 72 and 74 are covered by small fixed sheet polarizers 78 and 80, respectively (FIG. 4). The fixed sheet polarizers 78 and 80 are oriented with their optical axes orthogonal to one another, as represented by the schematic striations in FIG. 4, and with the optical axis of the polarizer 78 oriented so as to extend parallel to the longitudinal axis of the inner gimbal 26.
Light which is emitted by the fibers 68-74 and transmitted through the disk 36 is received by the four return fibers 54-60, respectively. The latter fibers are embedded in the upper portion of the inner gimbal 26 so as to terminate at and open onto the upper surface of the slot 26a at positions which are aligned respectively with the ends of the excitation fibers 68-74. The ends of the return fibers 54-60 are provided with graded index rods to enhance collection of the light beams transmitted through the disk 36.
It will be noted that all of the optical fibers connected to the inner gimbal 26 are provided with excess length so as to provide sufficient flexibility to accommodate the range of motion of the gimbals relative to the case 10.
The intensity of the beams received in the return fibers 58 and 60 may be measured at a remote station, for example, with photodiodes. Photodiodes are preferred for this purpose because they are characterized by a constant sensitivity over approximately ten decades of light intensity. Suitable photodiodes include those commercially available from Hewlett-Packard Corp. under the identification number 5082-4207.
The operation of the compass will be described with particular reference to FIGS. 4 and 5. The intensities of the incoming light beams in the two excitation fibers 72 and 74 are substantially equal. These beams are polarized in transverse directions as a consequence of being directed through the respective fixed polarizing sheets 78 and 80 prior to being directed onto the polarizing disk 36. The light beams directed onto the disk from the two fibers 68 and 70, which are not polarized, are also substantially equal as a consequence of the four beams being derived by two successive divisions of a single beam.
As is well known from optical physics, the intensity of each of the beams transmitted through the disk 36 from fibers 72 and 74 is proportional to the square of the cosine of the angle between the optical axis of the polarizing disk 36 and the optical axis of the respective fixed polarizing sheets 78 and 80. Since the fixed polarizing sheets 78 and 80 are oriented with their optical axes orthogonal to one another and respectively parallel to and orthogonal to the longitudinal axis of the inner gimbal 26, and because the optical axis of the disk 36 is parallel to the north-south axis of the magnets, it follows that the ratio of the intensities of the beams passing through the disk is equal to the square of the tangent of the angle θ between the longitudinal axis of the inner gimbal 26 and the north-south axis of the magnets 38 and 40. This relationship is given by the equation:
(I.sub.60 /I.sub.58)=tan.sup.2 θ
where I 58 and I 60 represent the intensities of the light beams received in the return fibers 58 and 60, respectively.
However, the above equation has four possible solutions. That is, although an angle θ between the N-S axis of the magnets and the longitudinal axis of the inner gimbal 26 can be determined from the ratios of the beam intensities in fibers 58 and 60 according to the above equation, this information alone is not sufficient to establish which of the four possible compass quadrants (NE, NW, SE or SW) the compass points to, as there are four possible compass directions which will satisfy the equation. In this regard, the compass direction is taken as a direction along the longitudinal axis of the inner gimbal 26. This direction is arbitrarily selected, and in the illustrated embodiment is taken as the direction along the longitudinal axis of the inner gimbal which extends away from the end of the gimbal opposite the optical fibers, as shown by the arrow 82 in FIG. 5. Thus, for a given intensity ratio in fibers 58 and 60 which has a solution the angle θ, the true magnetic direction of the compass, as indicated by the angle of the longitudinal axis 82 of the inner gimbal 26 with respect to magnetic north, could be any one of the angles θ; θ'=180°-θ; θ"=180°+θ; or θ'"=360°-θ (see FIG. 5).
This ambiguity is resolved by the beams received in fibers 54 and 56, which are either occluded or transmitted depending on the positions of the semicircular opaque strips 46 and 48. Referring to FIG. 5, for example, there are shown the four possible compass directions (θ, θ', θ" and θ'") in which the compass may be pointing which will give rise to an angle that is a solution to the above equation. These four possible angles are determined as described above. By next observing that the light beam from fiber 68 is occluded by the opaque strip 46 and thus not received in fiber 54; and by also observing that the light beam from fiber 70 is occluded by the opaque strip 48 and thus not received in fiber 56, it can be unequivocally concluded that the longitudinal axis 82 of the inner gimbal 26 is pointed in the north-east quadrant, and it can thus be deducted that the true direction of the compass (uncorrected for local magnetic declination) is in fact the angle θ.
The foregoing description of a preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto.
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A remotely readable fiber optic compass. A sheet polarizer is affixed to a magnet rotatably mounted in a compass body, such that the polarizer rotates with the magnet. The optical axis of the sheet polarizer is preferably aligned with the north-south axis of the magnet. A single excitation light beam is divided into four identical beams, two of which are passed through the sheet polarizer and through two fixed polarizing sheets which have their optical axes at right angles to one another. The angle of the compass magnet with respect to a fixed axis of the compass body can be determined by measuring the ratio of the intensities of the two light beams. The remaining ambiguity as to which of the four possible quadrants the magnet is pointing to is resolved by the second pair of light beams, which are passed through the sheet polarizer at positions which are transected by two semicircular opaque strips formed on the sheet polarizer. The incoming excitation beam and the four return beams are communicated by means of optical fibers, giving a remotely readable compass which has no electrical parts.
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BACKGROUND
[0001] The present invention is related to the field of garment steamers that apply steam to remove wrinkles from clothing and similar fabric items.
[0002] Garment steamers are generally constructed to include a user-fillable reservoir for water, a heating element for generating steam from water in the reservoir, and an external surface from which the steam escapes to be directed to a garment or similar item being worked on. Some garment steamers may be sufficiently compact to be used in an entirely handheld fashion, while others may employ a larger, relatively stationary reservoir connected by a hose to a handheld steaming head that is maneuvered by a user during operation.
SUMMARY
[0003] There are a variety of aspects of garment steamers that affect their usability. The reservoir, for example, is preferably easy to refill and relatively large in order to reduce the frequency of refilling. The garment steamer preferably heats up quickly so as to be ready for use soon after it has been turned on. Portability is often desired, as the garment steamer may be used in multiple places or moved between a storage location and a location of use. The garment steamer should also be safe to use.
[0004] A garment steamer is disclosed that includes features for enhanced usability, especially with respect to safe and effective filling of the reservoir and heating of the water to generate steam. Other features are directed to portability and user handling of the garment steamer.
[0005] In one embodiment, a disclosed garment steamer includes a base and a housing configured to be removably attached to the base. For example, the housing may be detached from the base and carried by the user. In one embodiment, the housing for a garment steamer system may include a first portion having an inlet for receiving water and a second portion having an outlet for discharging water, the second portion being in communication with the first portion. In some instances, the first portion of the housing can be the top side or the side wall of the housing. In other instances, the second portion can be situated underneath or below the first portion. In general, each of the first portion and the second portion can be integrally formed as a single unit into a water tank or reservoir. The housing includes a first device, such as a fill plug, in communication with the inlet for substantially sealing water within the first portion. The first device is capable of extending into the first portion of the housing. The housing also includes a second device, such as a valve assembly, in communication with the outlet for substantially sealing water within the second portion. The second device can be actuated by the first device such that in an engaged configuration, water may exit from the outlet to a separate boiler where the water is heated into steam.
[0006] By use of the above configuration, water being heated is generally separated from the generally larger amount of water in the water tank, promoting faster heating. When the first device is removed to permit filling of the water tank, the second device is de-actuated. In the event that the boiler is still hot, this de-actuation of the second device prevents heated water and steam from escaping via the inlet and potentially scalding the user. Thus user safety is enhanced.
[0007] In one embodiment, the garment steamer system may include a support structure such as a pole for supporting a user-held head or handle from which steam exits during use. The garment steamer system may include a conduit such as a hose between the handle and the heating apparatus to facilitate transfer of steam from the base to the handle. In another embodiment, the base of the garment steamer system may include a plurality of wheels to facilitate mobility of the garment steamer. In some embodiments, the housing and the base may be integrally formed such that the first portion and the second portion of the housing, as well as the base, may be produced as a single unit using a plastic injection molding process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The foregoing and other objects, features and advantages will be apparent from the following description of particular embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of various embodiments of the invention.
[0009] FIG. 1 is an illustration of a garment steamer according to one embodiment of the present disclosure.
[0010] FIG. 2 is a perspective view of a garment steamer according to one embodiment of the present disclosure.
[0011] FIG. 3 is a top-down view of a housing of the garment steamer of FIG. 2 .
[0012] FIG. 4 is a side-view of a plug for the housing of the garment steamer of FIG. 2 .
[0013] FIG. 5 is a side-view of a portion of the housing of the garment steamer of FIG. 2 without the plug of FIG. 4 .
[0014] FIG. 6 is a schematic sectional view of the housing of the garment steamer of FIG. 2 .
[0015] FIG. 7 is a an illustration of a garment steamer according to another embodiment of the present disclosure.
[0016] FIG. 8 is a top perspective view of a base for the garment steamer of FIG. 7 .
[0017] FIG. 9 is a top perspective view of the housing of the garment steamer of FIG. 7 .
[0018] FIG. 10 is a rear view of a housing of the garment steamer of FIG. 7 .
[0019] FIG. 11 is a rear view of an upper part of a support structure of the garment steamer of FIG. 7 .
[0020] FIG. 12 is a first side view of the upper part of the support structure of the garment steamer of FIG. 7 .
[0021] FIG. 13 is a second side view of the upper part of the support structure of the garment steamer of FIG. 7 .
DETAILED DESCRIPTION
[0022] FIG. 1 is an illustration of a garment steamer 10 according to one embodiment of the present disclosure. The garment steamer 10 includes a base 70 configured to support a housing 20 , where the housing 20 is capable of housing a water tank and a heating apparatus such as a boiler for converting water into steam, among other electrical components and circuitry. In one embodiment, the housing 20 and the base 70 may be integrally formed as a single unit or single component. In other words, the housing 20 and the base 70 may be concurrently manufactured via a plastic injection molding process.
[0023] The bottom of the base 70 may include a plurality of wheels 60 to facilitate transportation of the garment steamer 10 from place to place as necessary. In some instances, a support structure 30 such as a telescopic pole may be coupled to the top of the base 70 , the support structure 30 being substantially adjacent to the housing 20 . The support structure 30 may support the likes of a handle or “head” 90 , which may be in fluid communication with the housing 20 via a conduit 40 such as a hose for delivering steam onto a garment or similar item (not shown). In some embodiments, the support structure 30 may also include a hook for holding a piece of clothing or garment. In other embodiments, the handle 90 may include an on/off switch or a trigger (not shown) for discharging steam.
[0024] FIG. 2 is a perspective view of a garment steamer 10 according to one embodiment of the present disclosure, where the support structure 30 of the garment steamer 10 is in a retracted position. As shown, the top of the support structure 30 may include a holder 31 for supporting the handle 90 ( FIG. 1 ). In some instances, a side wall of the housing 20 may include an electrical cord 80 which may be plugged into a wall outlet for powering electrical assemblies and components within the housing 20 .
[0025] FIG. 3 is a top-down view of the housing 20 of the garment steamer 10 of FIG. 2 . In some embodiments, the upper section of the housing 20 may include a handle 21 to facilitate removal of the housing 20 from the base 70 . In other embodiments, the handle 21 may facilitate transportation of the housing 20 when the housing 20 is detachably removed from the base 70 . In some instances, the housing 20 may also include a strap (not shown) for carrying the housing 20 on a user's shoulder. In one embodiment, the top of the housing 20 includes an inlet 22 for filling a reservoir within the housing 10 with water.
[0026] FIG. 4 is a side-view of a cover or plug 50 for the housing of the garment steamer 10 of FIG. 2 . In one embodiment, the cover or plug 50 may be a device that can be removably coupled to the inlet 22 of the housing 20 to ensure that water does not spill when it is received in the housing 20 . In one example, the plug 50 may be secured to the inlet 22 by a twisting action (e.g., clockwise or counterclockwise). In another example, the plug 50 may secure the inlet 22 by a push-pull action using flexible valve baffles. In other instances, the plug 50 may be substantially secured to the inlet 22 via other suitable securing mechanism including a combination of twisting and pushing action, among others. In one embodiment, the bottom portion of the plug 50 may include an extension 52 that may extend substantially into the housing 20 when the plug 50 is coupled to the inlet 22 . The extension 52 may be used to trigger a complementary assembly within the housing 20 which will become more apparent in subsequent figures and discussion.
[0027] FIG. 5 is a side-view of a portion of the housing 20 of the garment steamer 10 of FIG. 2 . In one embodiment, the housing 20 includes a first section 24 and a second section 28 . In some instances, each of the first section 24 and the second section 28 may form a portion of a water tank for storing water in the housing 20 . In other instances, the first section 24 and the second section 28 may collectively form a water tank within the housing 20 . In some embodiments, the first section 24 and the second section 28 may be integrally formed as a single unit.
[0028] In one embodiment, the first section 24 includes an inlet 22 for receiving water in the first section 24 . The inlet 22 may be sealed by a plug 50 or other suitable securing devices. In some embodiments, the first section 24 may include the top side of the housing 20 . In other embodiments, the first section 24 may include a side wall of the housing 20 . In one embodiment, the second section 28 includes an outlet 29 where water can exit from the second section 28 . In one embodiment, the second section 28 may include an actuable assembly 26 . The actuable assembly 26 may be a valve assembly 26 capable of being actuated by the plug 50 . For example, the valve assembly 26 may engage the extension 52 of the plug 50 . In one embodiment, in a disengaged position (e.g., plug 50 unsecured or removed), the valve assembly 26 is not being actuated by the extension 52 . Accordingly, the valve assembly 26 is able to substantially secure the outlet 29 and prevent water from leaving. It will be appreciated that this can be accomplished using a spring or similar element to bias the valve assembly 26 in a closed position, where the bias is overcome upon actuation by the extension 52 of the plug 50 moving the valve assembly 26 into an open position. In other instances, the valve assembly 26 can be coupled to the outlet 29 in a substantially similar manner as that of the plug 50 and the inlet 22 for performing substantially similar functions.
[0029] FIG. 5 shows the garment steamer 10 including the plug 50 installed or located in the inlet 22 . In this configuration with the plug 50 coupled to the inlet 22 , the plug 50 can substantially seal water within the first section 24 . In addition, the extension 52 of the plug 50 extends substantially into at least a portion of the first section 24 for actuating the valve assembly 26 when the inlet 22 is secured with the plug 50 , as explained in more detail below.
[0030] FIG. 6 is a schematic view of the housing 20 of the garment steamer 10 of FIG. 2 , the schematic including structure shown in FIG. 5 . As shown, the housing 20 also includes a water drain 36 , a heating element assembly 32 , a boiler assembly 34 , and a conduit 40 for sending the steam up into the handle 90 ( FIG. 1 ). In case there is excess water buildup, it may be drained by unplugging the plug in the water drain 36 . FIG. 6 shows the plug 50 and valve assembly 26 in the above-discussed configuration in which the extension 52 actuates the valve assembly 26 of the second section 28 such that water can exit the outlet 29 . Once water exits the second section 28 as indicated by the arrow, water can be heated by the heating element assembly 32 and the boiler assembly 34 . In some embodiments, additional electrical components or circuitry (not shown) may be incorporated as necessary for heating purposes. Once an appropriate temperature has been achieved, water can be converted to steam and transported up the conduit 40 to be discharged from the handle 90 onto a piece of garment.
[0031] Some of the advantages of the current system over those of the prior art include the ability to retain water in the housing 20 without substantial leaking to occur, among others. This can occur when the housing 20 is attached to the base 70 or when the housing 20 is used as a mobile unit. In addition, minimal condensation may form within the conduit 40 .
[0032] FIG. 7 is an illustration of a garment steamer 110 according to a second embodiment of the present disclosure. The garment steamer 110 includes a base 170 configured to support a housing 120 , where the housing 120 is capable of housing a water tank and a heating apparatus such as a boiler for converting water into steam, among other electrical components and circuitry. In one embodiment, the housing 120 and the base 170 may be integrally formed as a single unit or single component. In other words, the housing 120 and the base 170 may be concurrently manufactured via a plastic injection molding process.
[0033] The bottom of the base 170 may include supports such as front posts 172 and rear wheels 160 , which facilitate transportation of the garment steamer 110 from place to place as necessary. To this end, a foldable handle 200 is used to tilt and steer the garment steamer during such transportation on a floor or similar surface. A support structure 130 such as a telescopic pole may be coupled to the top of the base 170 , the support structure 130 being substantially adjacent to the housing 120 . The support structure 130 includes a plurality of pole segments 132 and segment locks 134 . The support structure 130 may also include a holder 131 for supporting a handle or “head” 190 , which is generally in fluid communication with the housing 120 via a conduit 140 such as a hose for delivering steam onto a garment or similar item (not shown). The handle 90 may include an on/off switch or a trigger (not shown) for discharging steam. As shown, the support structure 130 may also support the foldable handle 200 , as well as a cross arm 210 with a clip 212 for holding a garment in position as described in more detail below.
[0034] FIG. 8 provides a top view of the base 170 , showing a central well 174 for receiving the housing 120 . Channels 176 provide clearance for passage of electrical cords extending from the rear of the housing 120 as described below. The support structure 130 is secured to the base 170 by a female threaded collar 178 that holds a flanged end of the lowest pole 132 against a corresponding male threaded post (not visible) extending upwardly from the base 170 .
[0035] In FIG. 8 the cross arm 210 is shown in a vertical or “unused” position, having been rotated 90 degrees from the horizontal or “in-use” position of FIG. 7 . In the unused position there is less possibility of the cross arm 210 undesirably interfering with a user or with other apparatus.
[0036] FIG. 9 shows an upper part of the housing 120 including a plastic sleeve 142 on the lower part of the conduit 140 where it meets the housing 120 . An electrical cord 144 passes through a lateral opening of the sleeve 142 and extends along the length of the conduit 140 to the handle 190 ( FIG. 7 ). Within the conduit 140 , the electrical cord 144 is disposed between an inner flexible hose member of the conduit 140 (not shown) an a woven outer sheath of the conduit 140 (visible in FIG. 9 ). The electrical cord 144 provides electrical current to a heating element in the handle 190 as described in more detail below.
[0037] Also shown in FIG. 9 is a fill plug 150 used to close a fill opening 122 in the top of the housing 120 . The fill plug 150 may mechanically engage the fill opening 122 in any of a variety of ways, including for example by use of a surrounding O ring or similar component establishing a frictional fit, or by screw threads or similar twisting mechanism. The fill plug 150 includes an extension 152 that engages an actuable assembly or valve within the housing 120 in the same manner as discussed above for the plug extension 52 and actuable assembly 26 . The fill plug 150 is secured to the housing 120 by an elongated tether 154 , preferably made of a flexible and strong plastic material.
[0038] FIG. 10 shows the rear of the housing 120 . The electrical cords 180 and 144 extend rearward from respective projections 128 of the housing 120 . As mentioned above, the end portions of the electrical cords 180 , 144 at the housing 120 are received within the channels 176 of the base 170 ( FIG. 8 ) when the housing 120 is seated thereon.
[0039] FIG. 11 shows the upper part of the support structure 130 and handle 190 in greater detail. The handle 190 includes an electrically heated pressing element 192 and an immediately adjacent steaming area shown covered by a permeable cloth 194 . The steaming area of the handle 190 generally includes a plurality of small openings (not visible in FIG. 11 ) through which steam from the conduit 140 passes in use. The pressing element 192 is heated by internal electrical coils with current from the electrical cord 144 ( FIG. 9 ). In one embodiment, the pressing element 192 has a positive-temperature-coefficient (PTC) characteristic that automatically regulates the operating current and temperature. The pressing element 192 is preferably heated at a rate commensurate with the rate at which steam is generated, so that a situation can be avoided in which steam contacts a relatively cold pressing element 192 forming undesired condensation.
[0040] Also shown in FIG. 11 is the foldable handle 200 in a downward or retracted position. A pushbutton 202 is used to release an internal rotary latch to enable the foldable handle 200 to be rotated to an upward or in-use position. Formed integrally with the foldable handle 200 is a hook 204 usable to receive a clothes hanger to support a garment which is to receive steam treatment. In this case the garment will hang downward, and the support structure 130 and cross arm 210 can be adjusted so that the clip 212 ( FIG. 8 ) can hold the bottom part of the garment in place.
[0041] FIG. 12 shows a side view of the upper part of the support structure 130 with the foldable handle 200 in the downward position as in FIG. 11 .
[0042] FIG. 13 shows a side view of the upper part of the support structure 130 with the foldable handle 200 in an upward position, having been rotated upward from the downward position of FIG. 12 . In this position, the foldable handle 200 can be grasped by a user to enable the user to both tilt the garment steamer 110 rearward and push or pull to move the garment steamer 110 on its rear wheels 160 .
[0043] While various embodiments of the invention have been particularly shown and described, 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 scope of the invention as defined by the appended claims.
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A garment steamer has a housing with a reservoir and a boiler for converting water to steam. The housing includes a normally closed valve in a flow path between the reservoir and the boiler. A removable fill plug in a fill opening or inlet of the reservoir is configured to engage the valve to permit water to be communicated from the reservoir via an outlet to the boiler for conversion into steam. The plug-actuated valve isolates the boiler from the reservoir when the plug is removed, providing safer refilling when the boiler is hot. The garment steamer also includes a steam discharge head coupled by a hose to the housing and configured to direct steam onto a garment or similar item.
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BACKGROUND OF THE INVENTION
[0001] The present invention is directed to an improved capacitor. More specifically, the present invention is directed to a capacitor comprising channels for directing flex cracks in a benign direction wherein the function of the capacitor is not hindered.
[0002] Capacitors are well known in the art of electrical components. Capacitors typically comprise parallel plates with a dielectric there between. The parallel plates act as charge collectors and sources. The function of capacitors is well known and further discussion is not warranted herein.
[0003] Capacitors are passive elements that are added to circuitry with the primary function of being a source of energy for circuit functionality. Capacitors are primarily mounted onto circuit traces as a reserve of energy, and in themselves do not typically contribute to the circuit charge or discharge path.
[0004] Multilayer ceramic capacitors (MLCC) are used in a variety of electrical applications including automotive products, aerospace products, heavy equipment and military applications, as examples. Typical applications include telemetrics, entertainment systems, drive control systems, environmental control systems, console instrumentation, communication systems, weapons fire control systems, detection systems and the like. Many applications involve particularly harsh environments including extreme temperature and humidity excursions, vibrations, jolting, and other potentially harmful activities. All of these conditions can lead to substrate flexing which places considerable stress on the capacitor. The stresses due to flexing typically lead to failures in the insulation and are referred to as insulation failure (IR) losses.
[0005] Flex cracks, which are a common problem in MLCC's, often lead to a loss of both capacitance and IR. Decreases in IR is considered to be the most severe issue with regards to the percentage of diagnosed capacitor failures, severe cases lead to “short-circuit” and circuit failure. They can occur in many areas of the lifecycle including manufacturing, device assembly, module assembly and during the ultimate application or use. Flex cracks lead to a myriad of problems from manufacturing losses to complete device malfunction with many failure modes there between. As there is no method for 100% electrical or visual testing of this fault, most problematic is the flex crack whose failure is delayed to the point where field failures occur.
[0006] Various designs have been described to avoid flex cracks. These include open-mode, floating electrode and flexible termination capacitors. The open-mode designs use wide end margins to prevent the crack from propagating into the active area. Floating electrode capacitors use coplanar non-contacting electrode plates with non-terminated plates interleaved between the planes. Flexible terminations create an elastic connection to the substrate, or printed circuit board, so that small displacements at the termination point on the substrate can be withstood without cracks occurring in the capacitor.
[0007] Eliminating flex cracks has proven to be a very difficult task using the techniques currently employed in the art. Furthermore, the methods described are design specific therefore requiring a different method of crack failure mitigation with each new capacitor design. The present invention provides a method of mitigating the impact of flex cracks which is not design specific.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to provide an improved capacitor wherein failures resulting from stress cracks are mitigated.
[0009] It is another object of the present invention to provide a capacitor which channels stress cracks to a location wherein minimal damage to the conductive electrodes occurs.
[0010] A particular feature of the present invention is the ability to manufacture the capacitor in conventional manufacturing equipment with minimal changes to manufacturing equipment, chemical compositions used or process.
[0011] These and other advantages, as will be realized, are provided in a capacitor with parallel plates of opposing polarity and a dielectric there between and with at least one crack mitigation void between a lower face of the capacitor and a first plate of the parallel plates.
[0012] Yet another embodiment of the invention is provided in a method of forming a capacitor comprising:
[0000] forming a channel layer wherein the channel layer comprises at least one pre-channel in a predetermined pattern;
forming a first conductor over the channel layer;
forming a dielectric on the first electrode;
forming a second conductor on the dielectric; and
removing the pre-channel thereby forming a crack mitigation void in the predetermined pattern.
BRIEF DESCRIPTION OF FIGURES
[0013] FIG. 1 is a cross-sectional schematic view of a capacitor with a stress crack therein.
[0014] FIG. 2 is a cross-sectional schematic view of a floating plate electrode with fail-open end margins.
[0015] FIG. 3 is a cross-sectional schematic view of an embodiment of the present invention.
[0016] FIG. 4 is a partial cross-sectional schematic view of an embodiment of the present invention wherein the utility is illustrated.
[0017] FIG. 5 is a partial cross-sectional schematic view of another embodiment of the present invention wherein the utility is illustrated.
[0018] FIGS. 6 is an exploded perspective and cross-sectional schematic views of embodiments of the present invention.
[0019] FIGS. 6 a - 6 c further illustrate the formation of the channel layer of FIG. 6 .
[0020] FIG. 7 is an exploded perspective and cross-sectional schematic views of embodiments of the present invention.
[0021] FIGS. 7 a - 7 c further illustrate the formation of the channel layer of FIG. 7 .
[0022] FIG. 8 is an exploded perspective and cross-sectional schematic views of embodiments of the present invention.
[0023] FIGS. 8 a - 8 c further illustrate the formation of the channel layer of FIG. 8 .
DETAILED DESCRIPTION OF THE INVENTION
[0024] The invention will be described with reference to the drawings forming an integral part of the disclosure. In the various figures similar elements will be numbered accordingly.
[0025] A capacitor is illustrated in schematic cross-sectional view in FIG. 1 . The capacitor, generally represented at 1 , is attached to a substrate, 2 , such as by solder, 3 , at circuit traces, 9 . The capacitor comprises parallel plates, 4 , alternately in contact with the external terminations, 5 , of opposing polarity covering the termination face, 5 ′, with overlaps along the top and bottom face, 10 of the capacitor. A dielectric, 6 , is between the plates. Flexing of the substrate places compressive or strain forces on the capacitor. Compressive forces are not crucial but once the strain reaches a critical level a stress crack, 7 , is created. As illustrated in FIG. 1 the stress crack is generally directed away from the substrate at an acute or right angle, initiating at the terminal edge, 8 , along the bottom face, 10 , of the external termination, and rising up into the body of the capacitor and terminating at the termination face, 5 ′, or top face of the capacitor. The crack may also project upward at a right angle into the top face of the capacitor, or start out at an acute angle and then curve upward into the top face. While not readily visible from this view the stress crack is typically completely through the capacitor, into and out of the plane of the view, and causes a fracture of at least some of the plates, possibly decreasing the capacitance. As would be readily realized a typical capacitor may have hundreds of plates and the number of plates subject to shearing is very large relative to the schematic views illustrated herein. Critical in this crack creation is that it creates the foundation for a conductive path, through the insulating ceramic across oppositely terminated electrode plates. Upon initial creation, there is normally no entrapment of conductive material and the device may appear with “normal” leakage resistance and capacitance. With moisture ingress into the crack over time, the moisture may carry conductive ions, and over time, a conductive path is formed. The conductivity of this path can increase over time, and fault current here may reach levels to degrade the component to catastrophic failure.
[0026] FIG. 2 illustrates prior art in cross-sectional schematic view in which extended end margins and a floating electrode design are incorporated to establish a fail-safe design. This drawing represents the embodiment of two methods practiced today to mitigate the leakage failures in ceramic capacitors: extending the end-margins free of opposing electrodes, 53 , and creating two capacitors in series. The end margin of the termination overlap creates boundaries, 52 , where a crack initiated at the edge, 8 , at an acute angle direction now extends into a region, 53 , where the only electrodes it crosses are of the same polarity. If the crack became conductive, it would not draw any leakage current as the electrodes are of the same termination. The floating electrode capacitor, 50 , has adjacent non-connecting conductive plates, 16 , and floating plates, 51 , whereby they end before the outside termination wraps, 52 , and outside the safe region, 53 . Non-connecting conductive plates are preferably parallel and in common planes across the capacitor with coplanar plates being of opposing polarity. The current path is from non-connecting terminating plates on one side to the floating plates then to the non-connecting terminating plates on the opposing side, effectively creating two capacitors in series. This represents the ultimate in present mitigation techniques in case the ends of the floating electrode extend into the safe region, a near right angle crack could involve electrodes of opposite polarity but it would involve only one of the two capacitors in series. The chances that the floating electrode could violate safe regions, 53 , at both ends, and have both capacitors suffer cracks simultaneously is small. Both ends would have to fail simultaneously because if one end fails first, there is no mechanical anchor at that end to develop strain on the other end. Alternative offerings include using the floating electrode or cascade design alone, or using the safe-region created with shorter electrodes. All of these practices improve flex reliability, but all allow the crack to penetrate deep into the body of the capacitor.
[0027] An embodiment of the present invention is illustrated in schematic cross-sectional view in FIG. 3 . In FIG. 3 a capacitor comprising alternating plates, 4 , external terminations, 5 , and dielectric, 6 , between and partially encasing the plates is illustrated. A series of crack mitigation voids, 11 , between the lower face, 10 , and first outermost plate, 4 , provides protection from crack propagation. These crack mitigation voids could be cylindrical projections perpendicular to the plane of the view, and in this view would appear as circular shapes as the cylindrical shape is being cut perpendicular to its height.
[0028] The advantages of the present invention will be described with reference to FIG. 4 , wherein a partial cross-sectional area of an inventive capacitor is illustrated. In FIG. 4 , a series of crack mitigation voids, 11 , are provided which form a line, which is preferably arranged parallel to the plates and perpendicular to the capacitor's termination face, 5 ′. Cracks, represented at 100 , typically form at the junction of the edge of the bottom termination wrap, 8 , and extend across a portion, up to the entire width, of the capacitor body. This is not visible in FIG. 4 since the crack would extend at a large angle relative to the page and typically approximately perpendicular to the page. While not limited thereto, the invention will be described based on this most common failure mode with the understanding that crack initiation anywhere along the lower face, 10 , will be mitigated by the invention. A crack typically propagates at an acute angle away from the lower face, 10 . As realized from the discussion above the crack typically damages plates, 4 ′ and 4 . In the present invention the crack mitigation voids, 11 , are arranged in a row, preferably parallel to the lower face, such that as the crack propagates it encounters a crack mitigation void. The crack mitigation voids, represented as cylindrical crack mitigation voids without limit thereto, has a general structure of crack mitigation voids, 11 , and struts, 12 , between the crack mitigation voids. It is preferable that the width of the struts, measured as the closest approach of adjacent crack mitigation voids, be less than the closest distance between the crack mitigation voids and the closest plate. The struts therefore represent the lowest path of resistance for crack propagation thereby persuading the crack to propagate along the line of crack mitigation voids into the termination face, 5 ′, as illustrated, and prohibiting them from approaching the plates, 4 ′ and 4 . The crack is therefore channeled to a location which is not harmful to the capacitor while, at the same time, allowing the stress to be relieved.
[0029] As illustrated in FIG. 4 , crack propagation tends to migrate at an acute angle towards the closest termination face, 5 ′. In order to capture this crack, the series of crack mitigation voids must extend from the termination face to a point beyond the termination wrap's edge, 8 , along the bottom face of the capacitor. The crack mitigation voids may extend the entire length of the capacitor but this is not preferred due to the lack of structural integrity of the capacitor in this instance.
[0030] Another embodiment of the invention is illustrated in FIG. 5 . In FIG. 5 an open channel, 13 , is provided wherein a crack, 100 , which propagates to the channel will be mitigated from proceeding beyond the channel. This rectangular shape could be created by a series of parallel cylinders of the crack mitigation voids wherein the height of the cylinder is parallel to the plane of the drawing. In the same manner that the crack mitigation voids in FIG. 4 are a manifestation of parallel cylinders with a channel separation, 12 , these parallel cylinders would be separated in a like manner, each cylinder at a progressive depth into the capacitor body maintaining a like separation.
[0031] A preferred method of manufacturing the capacitor will be described with reference to FIGS. 6-8 . In each of FIGS. 6-8 an inventive capacitor, 40 , is illustrated schematically after sintering on the right side of the figure and in blown-apart perspective in the left side of the figure prior to sintering for clarity and to facilitate description. For convenience, a sintered layer of ceramic will be indicated by a primed number.
[0032] A base layer, 20 , which is preferably a ceramic dielectric is provided in accordance with the standard practice for MLCC manufacture in the art. A ceramic dielectric is preferred for manufacturing simplicity since the same material as the dielectric can be used thereby minimizing the number of materials and eliminating differences in the coefficient of thermal expansion. At least one channel layer, 21 , is applied to the base layer, 20 . It is preferred that multiple channel layers be applied thereby increasing the total thickness. Alternatively, a thick pre-channel layer can be applied, however, the application of multiple layers may be more efficient from a manufacturing perspective. The channel layer comprises pre-channels, 22 - 24 , with a predefined, preferably parallel, configuration. The pre-channels are areas of material which evaporate during the sintering of the channel layer. The pre-channels can be printed by any method, however, for convenience it is preferable that the channel layer be printed in a manner consistent with formation of the electrode. When the channel layer is sintered the material in the pre-channel is volatilized thereby leaving a crack mitigation void. The crack mitigation void is approximately the shape and dimensions of the pre-channel. The shape of the pre-channel is not particularly limited herein. It is preferable that the pre-channel terminate at a face to facilitate the escape of volatilized pre-channel material from the interior of the monolith during sintering. Pre-channels which are parallel to the side of the capacitor, as illustrated at 22 , are particularly preferred since they form cylindrical-like crack mitigation voids in the eventual capacitor, corresponding to the crack mitigation void detailed in FIG. 5 . Pre-channels which run perpendicular to a side of the capacitor, as illustrated at 23 , may be utilized to provide an open channel, and these patterns would create the patterns shown in FIG. 7 . Pre-channels arranged in a cross-hatch pattern, as illustrated at 24 , may be used to provide a crack mitigation void region with distinct pillars therein. When multiple layers are combined to form a channel layer each layer may be substantially identical to the previous layer such that the overlaid pre-channels coalesce into a continuous channel during sintering. In other embodiments adjacent layers, or groups of adjacent layers, may have a different pattern.
[0033] A first polarity layer comprising a dielectric, 25 , and first conductive layer, 26 , is applied atop the channel layer. The first conductor layer preferably comprises a first conductor which extends to an edge for eventual electrical contact with an external termination. A second polarity layer comprising a dielectric, 27 , and second conductive layer, 28 is applied to the first polarity layer such that the first and second conductive layers are separated by a dielectric with termination at differing external terminations. Additional first and second polarity layers are applied with each conductive layer separated from the adjacent conductive layer by a dielectric until the predetermined number of alternating plates is obtained. It is realized in the art that the parallel plates separated by a dielectric provide the function of capacitance. The polarity layers may be added sequentially wherein, for example, a dielectric layer is formed followed by a first conductive layer, followed by a dielectric layer, followed by a second dielectric layer in repeating sequence. Alternatively, the capacitor layer comprising a dielectric and first conductor may be formed and then deposited followed by a dielectric and second conductor being formed and then deposited. Any number of preformed layers may be utilized.
[0034] After a sufficient number of plates of alternating polarity are provided an optional, but preferred, second channel layer, 29 , is applied. The second channel layer comprises a pre-channel, 30 - 32 , as described above. A top base layer, 33 , is preferably added on the channel layer. As it is preferable that the finished capacitor be mounted in a manner where the crack mitigation void elements are along the bottom face of the chip, the top layer of crack mitigation void patterns allows the chip to be mounted top-up or top-down to create the required arrangement. As it is imperative that the crack mitigation voids be along the bottom face of the capacitor, capacitor styles where the width and thickness are indistinguishable would require external marks, such as electrode ink dots, on the top and bottom face of the chip to correctly identify a top or bottom face alignment.
[0035] The assembly is heated to form sintered ceramic, 21 ′, 25 ′, 27 ′ and 29 ′ and crack mitigation voids, 22 ′, 23 ′, 24 ′, 30 ′, 31 ′ and 32 ′.
[0036] Channel layer formation is more thoroughly described with reference to FIGS. 6 a - c , 7 a - e and 8 a - b . In each illustration the channel layer, 296 - 298 , is formed by building up sequential layers. In each layer a pre-channel material, 306 - 308 , is printed in a pattern which will correspond to the crack mitigation void, 316 - 318 . Upon sintering the pre-channel material vaporizes leaving a void in the shape of the printed channel. As illustrated in FIGS. 6 a - c , the pre-channel material, 306 , is printed in the form of a rectangle which ultimately forms a rectangular crack mitigation void, 316 . In FIGS. 7 a - 7 e the pre-channel material is printed in patterns which are progressively wider towards the middle and than progressively narrower thereby approximating a somewhat cylindrical bore as the crack mitigation void 317 . In FIGS. 8 a - b a honeycomb pattern is printed thereby yielding a crack mitigation void, 318 , with pillars therein. It is preferable that the void comprise open areas with no pre-channel material totally enclosed thereby facilitating vaporization of the pre-channel material during sintering.
[0037] The pre-channel material is any material which can be applied in a predetermined pattern and, upon sintering of the layer, leaves a crack mitigation void. A particularly preferred material is an electrode ink with the metal excluded there from. Such materials are preferred due to their ready availability and their inherent suitability with the manufacturing environment.
[0038] It is most preferable that the capacitor have a rectangular configuration, most preferably, with the thickness being less than the width. The width is determined parallel to the plates and the thickness is determined perpendicular to the plates. If a square configuration is used it is difficult to insure that the plates are perpendicular to the substrate unless a physical element is included in the shape to indicate orientation. Pick and place devices can not easily distinguish orientation for a square, or symmetrical, part easily and elements such as visual recognition, to indicate orientation are cost prohibitive. Therefore, it is most preferable to avoid square capacitors due to the inability to easily predict the orientation of the plates in a manufacturing environment. In a particularly preferred embodiment the width is at least about 10% greater than the thickness. This allows for the correct orientation of capacitors with the electrode plates in a vertical orientation. As flex cracks are more abundant in larger ceramic chip capacitors, this method would not typically be necessary from chips sizes of 0603 (6 mm×3 mm) and smaller.
[0039] The capacitor is preferably designed to accommodate pick and place equipment. Typically, parts are placed on a printed circuit board using automated pick and place equipment that removes parts from a tape. The tape has slots in which the capacitors reside and the tape is typically on a reel. The parts must be properly oriented within the slots of the tape to insure vertical orientation. Most reelers utilize precision slots and vibration to align and load parts into the pockets of the tape packaging. To insure adequate placement within the indention it is preferable for the parts to have a width to thickness ratio greater than 1.1 to 1.0 for the parts to always fall properly into the slots. Decreasing the center of gravity of the parts drives them to orient with the wide side down.
[0040] The dielectric layers have an appropriate Curie temperature which is determined in accordance with the applicable standards by suitably selecting a particular composition of dielectric material. Typically the Curie temperature is higher than 45° C., especially about 65° C. to 125° C.
[0041] Each dielectric layer preferably has a thickness of up to about 50 μm, more preferably up to about 20 μm. The lower limit of thickness is about 0.5 μm, preferably about 2 μm. The present invention is effectively applicable to multilayer ceramic chip capacitors having such thin dielectric layers for minimizing a change of their capacitance with time. The number of dielectric layers stacked is generally from 2 to about 300, preferably from 2 to about 200.
[0042] The conductor which forms the internal electrode layers is not critical, although a base metal preferably is used since the dielectric material of the dielectric layers has anti-reducing properties. Typical base metals are nickel and nickel alloys. Preferred nickel alloys are alloys of nickel with at least one member selected from Mn, Cr, Co, and Al, with such nickel alloys containing at least 95 wt % of nickel being more preferred. It is to be noted that nickel and nickel alloys may contain up to about 0.1 wt % of phosphorous and other trace components.
[0043] The thickness of the internal electrode layers may be suitably determined in accordance with a particular purpose and application although its upper limit is typically about 5 μm, more preferably about 2.5 μm, and its lower limit is typically about 0.5 μm. Most preferable is a thickness of about 1 μm.
[0044] The conductor which forms the external electrodes is not critical, although inexpensive metals such as nickel, copper, and alloys thereof are preferred. The thickness of the external electrodes may be suitably determined in accordance with a particular purpose and application although it generally ranges from about 10 μm to about 50 μm. In one embodiment a conductive metal, preferably silver, filled epoxy termination is utilized as a termination.
[0045] The multilayer ceramic chip capacitor of the present invention generally is fabricated by forming a green chip by conventional printing and sheeting methods using pastes, firing the chip, and printing or transferring external electrodes thereto followed by baking.
[0046] Paste for forming the dielectric layers can be obtained by mixing a raw dielectric material with an organic vehicle. The raw dielectric material may be a mixture of oxides and composite oxides as previously mentioned. Also useful are various compounds which convert to such oxides and composite oxides upon firing. These include, for example, carbonates, oxalates, nitrates, hydroxides, and organometallic compounds. The dielectric material is obtained by selecting appropriate species from these oxides and compounds and mixing them. The proportion of such compounds in the raw dielectric material is determined such that after firing, the specific dielectric layer composition may be met. The raw dielectric material is generally used in powder form having a mean particle size of about 0.1 to about 3 μm, preferably about 1 μm.
[0047] The organic vehicle is a binder in an organic solvent. The binder used herein is not critical and may be suitably selected from conventional binders such as ethyl cellulose. Also the organic solvent used herein is not critical and may be suitably selected from conventional organic solvents such as terpineol, butylcarbinol, acetone, and toluene in accordance with a particular application method such as a printing or sheeting method.
[0048] Paste for forming internal electrode layers is obtained by mixing an electro-conductive material with an organic vehicle. The conductive material used herein includes conductors such as conductive metals and alloys as mentioned above and various compounds which convert into such conductors upon firing, for example, oxides, organometallic compounds and resinates. The organic vehicle is as mentioned above.
[0049] Paste for forming external electrodes is prepared by the same method as the internal electrodes layer-forming paste.
[0050] No particular limit is imposed on the organic vehicle content of the respective pastes mentioned above. Often the paste contains about 1 to 5 wt % of the binder and about 10 to 50 wt % of the organic solvent. If desired, the respective pastes may contain any other additives such as dispersants, plasticizers, dielectric compounds, and insulating compounds. The total content of these additives is preferably up to about 10 wt %.
[0051] A green chip then may be prepared from the dielectric layer-forming paste and the internal electrode layer-forming paste. In the case of printing method, a green chip is prepared by alternately printing the pastes onto a substrate of polyethylene terephthalate (PET), for example, in laminar form, cutting the laminar stack to a predetermined shape and separating it from the substrate.
[0052] Also useful is a sheeting method wherein a green chip is prepared by forming green sheets from the dielectric layer-forming paste, printing the internal electrode layer-forming paste on the respective green sheets, and stacking the printed green sheets. A capacitor with a large number of layers can be prepared in this manner as well known in the art.
[0053] The method of forming the capacitor is not particularly limiting herein.
[0054] The binder is then removed from the green chip and fired. Binder removal may be carried out under conventional conditions, preferably under the following conditions where the internal electrode layers are formed of a base metal conductor such as nickel and nickel alloys.
[0055] For binder removal the heating rate is preferably about 5 to 300° C./hour, more preferably 10 to 100° C./hour. The holding temperature is preferably about 200 to 400° C., more preferably 250 to 300° C. and the holding time is preferably about ½ to 24 hours, more preferably 5 to 20 hours in air. The green chip is fired in an atmosphere which may be determined in accordance with the type of conductor in the internal electrode layer-forming paste. Where the internal electrode layers are formed of a base metal conductor such as nickel and nickel alloys, the firing atmosphere may have an oxygen partial pressure of 10 −8 to 10 −12 atm. Extremely low oxygen partial pressure should be avoided, since at such low pressures the conductor can be abnormally sintered and may become disconnected from the dielectric layers. At oxygen partial pressures above the range, the internal electrode layers are likely to be oxidized.
[0056] For firing, the chip preferably is held at a temperature of 1,100° C. to 1,400° C., more preferably 1,250 to 1,400° C. Lower holding temperatures below the range would provide insufficient densification whereas higher holding temperatures above the range can lead to poor DC bias performance. The heating rate is preferably 50 to 500° C./hour, more preferably 200 to 300° C./hour with a holding time of ½ to 8 hours, more preferably 1 to 3 hours. The cooling rate is preferably 50 to 500° C./hour, more preferably 200 to 300° C./hour. The firing atmosphere preferably is a reducing atmosphere. An exemplary atmospheric gas is a humidified mixture of N 2 and H 2 gases.
[0057] Firing of the capacitor chip in a reducing atmosphere preferably is followed by annealing. Annealing is effective for re-oxidizing the dielectric layers, thereby optimizing the resistance of the ceramic to dielectric breakdown. The annealing atmosphere may have an oxygen partial pressure of at least 10 −6 atm., preferably 10 −5 to 10 −4 atm. The dielectric layers are not sufficiently re-oxidized at a low oxygen partial pressures below the range, whereas the internal electrode layers are likely to be oxidized at oxygen partial pressures above this range.
[0058] For annealing, the chip preferably is held at a temperature of lower than 1,100° C., more preferably 500° C. to 1,000° C. Lower holding temperatures below the range would oxidize the dielectric layers to a lesser extent, thereby leading to a shorter life. Higher holding temperatures above the range can cause the internal electrode layers to be oxidized (leading to a reduced capacitance) and to react with the dielectric material (leading to a shorter life). Annealing can be accomplished simply by heating and cooling. In this case, the holding temperature is equal to the highest temperature on heating and the holding time is zero. Remaining conditions for annealing preferably are as follows.
[0059] The binder removal, firing, and annealing may be carried out either continuously or separately. If done continuously, the process includes the steps of binder removal, changing only the atmosphere without cooling, raising the temperature to the firing temperature, holding the chip at that temperature for firing, lowering the temperature to the annealing temperature, changing the atmosphere at that temperature, and annealing.
[0060] If done separately, after binder removal and cooling down, the temperature of the chip is raised to the binder-removing temperature in dry or humid nitrogen gas. The atmosphere then is changed to a reducing one, and the temperature is further raised for firing. Thereafter, the temperature is lowered to the annealing temperature and the atmosphere is again changed to dry or humid nitrogen gas, and cooling is continued. Alternatively, once cooled down, the temperature may be raised to the annealing temperature in a nitrogen gas atmosphere. The entire annealing step may be done in a humid nitrogen gas atmosphere.
[0061] The resulting chip may be polished at end faces by barrel tumbling and sand blasting, for example, before the external electrode-forming paste is printed or transferred and baked to form external electrodes. Firing of the external electrode-forming paste ma y be carried out in a humid mixture of nitrogen and hydrogen gases at about 600 to 800° C., and about 10 minutes to about 1 hour.
[0062] Pads are preferably formed on the external electrodes by plating or other methods known in the art.
[0063] The external terminations are preferably formed by dipping with other methods, such as ink-jet spraying being suitable.
[0064] The multilayer ceramic chip capacitors of the invention can be mounted on printed circuit boards, for example, by soldering.
[0065] The present invention has been described with particular reference to the preferred embodiments without limit thereto. One of skill in the art would realize additional, and alternative, embodiments which are not specifically stated herein but which are within the scope of the invention more specifically set forth in the claims appended hereto.
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A ceramic multilayer surface-mount capacitor with inherent crack mitigation void patterning to channel flex cracks into a safe zone, thereby negating any electrical failures.
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This application is a continuation, of application Ser. No. 07/517,689, filed May 2, 1990, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for recording data, such as a film loading date and a time, or a film unloading date and time onto the film.
2. Description of Related Art
There is a known data recording apparatus in which date and time when a picture of an object is taken is recorded in the same picture plane, as disclosed, for example, in Japanese Unexamined Patent Publication Nos. 61-259244 and 61-267746. In such a known apparatus, the photographing date and time are usually recorded in a lower right or left corner of a picture plane.
However, in the known data recording apparatus in which the photographing date and time of each picture of an object to be taken can be easily identified, there is no way to learn when a first picture of one film is taken and when a last picture of the same film is taken or the photographing order of two or more than two films.
SUMMARY OF THE INVENTION
The primary object of the present invention is to provide a data recording apparatus of a camera in which data, such as a film loading date (and/or time), a first picture taking date (and/or time), a last picture taking date (and/or time), a film unloading date (and/or time) is recorded in a frame of film in which no picture is taken, i.e. in a non-photographing area of a film.
To achieve the object mentioned above, according to the present invention, there is provided a data recording apparatus of a camera which records data on a film, comprising data forming mechanism for forming at least one of data relating to the loading of the film or commencing the photographing and data relating to unloading or rewinding the film or finishing the photographing and a data recording means for recording said data formed by said forming means in an area of the film in which no picture is taken is provided.
With this construction, since one or both of the data relating to loading the film and the data relating to finishing the photographing is or are recorded in the non-photographing area of the film, the data for the commencement of the photographing and the completion of the photographing can be easily confirmed.
Preferably, the non-photographing area is defined by a frame which is immediately before the first frame which is usually and automatically set in a normal automatic loading, or which is a frame after a predetermined number of photographing frames depending on the film. This enables the necessary data to be recorded in the non-photographing area in which no picture is taken. Namely, the required data has no effect on the photographing frames of the film in which pictures are taken.
If the data is date and/or time, the time when the first and last pictures are taken can be easily learned.
When the data relating to loading the film and the data relating to finishing the photographing are located in the same frame, as to be adjacent to each other, both data can be confirmed at one time.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described below in detail with reference to the accompanying drawings, in which:
FIG. 1 is a back view of the inside of a camera body having a data recording apparatus, according to the present invention;
FIG. 2 is an inside view of a back cover of a camera shown in FIG. 1;
FIG. 3 is a schematic view of a pulse outputting mechanism which outputs pulses when a film is advanced;
FIG. 4 is a block diagram of a control system of a data recording apparatus, according to the present invention;
FIG. 5 is a schematic view of display modes of dates which can be set in a camera, according to the present invention;
FIG. 6 is a program diagram showing a relationship between the quantity of light emitted from a lamp and a luminance of an object;
FIG. 7 is a schematic view showing how data (photographing date, etc.) is recorded in a picture plane by a data recording apparatus, according to the present invention;
FIGS. 8A and 8B are flow charts of an automatic film loading operation and a data recording operation upon loading a film;
FIG. 9 is a flow chart of a release operation of a camera according to one aspect of the present invention;
FIG. 10 is a flow chart of a film rewinding operation and a data recording operation upon completion of photographing; and,;
FIG. 11 is a flow chart of a release operation, a data recording operation upon completion of photographing and a film rewinding operation, according to another aspect of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
First, with reference to FIGS. 1 through 3, in a camera body 10 there are provided electrical contacts 11, 12 and 13 which supply electrical power and control signals to a data recording apparatus provided on aback cover 20 (FIG. 2), and DX contact pins DX1˜DX9 which are connected to DX code areas provided on a patrone surface of a film. As is well known, the DX codes include information, such as an ISO sensitivity of a film, the number of frames in which pictures can be taken, and latitude data, etc. The DX contact pins DX8 and DX9 are used to read the number of film frames and are electrically connected to the corresponding areas relating to the number of film frames among the DX code areas.
On the back cover 20 are provided contacts 11A, 12A and 13A corresponding to the contacts 11, 12 and 13 of the camera body 10, so that when the back cover 20 is closed, the contacts 11A, 12A and 13A on the back cover are connected to the corresponding contacts 11, 12 and 13 on the camera body to transmit electrical power and signals therebetween.
The back cover 20 is provided on its inner side face with a pressure plate 25 which keeps the film flat upon the advance thereof. The pressure plate 25 has a window 26 for recording data (date) via through the data recording apparatus. Consequently, the date is exposed and recorded on the film through the window 26.
The camera body 10 has a film winding spool 15, guide rails 14 which ensure a stable and smooth travel of the film, and a sprocket 16 which rotates a slit disc 32 for detecting the displacement (quantity of advance) of the film. The arrangement of these elements are illustrated in FIG. 3. The operation of film winding and rewinding mechanism utilizing the elements shown in FIG. 3 is fully described in Ser. No. 301,362 filed Jan. 1, 1989 the disclosure of which is incorporated herein by reference.
A film winding and rewinding motor 30 is provided in the film winding spool 15, so that when the motor 30 rotates, the sprocket 16 is rotated in the film winding through the spool 15 upon winding of the film. On the other hand, upon rewinding the film, the spool 15 is disengaged from the sprocket 16, so that a rewinding shaft 17 is rotated in the film rewinding direction.
When a film is loaded in the camera body 10, upon winding, the spool 15 rotates to wind the film, so that the slit disc 32 is rotated through the sprocket 16 which engages with perforations of the film to rotate together. The slit disc 32 has radial slits 32A spaced from one another at predetermined angular distance. The slits 32A successively pass a detection space between a light receiver and a light emitter of a photointerrupter 33.
Upon rewinding, the film is rewound, by the rewinding shaft 17, back into the casette, so that the sprocket 16 which engages with the perforations of the film is rotated to rotate the slit disc 32. As a result, the photointerrupter 33 generates pulses, the number of which corresponds to the number of revolution of the slit disc 32. One pulse corresponds to one perforation of the film. Thus, the advance of the film and the displacement amount advance displacement thereof can be detected by the pulses and by the number of pulses, respectively.
FIG. 4 schematically shows a block diagram of a control system of a data recording apparatus of a camera according to an embodiment of the present invention.
FIG. 4, a main CPU 40 which is provided in the camera body 10 operates when a main switch SW is turned ON. To the main CPU 40 is connected a photometering circuit 42 which logarithmically compresses the detection signal issued from a light receiver 41 which detects the luminance of an object to be photographed and amplifies the same to convert the analog signal to a digital signal (A/D conversion). The luminance signal input to the main CPU 40 from the photometering circuit 42 is one of operational factors which determine the diaphragm value and the shutter speed, upon releasing of the camera shutter.
An E 2 PROM 43 temporarily memorizes the photographing data of the camera. The stored data is data which is used to arithmetically calculate the luminance etc.
The pulse signal issued from the photointerrupter 33 is input to an FMP terminal of the main CPU 40, so that the main CPU 40 recognizes the feed (advance) of the film in accordance with the pulse signal.
The rotational direction and the stopping of the winding and rewinding motor 30 are controlled by a motor driver 35 which operates in accordance with the command of the main CPU 40 to operate the winding and rewinding motor 30 in the winding or rewinding directions. The main CPU 40, the spool 16, the winding and rewinding motor 30, and the motor driver 35 etc. constitute a film feeding (advancing) means.
The main CPU 40 outputs an indication signal to a display 45 which indicates set camera modes or the state of film feed, etc. in accordance with the indication signal.
The main CPU 40 performs an arithmetic operation to determine the exposure value and a shutter speed in accordance with the luminance signal of the photometering circuit 42 and the ISO sensitivity of the film, etc. As a result, an exposure control apparatus 46 is actuated in accordance with the result of the arithmetic operation to drive the shutter (not shown) and the diaphragm (not shown).
Various switches, such as a back cover switch SWU which is turned ON when the back cover 20 is closed, a release switch SWR which is turned ON when the release button is actuated, and a film rewinding switch SWRe which is actuated to rewind the film, etc. are connected to the main CUP 40. The main CPU 40 performs the associated positions in accordance with the operations of these switches.
The DT terminal of the main CPU 40 is connected to the contact 12 through pull-up resistances R1 and R2 and a transistor Tr1 to control the data recording operation.
The input ports DX2˜DX9 of the main CPU 40 are connected to the DX contact pins DX2˜DX9. The main CPU 40 detects the number of film frames and the ISO sensitivity Sv in accordance with the input levels of the input ports DX2˜DX9. A regulator 44 supplies the electrical power to the main CPU 40 when the PH terminal of the main CPU 40 is set to be "L" level. The DX contact pin DX1 is connected to the ground (GND).
The back cover 20 is provided with a sub-CPU 50 which controls the data recording operation. The sub-CPU 50 contains a data recording LCD (liquid crystal display) 52 which records data, such as date data on the film F and a lamp 51. The lamp 51 is turned ON and OFF by the sub-CPU 50 through a power transistor Tr2.
In the data recording LCD 52, data to be recorded is formed by a light transmission portion, so that light emitted from the lamp 51 is transmitted through the light transmission portion of the data recording LCD 52 to be incident upon the film F, so that the data formed by the light transmission portion is exposed on the film F. The sub-CPU 50 and the LCD 52 constitute a data forming means and the main CPU 40, sub-CPU 50 and the lamp 51 constitute a data recording means.
The sub-CPU 50 causes the lamp 51 to emit light in response to the signal output from the DT terminal of the main CPU 40.
An indicating LCD 53 is provided on the outer face of the back cover 20 to easily confirm the data to be recorded.
The switch SWM outputs a signal for changing the indication modes of data to the sub-CPU 50. The sub-CPU 50 successively changes the indication modes of date data in the order shown in FIG. 5 every time the switch SWM is pushed down. For example, when the switch SWM is pushed down, the indication mode is changed from "'89 1 31" (year, month, date) to "1 31 '89" (month, date, year). From this position, if the switch SWM is pushed down three times, the indication becomes "OFF". In the "OFF" mode, no date is recorded on the film. Note that "31 14 : 22" in FIG. 5 designates "twenty two minutes past two o'clock in the afternoon on the date of 31".
The following discussion will be directed to the data recording operation according to an aspect of the present invention.
When the back cover 20 is closed after the film F is loaded, the back cover switch SWU is turned on, so that electrical power is supplied to the main CPU 40.
The main CPU 40, which checks if the back cover switch SWU is ON, drives the winding and rewinding motor 30 to wind the film F. The main CPU 40 counts the number of pulses issued by the photointerrupter 33 to check the amount of winding of the film. When the number of pulses reaches a predetermined value, the winding and rewinding motor 30 is stopped. In the illustrated embodiment, the film is wound up until 1.5 frames before the first photographing frame which is usually set by the automatic loading mechanism.
Upon completion of the film winding, the data recording apparatus operates to record date data in an indication mode selected by the switch SWM. The date data is recorded in the lower left end of the film frame F, as shown at A in FIG. 7.
When the date data is recorded on the film F, the main CPU 40 makes the winding and rewinding motor 30 ON again to wind the film F until the film comes to the normal first frame, in accordance with the number of pulses issued from the photointerrupter 33. Thus, the camera is ready for photographing.
Thereafter, every time the release switch SWR is turned ON, the date data is recorded in the lower right end of the exposed picture plane, as shown in FIG. 7.
When the rewinding switch SWRe is turned ON, upon completion of photographing, the main CPU 40 drives the winding and rewinding motor 30 in the rewinding direction to rewind the film F to a predetermined position, i.e. until the frame in which the date has been recorded upon loading the film appears, in accordance with the number of pulses issued from the photointerrupter 33.
When the film rewinding is finished, the data recording apparatus operates to record the date data in an indication mode selected by the switch SWM. The date data is taken in the lower right end of the frame in which the date data A has been recorded upon loading of the film F, as shown at B in FIG. 7.
When the date data is recorded on the film, the winding and rewinding motor 30 is rotated again in the rewinding direction. Thereafter, when no pulse is issued from the photointerrupter 33, the winding and rewinding motor 30 is stopped. After issuance of the pulses is stopped, the film F can be completely wound in the cassette for a predetermined time.
Thus, upon loading the film, the film loading date is recorded in the lower left end of a frame immediately before the first frame which is usually used for normal photographing. During photographing, the date data is recorded in the lower right end of the picture frame, similar to a conventional camera. After pictures of a predetermined number of frames are taken, when the film is rewound, the film unloading date is recorded in the lower right end of the frame in which the film loading date has been recorded.
The following explanation will be directed to the operations of the data recording apparatus (particularly see FIGS. 8 through 11). The operations are performed by the main CPU 40, in accordance with the program stored in the internal ROM of the main CPU 40.
FIGS. 8A and 8B show operations upon loading of the film.
When the back cover 20 is closed after the film F is loaded, the back cover switch SWU is turned ON to start the programmed operations. The main CPU 40 initializes the ports (terminal) and the register of the CPU (steps S11 and S12), and sets the output of the PH terminal to the "L" level, so that the electrical power is supplied from the regulator 44 (step S13).
The main CPU 40 inputs the level of the input ports DX2˜DX9 (step S14), and converts the level of the input ports DX8 and DX9, relating to the number of frames on the film which is prestored in the memory of the main CPU 40, to be set in a counter N2 of the E 2 PROM 43 (steps S15 and S16). Furthermore, the level of the input ports DX2˜DX7 is converted to the ISO sensitivity which is prestored in the memory of the main CPU 40 to be set in a counter N3 of the E 2 PROM 43 (steps S17 and S18).
The main CPU 40 detects when a switch is turned ON, from among the switches, in accordance with the switch data input thereto (steps S19 and S20). At step S20, if the rewinding switch SWRe is ON, the rewinding operation is performed (step S21). If the release switch SWR is ON, the release operation is performed (step S22). Thereafter, the control ends.
If the main CPU 40 judges that the electrical power is supplied by the back cover switch SWU, the main CPU 40 sends a command signal to the motor driver 35 to actuate the same and actuate the timer, so that the winding and rewinding motor 30 is rotated in the winding direction to commence the loading of the film, i.e. the winding of the film F (steps S23 and S24).
When the winding of the film is commenced, the sprocket 16 rotates, as mentioned above. As a result, the slit disc 32 rotates, so that the photointerrupter 33 alternately and periodically issues "H" and "L" signals in accordance with the slits 32A. Thus, the pulses are periodically generated from the photointerrupter 33. The pulses are sent to the main CPU 40 through the FMP terminal thereof to count the number of pulses in order to check the counted number (step S25).
When the number of pulses is K1, the winding and rewinding motor 30 is stopped to stop the winding of the film F (steps S25˜S28). The number K1 is the number of pulses necessary for advancing the film F to the data recording position. Therefore, the film F is wound until the data recording position comes to a lower left end of a frame immediately before the first frame, that is, until it comes to one and half (1.5) frames before the first frame used in normal photographing.
The reason that the timer starts at step S24 is that if the film F fails to be advanced during the winding operation thereof, for some reason (for example, no film F is wound, i.e. no pulse is input to the FMP terminal of the main CPU 40), the winding and rewinding motor 30 is stopped to prevent a possible overload of the motor 30. The failure is detected, when time of the timer is up, so that the main CPU 40 stops the winding and rewinding motor 30 to warn of the failure. These operations are repeated until the back cover switch SWU is made OFF (steps S28˜S30).
When the film F is wound to the data recording position, the main CPU 40 turns the DT terminal ON ("H" level) to turn the transistor Tr1 ON, so that the contact 12 becomes "L" level. As a result, a data recording command is given to the DT terminal of the sub CPU 50. In response to the command signal, the sub-CPU 50 causes the LCD 51 to indicate desired information and the lamp 52 to emit light.
During these operations, the main CPU 40 waits for the operation for a predetermined time and then turns the DT terminal OFF ("L" level) at steps S31˜S33. Thus, the film loading date data is recorded in the picture, as shown in FIG. 7.
The main CPU 40 then commences the supply of the electrical power to the winding and rewinding motor 30 through the motor driver 35 in the film winding direction to count the number of pulses input from the FMP terminal in order to set the film at the first frame for normal photographing.
When the number of pulses input from the FMP terminal is K2, that is, when the film F is advanced by a displacement corresponding to one and half (1.5) frames from the data recording position, the counter N1, which counts the number of frames of the film F, of the E 2 PROM 43 is set at 1, to stop the power supply to the winding and rewinding motor 30 and to set the PH terminal at the level H. Thus, the power supply to the main CPU 40 is stopped to end the operation (steps S34˜S39). Thereafter, the control waits until the release switch SWR is pushed down.
FIG. 9 shows a flow chart of the release operation.
When the release switch SWR is turned ON to commence the photographing, the main CPU 40 performs the program operation (refer to FIG. 6) to obtain the shutter speed Tv and the diaphragm value Av in accordance with the object luminance Bv detected by the light receiver 41 at steps S41˜S43, and operates the exposure control apparatus 46 in accordance with the result of the program operation to actuate the diaphragm and the shutter, thereby to expose the film (step S44). The operation of a camera having a program operation as illustrated in FIG. 6 is fully described in Ser. No. 473,044 filed Jan. 31, 1990 the disclosure of which is incorporated herein by reference.
Upon completion of exposure, the main CPU 40 supplies the electrical power to the winding and rewinding motor 30 through the motor driver 35 to rotate the motor 30 in the film winding direction (step S45).
Thereafter, the main CPU 40 counts the number of pulses which are generated from the photointerrupter 33 to be input thereto through the FMP terminal. When the number of pulses becomes K3, namely, when the film F is wound by one frame, the power supply to the winding and rewinding motor 30 is stopped to increase the counter N1 of the E 2 PROM 43 which counts the number of frames by one increment (steps S46˜S49).
The main CPU 40 checks if the increased value of the counter N1 is equal to the value of the counter N2 at step S50. If the increased value is not equal to the value of the counter N2, the control proceeds to step S51 in which the terminal PH is set at "H" to stop the power supply to the main CPU 40, and then, the operation ends. At step S50, if the increased value is equal to the value of the counter N2, the rewinding operation is performed at step S52, since the picture of the last available frame has been already taken.
FIG. 10 shows a flow chart of the rewinding operation which is performed at step S21 and step S51 mentioned above. When pictures of all the frames are taken, or when the rewinding switch SWRe is manually made turned ON by a photographer, the control proceeds to the rewind routine shown in FIG. 10.
The main CPU 40 reverses the winding and rewinding motor 30 in the rewinding direction to rewind the film F (step S61). The main CPU 40 counts the number of pulses which are issued from the photointerrupter 33 and which are input to the main CPU 40 through the FMP terminal. When the counted number becomes K3, the value of the counter N1 of the E 2 PROM 43 is decreased by one decrement (steps S62˜S64).
The above mentioned operations are repeated until the value of the counter N1 is -1, that is, until the data recording position comes to the lower right end of the frame in which the film loading date has been recorded (steps S62˜S65).
When the value of the counter N1 is -1, the main CPU 40 stops the power supply to the winding and rewinding motor 30 and makes the DT terminal ON (level "H") to give the data recording command signal to the sub-CPU 50. In response to the command signal, the sub-CPU 50 causes the lamp 52 to emit light. During these operations, the main CPU 40 counts the time in which the DT terminal is on and that turns the DT terminal OFF.
Thus, upon rewinding, the date data is recorded in the picture, as shown at B in FIG. 7 (steps S66˜S69).
To completely rewind the film F, the main CPU 40 commences the power supply to the winding and rewinding motor 30 through the motor driver 35. In accordance with the change in pulse input to the main CUP 40 through the FMP terminal, the main CPU 40 stops the power supply to the winding and rewinding motor 30 at a predetermined time after no issuance of pulse and turns the PH terminal OFF (level "H"), so that the power supply to the main CPU 40 is stopped (steps S70˜S74).
Although, in the illustrated embodiment, the date data is taken recorded in the lower right end of the picture plane, it is possible to record the date data in the lower left end thereof.
The position and the frame in which the date data is to be recorded are not limited to those in the illustrated embodiment mentioned above and can be optionally set. For example, the date data can be taken recorded in a predetermined frame member by reading the DX code data relating to the number of frames. FIG. 11 shows a flow chart of operations for such an alternative.
The exposure and film winding operations of steps S81˜S89 are the same as those of steps S41˜S49 in FIG. 10.
When the film is wound by one frame upon completion of the release operation, the value of the counter N1 which is increased by one increment is compared with the value of the counter N2 (steps S89 and S90). If the values are not identical to each other, or if the increased value of the counter N1 is smaller than the value of the memory N2, since photographing of the last frame has not yet been performed, the PH terminal is set at "H" to stop the power supply to the main CPU 40 to end the operation (step S91).
On the other hand, if the increased value of the counter N1 is equal to the value of the counter N2, since the picture of the last frame has been taken, the DT terminal is set at "H" to make the lamp 51 ON, thereby to commence the data recording operation and to start the timer to measure the exposure of the data recording operation time. When time of the timer is up, the DT terminal is set at "L" to make the lamp 51 OFF, thereby to end the data recording operation (steps S92˜S94).
Upon completion of the data recording operation, the winding and rewinding motor 30 is reversed in the rewinding direction to completely rewind the film F. The control waits until there is no change in output level of the FMP terminal (steps S95 and S96).
When there is no change in level of the FMP terminal, after the film F is completely rewound into the cassette, the power supply to the winding and rewinding motor 30 is stopped. The PH terminal is set "H" to stop the power supply to the main CUP 40 in order to end the operation.
Thus, the data when the film F is loaded is recorded in a frame before the first frame and the data when photographing is finished is recorded in a frame subsequent to a predetermined last frame. When the rewind switch SWRe is made ON during taking a roll of pictures, the rewinding operation shown in FIG. 10 is performed.
Although data to be recorded is date data in the illustrated embodiment, the present invention is not limited thereto. For example, marks represented by letters, such as alphabet indicia can be recorded as data. In this alternative, initials of photographers, places in which pictures are photographed, or an identification mark relating to the film can be recorded.
As can be understood from the above discussion, according to the present invention, since data when the film is loaded and unloaded is recorded in a desired frame of the film in which no picture is taken, the data can be easily recognized.
If the data is date data, a photographer can easily learn the period of photographing (when first and last pictures are taken).
Furthermore, if no data should be recorded in a picture, the present invention can be advantageously used, since data is recorded in a not-photographing frame of a film in which no picture is taken, according to the present invention.
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A data recording apparatus in a camera including a data recording device for recording at least one item of data upon loading a film or commencing the photographing and data upon unloading the film or finishing the photographing, in an area of the film in which no picture is taken. A film feeding device is provided for feeding the film to a data recording position in which the data is recorded.
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BACKGROUND OF THE INVENTION
Low side hermetic refrigeration compressors are those in which most, if not all, of the interior of the shell is at suction pressure. Normally, some, or all, of the suction flow is used to cool the motor which is provided with a thermal protector. The thermal protector causes the motor, and thereby the compressor, to stop when the motor overheats.
In U.S. Pat. No. 5,141,407 it is recognized that hot, discharge gas could cause the thermal protector to react and stop the compressor. To cause the thermal protector to react, a discharge to suction/shell interior bypass is controlled by a thermally responsive valve which senses and reacts to the temperature of the discharge gas. As a result, the compressor can be stopped responsive to conditions resulting in an excessive discharge temperature. These conditions include the loss of working fluid charge, a blocked condenser fan in a refrigeration system and a low pressure condition or a blocked suction condition. Thus, the thermal protection disclosed in U.S. Pat. No. 5,141,407 is basically that of "general heat" where the heat is generated all around the scroll as friction heat caused by lack of lubrication, the thermodynamic heat of the compressed gas, high motor temperature and/or high ambient temperature. The basic presumption of this approach is, however, that the discharge gas temperature always follows closely the actual failure indication which is not always true.
In addition to general heat there can be "local heat" which is heat generated in a certain area. The source of local heat is usually localized high friction caused by a concentrated load. With local heat, the amount of total heat may not be sufficient to significantly influence the temperature of the discharge gas such as under the high mass flow conditions associated with a blocked condenser fan. Thus, a gas temperature sensing device may not detect an incipient failure caused by local friction.
Scroll compressors are unusual in that there is a continuous progression of the compression process from the outermost suction region to the inner discharge region and in that relative movements between contacting points on the two scrolls is limited to a circle, the orbit, which is typically 0.5 inches or less. As a result, there is a thermal gradient from the outer periphery to the center of the scrolls and contact between the members is localized. The wraps of a scroll compressor exhibit a differential thermal growth reflecting the thermal gradient, with the inner portion of the wraps having the greatest thermal growth. A "worn in" scroll wrap will, typically, be dished concavely at ambient temperatures and planar at operating temperatures. During abusive conditions such as loss of working fluid charge, the compressor may operate at high pressure ratios which can lead to high discharge temperatures. Due to thermodynamic heat, the resultant thermal gradient causes the inner portion of the scrolls to expand beyond the "normal" planar state and results in convex dishing. This will cause the axial thrust load to be concentrated on a very small area near the center of the scroll wrap. The failure mechanism for a scroll compressor under these conditions could be excessive wear of the scroll surface and/or galling near the center. Galling is a continuous weld-tear between the wrap tip and floor of coacting scroll members. The major factors that contribute to failure are (1) heat generated in the compressor which causes breakdown of oil, reducing lubrication and increasing friction and friction heat between the scrolls, and (2) high net axial thrust force or concentrated thrust loading between the scrolls which can increase friction and create more friction heat.
Loss of working fluid charge creates significant local and general heat. As charge is lost from the system, the discharge to suction gas pressure ratio increases. As the pressure ratio increases, the temperature difference between suction and discharge increases and results in dishing of the scroll members which eventually creates a high spot. The high spot takes all the load (normal force) and causes high local friction and resultant local heat. Additionally, because the lubrication media is oil entrained in the refrigerant, the reduction in mass flow reduces the available lubrication for the scrolls, increasing friction and its resultant general heat. The normal thermodynamic heating of the gas will also provide general heat.
SUMMARY OF THE INVENTION
The protection mechanism senses a pre-failure mode as a high fixed scroll floor temperature in the vicinity of the protection mechanism and may therefore be a local or a general heating. Responsive to the sensed high fixed scroll floor temperature, a valve is opened to bleed high temperature and pressure gas to the suction side represented by the interior of the shell. The opening of the valve (1) reduces the pressure ratio because there is a leak from high to low pressure regions; (2) heats the linebreak/motor overheat protector which trips if heated sufficiently and thereby stops the motor; (3) reduces the flow that goes to refrigeration system and gets cooled; and, (4), in essence, cuts off the flow of cool gas around the motor.
It is an object of this invention to sense initial indications of a pre-failure mode of a scroll compressor during a loss of charge condition.
It is another object of this invention to stop a compressor responsive to a sensed pre-failure mode. These objects, and others as will become apparent hereinafter, are accomplished by the present invention.
Basically, a thermally responsive sensor is located in the fixed scroll in the general area of the outlet and, responsive to the sensing of a excess temperature indicative of a pre-failure mode, opens a bypass between the discharge and the interior of the shell thereby causing the thermally responsive line break to trip.
BRIEF DESCRIPTION OF THE DRAWING
For a fuller understanding of the present invention, reference should now be made to the following detailed description thereof taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a partial sectional view of a low side scroll compressor employing the thermally responsive bypass valve of the present invention;
FIG. 2 is an enlarged sectional view of the bypass valve of FIG. 1 in the closed position;
FIG. 3 is a view of the bypass valve of FIG. 2 in the open position;
FIG. 4 is an enlarged sectional view of a modified bypass valve in the closed position; and
FIG. 5 is a view of the bypass valve of FIG. 4 in the open position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, the numeral 10 generally designates a low side hermetic scroll compressor. Compressor 10 has a shell 12 with an end cap 12-1 and a separator plate 14 which divides the interior of the shell 12 into a suction chamber 15 and a discharge chamber 16. Fixed or non-orbiting scroll 18 has a wrap 18-1, discharge port 18-2 and bore 18-3 which receives discharge tube 19. An orbiting scroll coacts with fixed scroll 18 but only the wrap 20-1 is illustrated. The structure described so far is generally conventional and would operate in a conventional manner.
Referring to FIGS. 1-3 it will be noted that fixed scroll 18 has bores 18-4 and 18-6 which coact to form shoulder 18-5 therebetween. Bore 18-6 has a dished end surface 18-7 which is in close proximity to the floor 18-11 of fixed scroll 18. Bore 18-8 intersects bore 18-6 and coacts with bore 18-10 to define shoulder 18-9. Thermally responsive bypass valve 30 is located in bores 18-4 and 18-6 and includes disc 32 which is press fit or otherwise suitably located in bore 18-4 and supported by shoulder 18-5. Disc 32 has an opening 32-1 which is surrounded by sleeve portion 32-2 which extends into bore 18-6. Valve member 34 seats on disc 32 and blocks opening 32-1, as shown in FIGS. 1 and 2. Valve 34 has a stem 34-1 which is received in and guided by sleeve 32-2. Actuator 36 may be a bimetal snap disc or of shape memory alloy and generally conforms to the shape of end surface 18-7 in the unactuated configuration of FIG. 2.
In operation, the fixed and orbiting scrolls coact to compress refrigerant gas which serially passes through discharge port 18-2, bore 18-3 and discharge tube 19 into discharge chamber 16 from which is passes to the refrigeration system (not illustrated). As is clear from FIGS. 1-3, the tip of wrap 20-1 is coacting with the floor 18-11 as well as wrap 18-1 of scroll 18 and that the floor 18-11 is in close proximity to surface 18-7. Because surface 18-7 is in proximity to the discharge portion of the fixed scroll 18 it is in the region that is subject to the greatest thermal growth of the wraps 18-1 and 20-1. Being somewhat downstream from the suction side and therefore more likely to be affected by inadequate lubrication or the like, the portion of the wraps 18-1 and 20-1 in the vicinity of surface 18-7 are more likely to be subject to localized heating as from friction. Upon heating of the floor 18-11 in the vicinity of surface 18-7, the heat is transmitted to actuator 36. Upon a sufficient heating of actuator 36, actuator 36 goes from its FIG. 2 configuration to its FIG. 3 configuration and causes the unseating of valve 34. With valve 34 unseated, as shown in FIG. 3, a discharge to suction bleed is established whereby discharge gas serially passes from bore 18-3, into bore 18-4, through opening 32-1 and sleeve 32-2 into bore 18-6 from which it passes to bore 18-8 and bore 18-10. From bore 18-10, the discharge bleed may be directed via a tube 38, as illustrated in FIG. 1, to a desired locations such as to the motor thermal protector, or to the suction chamber 15 defined by shell 12 as shown in FIGS. 2 and 3. Although actuator 36 is shown as a separate member, it can be attached to stem 34-1, if necessary or desired.
Thermally responsive bypass valve 130 of FIGS. 4 and 5 is similar to valve 30 but relies upon a phase change material to cause its opening. Disc 132 has an opening 132-1 and is press fit or otherwise suitably secured in bore 18-4 so that it rests on shoulder 18-5. Valve member 134 has a stem 134-1 which extends through opening 132-1 and is sealingly and reciprocatably received in actuator 136 which includes a sealed container 136-1 which is filled with a phase change material 136-2. Phase change material 136-2 can be a wax that melts and increases in volume as the temperature increases, a liquid that changes to a gas and increases in volume as the temperature rises, or any suitable conventional phase change material. Because sealed container 136-1 does not change shape, dished end surface 18-7 may suitably be replaced with a flat surface 18-12, or a shape conforming to the corresponding portion of container 136-1.
In operation, heating of the floor 18-11 in the vicinity of surface 18-12 is transmitted to actuator 136. Upon a sufficient heating of container 136-1 and thereby phase change material 136-2 contained therein, the phase change material 136-2 expands in volume and acts on the end of stem 134-1 which functions as a piston. The increased volume moves valve 134 from the FIG. 4 position to the FIG. 5 position causing the unseating of valve 134. With valve 134 unseated, as shown in FIG. 5, a discharge to suction bleed is established whereby discharge gas serially passes from bore 18-3, into bore 18-4, through opening 132-1 into bore 18-6 from which it passes to bore 18-8 and bore 18-10. From bore 18-10, the discharge bleed may be directed via tube 38, as shown on FIG. 1, to a desired location, or to the suction chamber 15.
Although preferred embodiments of the present invention have been illustrated and described, other changes will occur to those skilled in the art. It is therefore intended that the present invention is to be limited only by the scope of the appended claims.
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A thermally responsive valve establishes a discharge to suction bleed responsive to the actuation of a thermal actuator. The thermal actuator is responsive to the temperature of the floor of the fixed scroll in a region near the outlet so that the actuator is responsive to local conditions indicative of impending failure.
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This is a continuation-in-part application of Ser. No. 06/749,391, filed June 27, 1985 now U.S. Pat. No. 4,624,082. This invention relates generally to building roof coverings and more particularly to a poured monolithic concrete or other like pourable, hardenable material atop a sloped roof.
In the past, as an alternative to well-known tar shingled roofing, various coverings have been devised to provide roof protection which outlives and better protects underlying building roofs. Well-known clay tile roofing does provide longer useful service and also provides a unique aesthetic appearance. However, clay tiles are expensive, fragile and expensive to install.
A process for molding a roof slab of concrete or other plastic material is disclosed in U.S. Pat. No. 2,543,939 to Rumble. However, the process requires erection of support structure and produces a heavy, flat slab typical of commercial structures. In U.S. Pat. No. 2,193,233 to Hardy, another method is disclosed for producing a roof covering of thin individually cast labor-intensive mortar or concrete shingles which appear likened to individual roof tiles. Still other prior art in U.S. Pat. No. 2,379,051 to Wallace discloses a sectioned self-hardening plastic formed roof covering and method which includes a unique means for insuring that trapped moisture thereunder exists to the exposed surface. This feature mandates horizontal separated sections which are poured in place aided by simple individual rails and labor intensive techniques.
The present invention discloses a reusable grid system and method for cast forming a monolithic concrete or the like roof covering which has the finished appearance of tile roofing but which is continuous from peak to eave and which reduces installation cost and time over previous methods.
BRIEF SUMMARY OF THE INVENTION
The present invention is for a reusable grid system and method for in place cast forming a monolithic roof covering for a sloped roof, the roof covering having the stepped and segmented appearance of a tiled roof. The grid system includes a plurality of horizontally disposed dam bars and transversly disposed fixed and movable spacer bars therebetween which, when removably assembled atop a sloped roof, are adapted to retain monolithic poured and scraped plastic uncured concrete or the like so as to have an exposed surface which substantially duplicates a conventional tile roof after curing and removal of the grid system. The cured roof covering is thus monolithic from one eave to peak to the other eave and may include foam-filled cavities for thermal insulation and weight reduction, longitudinal segmented elastomer-filled expansion joints, formed eaves with gutter connecting means and molded edges. The grid system may also include a movable spacer bar assembly, as well as means for forming the valley between two adjacent roof sections.
It is therefore an object of this invention to provide a reusable grid system and method for in-place cast forming a continuous concrete or the like monolithic roof covering having the exposed appearance of conventional individual clay, concrete, or ceramic stepped tile.
It is another object of this invention to provide a monolithic concrete or the like roof covering which is economical to cast form in place atop a sloped roof.
It is still another object of this invention to provide the above roof covering having favorable weight reduction features and integral finished roof edge-and-eave encapsulating contours and embedded gutter fasteners for use.
In accordance with these and other objects which will become apparent hereinafter, the instant invention will now be described with reference to the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the monolithic roof covering according to the present invention.
FIG. 2 is a section view in the direction of arrows 2--2 in FIG. 1.
FIG. 3 is a section view in the direction of arrows 3--3 in FIG. 1.
FIG. 4 is a section view in the direction of arrows 4--4 in FIG. 1.
FIG. 5 is a section view in the direction of arrows 5--5 in FIG. 1.
FIG. 6 is a portion of a section view similar to FIG. 2 of an alternate embodiment of the roof covering.
FIG. 7 is a perspective view of an insulating and weight reducing plate which may be embedded in the roof covering during cast forming.
FIG. 8 is a perspective view of the grid system of the present invention.
FIG. 9 is a perspective view of the angle peak bar retention bracket.
FIG. 10 is a perspective view of the connection between side bar segments of the peak grid.
FIG. 11 is a perspective view of one embodiment of the lower end movable spacer support means in the direction of arrows 11--11 in FIG. 8.
FIG. 12 is a section view in the direction of arrows 12--12 in FIG. 11.
FIG. 13 is a perspective view of a second embodiment of the movable spacer bar.
FIG. 14 is an elevation section view of the movable spacer bar of FIG. 13 in use.
FIG. 15 is a perspective view of the fixed spacer bar.
FIG. 16 is an elevation section view of the support spacer bar of FIG. 15 in use.
FIG. 17 is a perspective view of the expansion spacer bar.
FIG. 18 is an elevation section view of the expansion spacer bar of FIG. 17 in use.
FIG. 19 is a perspective view of the angle peak bar.
FIG. 20 is an elevation section view of the angle peak bar of FIG. 19 in use.
FIG. 21 is a perspective view of the bottom of a recess printer assembly showing an exploded enlarged view of one of the marker elements connected thereto.
FIG. 22 is a perspective view of a dam bar support insert and dam bar splice.
FIG. 23 is a perspective broken view of another embodiment of the expansion joint/dam bar splice.
FIG. 24 is a perspective view of another embodiment of the eave form.
FIG. 25 is an exploded perspective view of another embodiment of the edge form and mating eave form.
FIG. 26 is a section view in the direction of arrows 26--26 in FIG. 24.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, and particularly to FIGS. 1 through 5, the roof covering of the present invention is shown generally by the numeral 10 poured or cast formed in place atop the roof R of pourable, hardenable material such as concrete or the like. The roof covering 10 includes a plurality of rows 11 of panel portions 12, each adjacent panel portion 12 separated and defined by a recess line 20, each row 11 of panel portions 12 defined by a horizontal row edge 18. The recess lines 20 penetrate into the top or exposed surface of each row but do not go to the roof or tarpaper T1 and T2 which may be therebetween. These recess lines 20 are disposed transversly to each row 11 in alignment with the slope of the roof R. Each horizontal row edge 18 runs from one roof edge to the other or to a valley V formed by the intersection of two adjacent roof portions. The plane of each horizontal row edge 18 is disposed generally perpendicular to the roof R at that particular line across the roof R, but does not go down to the roof R or tarpaper T1 and, preferrably tarpaper T2. For simplicity, the roof covering 10 of this invention is disposed will be generally referred to as the "subsurface".
Spanning and covering the subsurface peak P of the roof R is a roof peak cover 13 defined by a plurality of adjacent peak step portions 14 and parallel peak cover edge planes 26 disposed on either side of the peak P. Each peak cover edge plane 26 is generally perpendicular to ground as shown, but does not extend to the subsurface tar paper T2.
Disposed between the roof peak cover 13 and the uppermost row 11 having defined panel portions 12 is variable width row 16, absent any recesses 20. The purpose for this variablility in width is to accommodate virtually any roof slope length so as to maintain a predetermined uniform length of each recess 20.
As best seen in FIG. 2, two layers of moisture barrier tarpaper T1 and T2 are typically used in the industry to insure a complete barrier to the wood roof R by any moisture from above. The concrete roof covering 10 is then in-place formed atop the subsurface tar paper T2, rather than the bare wood. The tar paper T1 and T2 are strongly adhered to the roof R by well known means while the pourable precured concrete also strongly adheres to the upper layer of tarpaper T2 as it hardens.
Each row 11, as well as the entire roof cover 10 has edge boundaries defined either by a valley recess 28 or by edge portions 32 and 34 which encapsulate the roof edge as shown in FIG. 3. Two layers of tarpaper T1 and T2 first surround the exposed wood of the roof R, then concrete edge portions 32 and 34 encapsulate both the tarpaper T1 and T2 for both protection and finished appearance.
Similarly, as seen in FIG. 2, the eave E, along with a portion of the facia board F are first wrapped with tarpaper layers T1 and T2, then the eave portion 30 encapsulates the entire eave E as shown to provide maximum protection and a finished appearance.
As may now be better understood, the roof covering 10 is truly monolithic or continuous in section from roof eave-to-eave and from roof edge-to-edge while still having the exposed stepped, and segmented top surface of a conventional tile roof. The various concrete portions, while varying in thickness to achieve the exposed stepped surface, nonetheless are uninterrupted even over the peak P of the roof R.
One planned optional and preferred exception to this continuity of roof covering 10 is a thermal expansion joint 21 running in zig-zag fashion along substantially the entire slope of the roof R. This expansion joint 21 is formed by segments 24 of each row edge 18 and predetermined recesses 22, all of which are connected. The expansion joint 21 is filled with an elastomeric material so as to completely transect the roof covering 10 down to the subsurface tarpaper T2. Although not shown, this expansion joint may also transect the roof peak cover 13 and the variable width rows 16.
Referring now to FIGS. 8 to 12, the grid system for cast forming the previously described roof covering 10 is shown generally at 40. This grid system 40 includes a plurality of parallel spaced-apart elongated rigid dam bars 42 disposed horizontally across the roof and a plurality of elongated rigid spacer bars 46, 48 and 50 transversly disposed and supportively connectable to the dam bars 42. Each dam bar 42 is placed edgewise spaced above the subsurface tarpaper T2, such as to be generally perpendicular to the slope of the roof R as shown. These dam bars 42 are held displaced above and apart from the roof R by expansion joint dam bar splice 61 which may also serve to splice the ends of two adjacent dam bars 42 together. The flow gap formed between the bottom edge of each dam bar 42 and the subsurface tarpaper T2 facilitates concrete flow therebetween during pouring.
Two styles of fixed spacer bars 46 and 48 are releasably connectable to the dam bars 42 by conventional threaded fasteners so as to both properly space and align the dam bars 42 and also to securely retain them in the position shown during the pouring process. Note that while support spacer bars 48 are disposed above the subsurface tarpaper T2, expansion spacer bars 46 extend down to, and contact, the subsurface tarpaper T2 and to support the dam bars 42 and support spacer bars 48.
A third movable spacer bar 50 is removable or placeable between any two dam bars 42 as shown after the dam bars 42 and expansion and support spacer bars 46 and 48 have been bolted into position. Like the support spacer bar 48, the movable spacer bar 50, when in position, is disposed above the subsurface tarpaper T2 so as to form a recess 20. These movable spacer bars 50 may include handles and are made releasably positionable at their upper end by support fingers 76 resting upon the top edge of a dam bar 42 and at their lower end by mateable engagement to support block 64 as best seen in FIGS. 11 and 12. These support blocks 64 are held in positon by snap pins 68 into their shaft portions 66 as shown.
To form the previously described roof covering encapsulating edges 32 and 34, an edge form 52 having apertures therethrough is adapted to align and slide over the ends of the dam bars 42 and abutt against the edge of the roof. Having a generally "L" cross section facilitates retention of the pourable concrete so as to accomplish the previously described roof edge encapsulation while the concrete cures.
To form the previously described stepped peak cover 13, a peak grid 53 is also included in the preferred embodiment of the grid system 40 and includes a pair of elongated side bars 56 placeable in spaced apart fashion horizontally atop the subsurface, tarpaper T2 and parallel to the peak P. Also included are a pluralilty of angle peak bars 54 which are releasably interconnectable transversely between the side bars 56 by "L" brackets 55 and 62 in FIGS. 9 and 10. These angle peak bars 54, generally matching the roof peak angle, span and are displaced above the subsurface at peak P so as to form a flow slot therebetween. The side bars 56 are also held above and displaced from the subsurface tarpaper T2 to form flow slots therebetween by riser blocks 58. The angle peak bars 54 as best seen in FIG. 9, supportively engage into mating "L" brackets 55 connected to the lower side of the side bars 56. Where the side bars 56 are spliced as shown in FIG. 10, these modified "L" brackets 62 also include apertures to receive a clip 61 for retaining the side bars 56 in aligned abuttment one to another as shown.
Where a finished and encapsulating roof cover eave 30, as previously described, is desired, an eave form 44 may also be included in the grid system 40. This eave form 44, elongated, rigid and having a generally "Z" cross-section, is clampable to the facia board F and so held during pouring of the concrete. With the tarpaper T1 and T2 wrapped and in place, clamped beneath the eave form 44, the eave incapsulating section 30, described and shown in FIG. 2 is accomplished.
To form the roof covering valley recess 28, a valley bar 74 is also provided which is placed edgewise in alignment with, and atop, the subsurface of the roof at valley V. The valley bar 74 is so held during concrete pouring by cornerplate 70, which telescopes over the adjacent eave forms 44, and by collars 72, which resistively telescope over the dam bars 42 to opposingly press against the sides of the valley bar 74.
Referring now to FIGS. 13 and 14, another embodiment of the moveable spacer bars is shown at 50' and includes at one end support fingers 76 which supportively rest on the top edge of a dam bar 42. At the other end of the movable spacer bar 50' is a support tab 80 and an end form bar 78. The support tab 80 supportively rests atop the edge of the next lower dam bar 42 as shown. The recess 20 between and defining each panel portion 12 is thus formed by the recess bar portion 82 and the end form bar 78. The handle portion 55 allows quick and positive installation and removal of these movable spacer bars 50 and 50' without interferring with the poured concrete scraping or trowelling process described more fully below.
The support spacer bar 48 is shown more fully in FIGS. 15 and 16 and includes a rigid elongated straight center portion and opposing tabs 84 and 86 at each end for secure, supportive installation between the dam bars 42. Threaded bolts 88 and 90 secure the support spacer bars in position against and between the dam bars 42.
In FIGS. 17 and 18 is shown the expansion spacer bar 46 which is held in position between the dam bars 42 by threaded fasteners 94 and 96. The expansion spacer bar 46 extends downward to the subsurface, tarpaper T2, as does the expansion joint dam bar splice 61, both of which cooperate to form the groove for the elastomer-filled expansion joint 21 previously described.
The angle peak bar 54 is shown in detail in FIGS. 19 and 20 and includes adjacent angle section portions which combine to form a peak angle PA which substantially matches that of the roof peak or may also be chosen to be unequal to that of the roof peak to produce other desired appearances in the peak step portion 14. Tabs 98 supportively engage into "L" brackets 59 or 62 as previously described.
Referring now to FIG. 21, a recess printer assembly is shown generally at numeral 100 and includes a plurality of recess bars 114 connected by mounting posts 116 and 118 to the cross members 104, 106 and 108 of rectangular frame 102. The recess printer assembly 100 also includes handle bars 110 which allow the recess printer assembly 100 to be repeatedly manipulated into the poured and partially cured concrete material. Referring to FIG. 14 for reference to understand the position into which the recess printer assembly 100 is repeatedly placed, the bottom surface of the cross members 104 at numeral 128 contacts and is supported by the top edge of an upper dam bar 42 while the bottom surface of the cross bar at numeral 129 contacts the top edge of the next adjacent lower dam bar 42. End surface 120 of each recess bar 114 contacts against the lower surface of the upper dam bar 42 while end surface 124 contacts the upper surface of the next adjacent lower dam bar 42 similar to the end form bar 78 in FIG. 14. The lower edge 122 of each recess bar 114 is tapered to facilitate the use of this recess printer assembly 100 in conjunction with partially cured concrete and also wherein the assembly 100 will be left in place embedded in the concrete as described for a short period of time during continued curing of the concrete, thus facilitating easy removal of the recess bars 114 therefrom. By this means, then, a user may quickly move along the concrete which has been poured in place and is curing to imprint recess lines 20 in each row 12 of the monolithic roof 10 as it is poured and scraped flat as previously described.
Referring now to FIG. 22, an alternate embodiment of the dam bar splice 130 is shown having a tubular construction and having a rigid bar 132 disposed along one edge and concrete dam bar support insert 134. The insert 134 is shaped to have a central longitudinal groove 136 which is adapted to receive the bar 132 attached to dam bar splice 130. The insert 134 is fabricated of concrete and is intended to be bonded to the subsurface tar paper T2 as the grid system is assembled in its proper position for pouring. The insert 134 is fabricated preferrably of concrete to become an integral part of the monolithic roof 10. Dam bars 42 slip into the tubular splice 130 in the direction of the arrows.
Referring now to FIG. 23, an alternate dam bar splice 140 is shown having a bar 142 disposed from its lower edge which is enlarged and intended to penetrate all the way to the subsurface T2. The dam bars 42 slip into place within the tubular splice 140 in the direction of the arrows as shown. This embodiment of the splice 140 is intended to form the segment 24 of the expansion joint 21 as previously described.
Referring now to FIGS. 24 and 26, an alternate and preferred embodiment of the eave form 150 is shown formed of a single rigid sheet and having perpendicularly disposed sides and an upturned edge so as to press against the subsurface of the tar paper T2 at 164. The eave form 150 is adapted to mate against and be held in place by bolt 162 to modified expansion joint spacer bar 152, which has been modified by adding portion 158 thereto matable to the inside contour of the eave form 150. The eave form 150 receives support from the modified expansion joint spacer bar 152 which is in turn bolted to dam bar 42 as previously described and is supported atop the subsurface tar paper T2 and roof R thereunder.
Referring lastly to FIG. 25, an alternate and preferred embodiment of the edge form bar 144 includes panel 146 which laterally extends in both directions from the central upright panel which includes apertures 148 configured to receive dam bars 42 passed therethrough. The inverted "T" configuration of this edge form bar 144 is intended to render same ambidextrous, thus usable at either right or left edge of the roof R. The lower folded end configuration 147 of panel 146, along with slot 149, is adapted to slideably receive eave form 150' which has been modified to include strengthening fold 151 at its upper margin as shown.
Both of the contoured eave form bars 150 and 150' have similar cross sections and are adapted to telescopically slideably engage one to another to provide the precise length required for a particular installation.
METHOD OF CONSTRUCTION
A roof covering 10 formed of pourable, hardenable material such as concrete is formed in place atop the subsurface of a roof R by first, if desired, spreading and attaching a layer of bituminous felt T1 over the entire roof R, followed by a layer of mineral roofing T2, both previously referred to for simplicity as tarpaper. Dam bars 42 are then laid atop the subsurface, tarpaper T2 in spaced parallel fashion horizontally or transverse to the slope of the roof R. Support spacer bars 48 are then placed transversly to and between the dam bars 42 and fastened in place. After determining the path of any thermal expansion joint(s), the appropriate expansion spacer bars 46 along with expansion joint splice blocks 61 are fastened in place, also positioned transversly to and between the dam bars 42. The dam bars 42 are now displaced and held above the subsurface, tarpaper T2 a certain distance referred to as a flow slot, supported thusly by the expansion joint splice bars 61.
The peak grid 53 is then assembled over the subsurface at peak P by interconnecting side bars 56 and angle peak bars 54 so as to evenly span the peak P. Riser blocks 58 support the side bars 56 above the subsurface to form a flow slot therebetween. Where desired, the eave form 44 and edge form 52 may also be here installed. Note that the edge form 52 may also be reversed and abutted against the edge of the roof R to eliminate any encapsulation there. Where there is a roof valley V, a valley bar 74 may be here installed along with telescoping collars 72 and corner plate 70. The grid system 40 is now in ready position for pouring the concrete therein.
The preferred concrete pouring sequence begins at the peak P, where concrete is poured between the side rails 56. A small amount of concrete is forced under each angle peak bar 54 and through the flow slot between the bottom edge of the side bars 56 and the subsurface. When sufficient concrete has been poured or pumped into the peak grid 53, excess concrete is scraped or screened away down to the planes defined by the top edge of each step of a side bar 56, the top edge of one side of the upright web 57 of one angle peak bar 54 and the bottom surface of the near horizontal web 55 of the adjacent angle peak bar 54.
After the variable width row 16 has been poured and scraped on either side of the now poured peak cover 13, more concrete is then poured down to and under the next adjacent dam bar 42 in the direction of arrows A in FIGS. 14 and 16. Scraping the excess concrete is done down to the top edge of the lower dam bar 42, and the top edge of the support and expansion spacer bars 48 and 46. This thusly defined plane of each row 11 is coplaner with the bottom edge of the adjacent upper dam bar 42. Immediately after scraping a particular row 11, the movable spacer bars 50 or 50" or recess bar assembly 100 are embedded into the wet concrete and seated into position between the adjacent dam bars 42 such that the top surface of each movable spacer bar 50 or 50' or recess bar 114 is also coplaner with this struck off concrete planer surface and forms the remainder of the recesses 20.
Pouring and scraping the concrete continues down the side of the roof to the eave and eave form 44. Accomplishing the encapsulation of both roof eave E and edge by concrete should now be well understood.
Where sufficient support manpower is unavailable, one side of the roof subsurface may be poured over at a time. However, it is then preferred that the first poured side begin at the uppermost row having recesses 20 and expansion joints 22. The peak cover 13 and unrecessed variable width rows 16 are then accomplished at the beginning of pouring the other side of the roof before proceeding downward with pouring and scraping the second side.
Removal of both movable spacer bars 50 or 50', or recess bar assembly 100 should be accomplished before the concrete is fully cured and hard so as to aid in this removal process. These spacer bars 50 or 50' or recess bar assembly 100 may then be used on the lower poured sections or stored for reuse. Note again that the tapered lower edge 122 of the recess bars 114 facilitates their removal.
While the instant invention has been shown and described herein in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope of the invention, which is therefore not to be limited to the details disclosed herein, but is to be accorded the full scope of the claims so as to embrace any and all equivalent apparatus and articles.
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A reusable grid system and method for in place cast forming a monolithic roof covering for a sloped roof, the roof covering having the stepped and segmented appearance of a tiled roof. The grid system includes a plurality of horizontally disposed dam bars and transversly disposed fixed and movable spacer bars therebetween which, when removably assembled atop a sloped roof, are adapted to retain monolithic poured and scraped plastic uncured concrete or the like so as to have an exposed surface which substantially duplicates a conventional tile roof after curing and removal of the grid system. The cured roof covering is thus monolithic from one eave to peak to the other eave and may include foam-filled cavities for thermal insulation and weight reduction, longitudinal segmented elastomer-filled expansion joints, formed eaves with gutter connecting means and molded edges. The grid system may also include a movable spacer bar assembly, as well as means for forming the valley between two adjacent roof sections.
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FIELD OF THE INVENTION
[0001] The technical field relates generally to container and lid assemblies, for instance container and lid assemblies that can be used in the commercial food processing industry.
BACKGROUND OF THE INVENTION
[0002] Various kinds of containers have been suggested over the years. Many containers designed for holding food include a main bottom section forming a tray, a dish, a bowl, a receptacle or the like, and each container is hermetically sealed around or near its top edges by a wrapping and/or a lid to protect the contents during the transportation, storage and handling. Some containers are sold to customers without any contents therein but others are sold together with food items, for instance as prepackaged meals or the like.
[0003] Designing food containers for the commercial food processing industry can be challenging. For instance, since most of these containers are only designed to hold food items until eaten by the customers, it is desirable that the quantity of materials required for making them and the manufacturing costs be minimized. Unfortunately, this is not always easy to achieve since the containers and their lids must also meet other requirements, such as resisting shipping, storage and handling, including handling at the stores or the restaurants where they are sold. The containers must remain intact and constantly sealed, between the packaging process and the moment customers open them, to avoid contamination and spoilage. On the other hand, adding too many packaging layers or features, such as a protective box made of cardboard or the like, or additional layers of wrapping, to mention just a few, increases the volume of waste material to be recycled and/or discarded after their use. This situation is not desirable and it will likely dissatisfy many actual or potential customers.
[0004] Further difficulties and challenges in the design of food containers are created when these food containers must also be used for heating/cooking food items directly therein, for instance in a microwave oven. In a microwave oven, the heat generated inside the food items is transferred to the container itself and the temperature of the container can eventually become very high. Containers must still remain sufficiently rigid even when heated at high temperatures.
[0005] Even more challenging is the design of food containers used for heating/cooking food items directly therein and that can be reclosed after the initial opening by the customer. These food containers are used with lids that can be reclosed during heating/cooking and/or afterwards for transportation and storage. For example, some prepackaged meals require separate ingredients to be mixed and/or added before heating/cooling them, such as a meal where water must be added before heating/cooking. Some meals can also be packaged with ingredients that must be mixed together by the customer inside the container but where not all ingredients are mixed at the same time. An example is a stir-fry meal where a sauce or the like is added only after some cooking/heating time. Still, physical interventions by the customer during the heating/cooking process, for instance to stir the content, may be another reason to have a reclosable lid. Other situations exist as well.
[0006] Containers must perform well in the hands of customers but they must also be easy to handle at the packaging end, for instance, by the packaging equipment. Some designs can be adequate for transportation, storage and handling but far less for the packaging process. Difficulties in handling containers and sealing their lids can increase costs and complexity of the packaging equipment and/or decrease the production rate.
[0007] Still, some container designs can create difficulties for the customers when they attempt to remove the sealed lid. Containers with rectilinear sides and relatively sharp corners are often difficult to handle when the lids are very light and flexible.
[0008] Unfortunately, none of the previously-suggested containers has proven entirely satisfactory to address many of the challenges encountered in the design of containers, particularly in the design of containers intended for the commercial food processing industry.
[0009] It is therefore clear that improvements in the related technical field are still and will always be needed.
SUMMARY OF THE INVENTION
[0010] According to one aspect of the present invention, there is provided a container, the container having a pair of side walls and a pair of end walls, corner walls extending between end walls and side walls, a flange formed on one of the corner walls, a ring member formed integrally with the flange, the ring being sized to sit on top of the container.
[0011] According to a further aspect of the present invention, there is provided a container having at least one flange portion extending outwardly from a wall of the container, the flange having a proximal section adjacent the wall, the proximal section having a recess formed therein, a distal section remote from the wall, the distal section having an upwardly extending projection; and the upwardly extending projection being sized to fit within the recess.
[0012] The container and lid of the present invention may be utilized in many different applications. In particular, in several of the embodiments, the containers are particularly suitable for the food industry and in particular, for packaging ready to use foods.
[0013] The present embodiments of the present invention utilize containers which normally have a generally overall rectangular configuration. It will be understood, of course, that many different configurations can be utilized including those having various arcuate configurations.
[0014] The containers are formed of conventional plastic materials and the containers are normally formed using a thermoforming process. However, other known processes may be utilized.
[0015] The ring member of the present invention, in one embodiment, is formed as a portion of the container during a thermal forming process. The ring member is hingedly connected to the container and suitable retaining means may be utilized for securing the lid member to the top of the container.
[0016] In a further embodiment of the present invention, the ring member is formed as part of the container and is then separated from the container to become a separate ring member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Having thus generally described the invention, reference will be made to the accompanying drawings illustrating embodiments thereof.
[0018] FIG. 1 is an exploded isometric view of an example of a container and lid assembly based on the proposed concept;
[0019] FIG. 2 is an isometric view of the container and lid assembly in FIG. 1 , where the assembly is illustrated in a closed position;
[0020] FIG. 3 is a top plan view of the container and lid assembly shown in FIG. 2 ;
[0021] FIG. 4 is a view similar to FIG. 2 but where the assembly is illustrated in an opened position as the lid is unconnected to the container;
[0022] FIG. 5 is an enlarged isometric view of the area inside line 5 - 5 in FIG. 4 ;
[0023] FIG. 6 is a transversal cross section view taken along line 6 - 6 in FIG. 2 ;
[0024] FIG. 7 is an enlarged view of the area inside line 7 - 7 in FIG. 6 ;
[0025] FIG. 8 is a semi-schematic view of an example of a mold in which the container and the lid frame are molded together;
[0026] FIG. 9 is a cross-sectional view of a variation of a lid frame;
[0027] FIG. 10 is a top plan view of a bowl and flange when thermoformed;
[0028] FIG. 11 is top plan view of the bowl and ring after the exterior edges are folded;
[0029] FIG. 12 is a partial sectional view illustrating a flange arrangement for a recess and a protrusion;
[0030] FIG. 13 illustrates folding of an outer part of a flange to mate with an inner portion of the flange,
[0031] FIG. 14 is a top plan view of a further embodiment of the container according to the present invention; and
[0032] FIGS. 15 and 16 illustrate folding of the member of FIG. 14 to mate with the top of the container.
DETAILED DESCRIPTION OF THE INVENTION
[0033] FIG. 1 is an exploded isometric view of an example of a container and lid assembly 100 based on the proposed concept. The assembly 100 is used for packaging a product, for instance one or more food items. Although the proposed concept is especially well adapted for holding meals and other food items, it is possible to design and/or use the assembly 100 for holding one or more products that are unrelated to the food industry. The following detailed description refers to the context of the commercial food processing industry only for the sake of simplicity.
[0034] As suggested by its name, the assembly 100 includes a container 102 and a corresponding lid 104 . The container 102 includes a main body 110 having one or more walls defining a hollow interior compartment 112 for storing the food items to be packed therein. The container 102 has an opening 114 at the top that is defined by the inner edge of an outwardly-projecting container rim 120 . The container rim 120 is made integral with the main body 110 . The top of the container rim 120 is at the horizontal in normal use. The opening 114 is substantially rectangular in shape, with rounded corners and slightly curved sides between the corners. Variants are possible as well. For instance, the container 102 could have an opening with substantially straight sides and sharper corners, an opening with a nonrectangular shape, such as a rounded shape, a triangular shape or a shape with more than four sides, etc. Many other variants are possible as well.
[0035] In the illustrated example, the main body 110 includes a bottom wall and four upwardly-disposed side walls configured to form a bowl or the like. The wall or walls forming the main body 110 are airtight and liquid tight.
[0036] It should be noted that the shape of the main body 110 of the illustrated container 102 is only one example of implementation. Variants are possible.
[0037] The container 102 can be made using a thermoforming process or an injection molding process, for instance using a plastic material. Other materials and/or manufacturing processes can be used as well. The wall or walls forming the main body 110 of the container 102 can be relatively thin and the container rim 120 will stiffen the container 102 , even if the container rim 120 is also relatively thin to minimize the quantity of material.
[0038] The lid 104 includes a ring-shaped lid frame 130 and a membrane 132 that will be attached over the lid frame 130 at some point of the packaging and/or manufacturing process. The lid frame 130 includes a relatively flat strip portion 134 having a continuous flat top surface and a continuous flat bottom surface. The periphery of the membrane 132 will adhere to the top surface of the lid frame 130 to form an airtight and liquid tight seal. The lid 104 is thus made with a minimized quantity of material and will be very light.
[0039] The lid frame 130 can be made using an injection molding process, for instance using a plastic material. Other materials and/or manufacturing processes can be used as well. However, the lid frame 130 is not molded directly to or over the container rim 120 . The lid frame 130 is only put in position onto the container rim 120 after the molding process.
[0040] The membrane 132 is in the form of a thin film, for instance a plastic film or a foil. Other materials can be used as well, depending on the actual implementation. The membrane 132 can be transparent, translucent or opaque, depending on the needs.
[0041] The lid frame 130 of the illustrated example also includes two diametrically opposite corner latching tabs 136 , 138 that are each made integral with the outer side edge of the lid frame 130 . Each latching tab 136 , 138 has a proximal section that extends outwards from the side edge of the flat strip portion 134 and a distal section that extends downwards. The latching tabs 136 , 138 are designed to prevent them from interfering with the continuity of the contact of the bottom surface of the flat strip portion 134 with the outer peripheral top surface 122 when it rests thereon. The lid frame 130 of the illustrated example also includes a lift tab 140 that is made integral with the free end of the distal section of the first corner latching tab 136 . Only one lift tab is provided in the illustrated example. The lift tab 140 extends horizontally outwards from the distal portion of the first corner latching tab 136 . Variants arc possible as well.
[0042] As can be seen, the lid 104 is devoid of a peripheral skirt or the like. The size of the latching tabs 136 , 138 is also kept to a minimum. Overall, this will greatly facilitate the opening and closing of the lid 104 . A lesser force is required to handle it and as a result, it is less likely to undergo a plastic deformation because the customer exerted an excessive pulling force. The lid frame 130 is relatively small and can be prone to deformation when subjected to an excessive pulling force.
[0043] FIG. 2 is an isometric view of the container and lid assembly 100 in FIG. 1 , where the assembly 100 is illustrated in a closed position. The lid 104 is then attached to the container 102 , more specifically to the container rim 120 . In FIG. 2 , the membrane 132 is sealingly attached to the lid frame 130 .
[0044] FIG. 3 is a top plan view of the container and lid assembly 100 shown in FIG. 2 .
[0045] FIG. 4 is a view similar to FIG. 2 but where the assembly 100 is illustrated in an opened position. The lid 104 is then unconnected to the container 102 .
[0046] As can be seen, for instance in FIGS. 3 and 4 , the top side of the container rim 120 includes an outer peripheral top surface 122 and an inner peripheral top surface 124 . Each of these surfaces 122 , 124 are flat and continuous. They are also substantially horizontal in normal use. However, the outer peripheral top surface 122 is slightly vertically below the inner peripheral top surface 124 so as to receive the bottom surface of the lid frame 130 when the lid 104 is in a closed position. These mating surfaces are configured and disposed to form an uninterrupted seal around the entire perimeter of the container rim 120 .
[0047] FIG. 5 is an enlarged isometric view of the area inside line 5 - 5 in FIG. 4 . As can be seen, the outer peripheral top surface 122 includes a through hole 150 at the corner where the first latching tab 136 is located when the lid 104 is in a closed position. A similar hole 150 is also provided at the opposite corner, thus at the corner where the second latching tab 138 is located. In the illustrated example, these holes 150 have an oblong shape that is generally oriented parallel to the medial axis of the outer peripheral top surface 122 . Variants are possible as well. For instance, the holes 150 can be provided with other shapes, including for instance a “lens” shape to help in aligning the studs 152 at the center of the holes 150 .
[0048] FIG. 5 also shows that the container rim 120 of the illustrated assembly 100 includes a downwardly projecting skirt 126 extending around the entire periphery of the container 102 . The skirt 126 promotes rigidity. Variants are possible as well.
[0049] FIG. 6 is a transversal cross section view taken along line 6 - 6 in FIG. 2 . It thus shows the lid 104 in a closed position. FIG. 7 is an enlarged view of the area inside line 7 - 7 in FIG. 6 . As can be seen, these figures show one of the studs 152 provided to engage the inner edge of a corresponding hole 150 , as best shown in FIG. 7 . A similar stud 152 is provided at the opposite corner to engage the other hole 150 . These studs 152 have a substantially circular cross section in the illustrated example. The engagement of the studs 152 with their corresponding holes 150 can be an interfering engagement, including for instance using a notch (not shown) or the like to create a snap fit interlocking connection. This removable interfering engagement will create a retention force resisting the lifting of the lid 104 and interlocking the lid 104 with the container 102 . However, the interfering engagement can be removed upon lifting the lid frame 130 using a mild force. Using the studs 152 and the corresponding holes 150 also greatly facilitates the closing of the lid 104 since the lid frame 130 is made of a relatively flexible part. It can become very flexible at high temperatures and the studs 152 can facilitate the positioning. The customer can used their thumbs to urge the studs 152 into the holes 150 when closing the lid 104 . Variants are possible as well.
[0050] The latching tabs 136 , 138 also help in centering the lid 104 on the container 102 and they can be shaped to engage, with a mild interfering force, the bottom edge of the skirt 126 . Each latching tab 136 , 138 can be provided with an undercut (not shown) or a similar feature to create an interlocking connection with the bottom edge of the skirt 126 . They can even replace the studs 152 and their holes 150 in some implementations. Variants are possible as well.
[0051] The holes 150 have an oblong shape in the illustrated example. This feature is to facilitate the positioning by the customer. Variants are possible as well.
[0052] FIG. 7 also shows that the top surface of the lid frame 130 and the inner peripheral top surface 124 of the container rim 120 are substantially flush with one another when the lid 104 is in a closed position. The bottom surface of the membrane 132 is then directly above the inner peripheral top surface 124 .
[0053] Still, FIG. 7 shows that the inner side edge of the flat strip portion 134 is spaced apart from the outer edge bordering the inner peripheral top surface 124 . This space can provide more room for aligning the parts when they are hot. The space also provides an increase of the manufacturing tolerances, thus mitigating the risks of having parts being rejected because they are too wide after the molding process.
[0054] During the packaging process, the item or items can be put inside the hollow interior compartment of each container 102 with the lid frame 130 being already in an interlocking engagement with the container rim 120 . This previous step can be achieved by hand or by appropriate equipment. The containers 102 , with their lids 104 thereon, can still be stacked so as to minimize space. Variants as possible as well.
[0055] An interesting benefit of the proposed concept is that since no peripheral skirt is provided on the lid 104 , the handling of the container 102 with the pre-connected lid frame 130 during the packaging process is made easier since a stack of these parts can be supported anywhere underneath the container rim 120 , with the exception of the two corners with the latching tabs 136 , 138 are provided, without the risks of accidentally lifting a portion of the lid frame 130 from the container rim 120 .
[0056] The membrane 132 is added at the end of the packaging process to simultaneously form the lid 104 and to seal the whole assembly 100 . For instance, if the membrane 132 is made of a thermoplastic material, the membrane 132 can be heated and pressure can be applied so as to simultaneously bond the outer perimeter of the membrane 132 to the outer and inner peripheral top surfaces 122 , 124 . This can be done in a single operation during which the underside of the container rim 120 is supported by a die while the membrane 132 is urged onto the lid frame 130 and onto the exposed inner peripheral top surface 124 by a heated pressure plate. The combination of heat and pressure bonds the membrane 132 over the top surface of the lid frame 130 and over the inner peripheral top surface 124 .
[0057] If desired, the inner peripheral top surface 124 can be positioned slightly lower than the top surface of the flat strip portion 134 when the lid 104 is in a closed position. This will make the bond between the inner peripheral top surface 124 and the membrane 132 slightly weaker than the bond between the top surface of the flat strip portion 134 and the membrane 132 . Still, as shown in FIG. 7 , the width of the outer section of the membrane 132 that is fused onto the top surface of the flat strip portion 134 is larger than the width of the adjacent inner section of the membrane 132 that is fused onto the inner peripheral top surface 124 . These features will make the membrane 132 less prone to detach from the lid frame 130 during the initial unsealing of the assembly 100 by the customer and will also decrease the required pulling force. This decrease of the pulling force can mitigate the risks of accidentally tearing the membrane 132 when the assembly 100 is unsealed. Variants are possible as well.
[0058] In use, to open the sealed assembly 100 , the customer will move the lift tab 140 upwards to create a peeling force that will progressively detach the membrane 132 from the inner peripheral top surface 124 of the container rim 120 , starting at the corner adjacent to the lifting tab 140 . The membrane 132 will stay attached on the lid frame 130 since the peeling motion will only remove the membrane 132 from the inner peripheral top surface 124 . Thus, it is relatively easy for the customer to lift a corner of the lid 104 using the lift tab 104 and then lift the whole lid 104 to access the interior of the container 102 . This way, the customer can add liquids or other ingredients, for instance additional ingredients from a pouch or the like. The lid 104 can be reclosed before continuing the heating/cooking process.
[0059] FIG. 8 is a semi-schematic view of a mold 200 in which the container 102 and the lid frame 130 are molded together in a same injection shot of molten plastic material but in separate cavities. The mold 200 includes a first cavity 202 for the container 102 and a second cavity 204 for the lid frame 130 . Both cavities 202 , 204 are in fluid communication using an intervening channel 206 . The channel 206 will also be filled with the molten plastic material after the injection shot and as the plastic material solidifies, it will form a connector linking the outer edge of the container rim 120 to the outer edge of the lid frame 130 . This connector 206 can be removed or cut to completely separate the container 102 and the lid frame 130 . However, one can also keep the connector 206 to facilitate handling during the packaging and/or by the customer, provided that the connector 206 remains relatively flexible at room temperature and is located at the corner opposite the corner with the lift tab 140 . The connector 206 can be useful for keeping the orientation of the lid frame 130 with reference to the container 102 and for preventing a customer from attempting to close the lid 104 while the studs 152 are at the corners where no holes are present.
[0060] FIG. 9 illustrates an alternative embodiment in which an injection molded snap ring 208 is placed on top of a flange 210 to a thermoformed bowl. The flange 210 is welded to the thermoformed bowl. The ring can also be welded directly to the container so that when one opens the lid, the film will stick to the ring, but the ring will be detached from the container. The ring will also snap in the flange. Preferably, the flange and ring are injected molded.
[0061] Alternative embodiments are illustrated in FIGS. 10 to 14 .
[0062] Referring to the embodiment of FIGS. 10 and 11 , there is illustrated a bowl or container 312 , includes a base 314 . Extending upwardly from base 314 are pair of side walls 316 and a pair of end walls 318 . At the point of joinder of and end wall 318 with a side wall 316 , there is provided bend lines 320 which form corner walls 322 . Each corner wall is located near a respective side wall 316 and end wall 318 .
[0063] Extending outwardly from side walls 316 , end walls 318 and corner walls 322 there is a flange which has an inner or proximal flange portion 324 and an outer or distal flange portion 326 . Between distal portion 326 and proximal portion 324 , there is a crease or fold line 328 to permit distal portion 326 to fold over on top of proximal portion 324 . Inner or proximal portion 324 is provided with recesses 330 while distal or outer portions 326 are provided with a protrusion 332 . Protrusions 332 are designed to mate with recesses 330 and lock the two pieces together.
[0064] As has previously been described, container 312 is provided with a upwardly extending top surface 323 . Top surface 323 extends above proximal flange portion 324 and distal flange portion 326 . This arrangement permits the membrane layer (not illustrated) secured to the flange portions to seal against upper surface 323 .
[0065] In the embodiment of FIGS. 12 and 13 , there is illustrated a portion of a bowl or a container which has a base 364 and a side wall 366 extending therefrom. The illustration includes a inner or proximal flange portion 368 and an outer or distal flange portion 370 . Proximal flange portion 368 includes recesses 372 while distal flange portion 370 includes a protrusion 374 designed to mate with recess 372 . This is done by folding of the distal flange 372 over top of proximal flange portion 368 .
[0066] A further embodiment is illustrated in FIGS. 14 to 16 . In this embodiment, there is provided a bowl or container 338 which has a base or bottom 340 . Extending upwardly from base 340 are a pair of side walls 332 and a pair of end walls 344 . Creases 346 are provided to form corner walls 348 . The top of the container includes an upper wall 350 .
[0067] At one of the corner walls 348 there is provided a hinge 352 which is connected to ring member 356 . Ring member 356 has protrusions which are designed to seat in recesses 354 of a flange 360 . As has been previously described in the embodiments, there is also an upper wall 350 which is of a height to seat the above flange 360 . A flexible membrane (not shown) is also utilized.
[0068] It will be understood that the above described embodiments are for purposes of illustration only and that changes and modifications may be made thereto without departing from the spirit and scope of the invention.
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A container having a pair of side walls and end walls and corner walls being provided between a respective end wall and side wall, a flange formed on one of the corner walls, said flange functioning as a hinge, a ring member formed integrally with the flange, the ring being sized to sit on top of the container.
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